Processes of 3D Fabrication of Prototypes and Props

1. KIM ENGLEBERT
Prototyping & Design
Northeast Wisconsin Technical College
Students of the Prototype and Design program,
are trained to build a variety of three
dimensional prototypes and models for use in
manufacturing, consumer products, and other
fields of product development.
Additionally, they are able to fabricate three-
dimensional models used for architectural
design, mechanical design, and props.
They possess skills in hand fabrication, high
quality painting and finishing, 3D drawing
software, CNC machining, RTV model making,
and welding,
… with an emphasis on problem solving and
critical thinking

2. PROGRAM OUTCOMES
• Develop planning strategies necessary to translate two-dimensional information into a three- dimensional prototype.
• Use critical thinking and problem-solving techniques in the construction of a prototype.
• Create a variety of computer aided drawings using AutoCAD and SolidWorks.
• Create programs to be used on CNC (computer numerical control) milling machines using Surf CAM software.
• Construct 3D models using a variety of rapid prototyping processes.
• Produce highly detailed and accurate parts using the laser machining center.
• Fabricate silicone rubber molds and rigid molds suitable for casting.
• Build patterns and molds to be used for vacuum forming.
• Create jigs and fixtures necessary for special machining operations.
• Select and apply a variety of industrial finishes on various materials.
• Effectively estimate the time and cost to design and fabricate a prototype.
• Manage computer files and utilize a variety of technically related software.
• Work efficiently as a part of a team, or independently.
• Safely operate all hand tools, metalworking, and woodworking equipment typically used in a professional model shop.
• Effectively select appropriate materials and adhesives and understand their properties.
• Use proper sanding and finishing techniques on various materials.
• Understand various design and engineering processes as they relate to the Prototype & Design Industry.

3. LASER ETCHING
CRIBBAGE BOARD
Processes…
• Import images into CorelDraw
• Post to Fusion Epilog Laser
• CNC Milling
• Routering
• Sanding
• Spray clear coat finish

4. WOODWORKING
KEEPSAKE BOX
Using a variety of wood-shop practices
created a keepsake box that contains the
following elements:
• Main box compartment
• Set of legs
• Bottom
• Top
• Handle
• Mitered corners
• Brushed clear coat finish

5. VACUUM-FORMING
FOOD TRAY
Constructed a vacuum form pattern with draft,
draw, fillets, rounds, and vacuum release holes.
Processes…
• Produced uniform and consistent fillets using
body filler
• Produced rounds that are tangent to adjacent
surfaces
• Produced a vacuumed-formed food tray of
Styrene from the created pattern mold

6. CNC MILLING
CRIBBAGE BOARD –holes, profile, card
pocket
BABY MONITOR – speaker grill
CUBE – set tools and toolpaths in
SurfCam; posted to CNC for milling
Processes…
• Homing Machine
• Zeroing out tools
• Running program on Haas CNC
Machine

7. BABY MONITOR
Created a three-dimensional
model of a baby monitor using
model-board as the primary
material.
Processes…
• Blueprint reading
• Milling
• Drilling
• Router shaping
• Sanding
• Spray finishes; smooth and
textured

8. METALWORKING
DRILL PRESS HOLE PROJECT
DEAD-BLOW HAMMER
SCREW JACK
Processes…
• Facing
• Tapering
• Knurling
• Cutting and tapping threads
• Kiln heat-tempered finishes

9. MODEL FINISHING
Processes…
• Wet/Dry sanding
• Applying body fillers
• Applying primers,
paints and clear coats
with a HVLP spray
gun to achieve
smooth or textured
finishes

10. CLOCK
PUTTING IT ALL TOGETHER
(Break down of process)
• Create design
• Create pattern
• Drill holes for dowels
• Cut out shapes on bandsaw
• Drill out face surface for walnut insert
• Shape walnut circle to fit in inside of face
• Laser image to walnut circle
• Drill out walnut for clock insert
• Lots of sanding
• Fit together with dowels and glue
• More sanding
• Spray clear coat finish

11. Watch-CLOCK

12. COMPUTER
AIDED
DRAFTING
AutoCAD
SurfCam
SolidWorks

13. DIY Metalworking
GARDEN ARCH ARBOR
WALL BIKE RACK
STAINGLASS SPINNING SPRINKLER
Processes…
• Cutting, shaping, drilling glass
• Cutting, grinding, drilling, polishing
pipe fittings and bike components
• Cutting, fitting, soldering copper

14. DIY Woodworking
Pull-out APPLIANCE BOXES and
Adjustable laminated SHELVING
Processes…
• Cutting and ripping on table-saw
• Creating dado joinery
• Nailing with air gun
• Laminating shelves
• Brush staining and clear coat
finishing

15. DIY Woodworking
KITCHEN CABINETS
Processes…
• Constructed new face frames for
cabinets with Kreg joinery
• Squared openings and perimeter
• Belt sanded frames flush
• Finished sanded frames and doors
• Applied stain and clear coats
• Installed frames and doors
• Created template for drilling
handle pulls

16. DIY Woodworking
STUDENT COMPUTER DESK
CEDAR BENCHES

17. DIY “Faux” Finishes
SNOWBOARD; Faux finish with soap CAR SEAT TRIM; Hydro-painting
ARNIS WEAPONS; Crackle finish CAR INTERIOR HATCH; Hammered-texture

18. INVOLVEMENT
and
Volunteerism

19. MENTORING
Martial Arts Head Master
Self Defense Instructor
Snowboard Instructor
Enjoying over 15 years of sharing the
love of martial arts and outdoor sports

20. ART

21. MARINE DRAFTING

22. …Thank you for viewing
Kim_Englebert@yahoo.com