Designed by: Ethan Sobkowich, Yanshen Zhou, Winnie Lin
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Needs statement: There exists a need to create a fixture that can hold specimens in a stationary position for adhesive curing while being adjustable able to accurately create different specimen sizes.
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Steel to steel
Composite to composite
Steel to composite
go thru reasoning to do this design. decision making matrix
show dimensions and material
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Fig. 1: An image of the base tray for the testing jig
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Figure 7, seen below, is a side view of one test specimen, whose material may vary depending on the test. This is how they will be aligned in the jig. The rectangular jigs will be placed in the gap spaces.
*jig can be spring with boards on either side (will remove tolerance error)
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Fig. 7: A 3D model of the specimens glued together
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Source: https://www.youtube.com/watch?v=uLH1MsaHnX4
one design matrix per step
Assembly Procedure
Step 1: Printing
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Use PrusaSlicer to print an array of support pieces on the tray. Two of the longer spacing supports are required per specimen and 3 of the spacing supports are required between two specimens.
You may need to change the dimensioning of the support beams to customize it to your specimen.
Print according to the number of specimens that are cured.
Remove the printed pieces.
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Table 2: Support Component Manufacturing Decision Matrix
Machine Shop Tools | Laser Cutting | 3D Printing | |
|---|---|---|---|
Ease-of-use | 0 | +1 | +1 |
Precision | 0 | +1 | +1 |
Affordability | 0 | -1 | +1 |
Time Required | 0 | +1 | +1 |
Feasibility | 0 | -1* | +1 |
Total | Datum | +1 | +5 |
*Feasibility for laser cutting is -1 because the Rapid Prototyping Centre does not machine parts that are thin enough for this application.
Step 2: Machining Cover
This component is placed on top of all the specimens after they are placed correctly. The purpose of this cover is to restrain joints with epoxy from lifting.
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Use AutoCAD to create layout of pieces that need to be laser cut. In total, this needs to include 4 copies of each component of the tray.
The idea behind this is to stack four 1/8 inch thick pieces of fiberboard to create a 1/2 inch tall tray.
Minimize the area occupied by the pieces. This is because the 3D Print Centre charges per square foot.
All vector cut lines should be 0.00 units line thickness and all raster/engraving lines should be set to a minimum of 0.25 units.
Submit a laser cutting request: https://uwaterloo.ca/3d-print-centre/laser-cutting-request-form
Turnaround time is 2-3 days.
Use wood glue to bond two copies of the same part.
Apply a thin strip of wood glue along the entire piece.
Clamp down both pairs of fiberboard pieces for curing. This takes 24 hours according to the glue manufacturer instructions.
After the pairs of fiber board have fully cured, repeat steps a-b to bond the two pairs of fiberboard. This creates four stacked layers of fiberboard.
After curing, use sand paper to sand off any excess glue.
Note: it is important to cure the layers as aligned as possible to create a flat edge.
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Table 3: Curing Tray Manufacturing Decision Matrix
Machine Shop Tools | Laser Cutting | 3D Printing | |
|---|---|---|---|
Ease-of-use | 0 | +1 | +1 |
Precision | 0 | +1 | +1 |
Affordability | 0 | +1 | +1 |
Time Required | 0 | +1 | -1 |
Feasibility | 0 | +1 | +1 |
Total | Datum | +5 | +4 |
3D printing such a large part would take a significant amount of time. It is also a simpler shape, so the complex structure capabilities of the 3D printer are not required.
Step 4: Anti-stick Solution
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Item | Amount | Description of Use | Supplier | Total Price |
|---|---|---|---|---|
1/8” Fiberboard | 2 square ft. | Material for laser cutting. Creates tray. | UW 3D Print Centre | $4.00 + tax |
ABS Printing Filament | 1 kg | Support material in between specimens and within specimen pieces. | Amazon (if no sufficient supply in Bay) | |
Saran Wrap | 900cmx30 cm | Prevents epoxy from curing to the fixture. | Walmart | |
3mm Birch Plywood | 20cmx30cm | Applies pressure from the top of curing fixture | E3 Machine Shop | |
Wood Glue | 236mL | For gluing the layers of laser cut fiberboard together. | Canadian Tire | |
Total cost per one fixture (CAD, includes tax) | $51.63 |
generally less walls of text. pictures explain for you, just use the right pictures.