Recognizing Limitations of Models

One of the primary takeaways of the project was learning to recognize and work with the limitation of models—namely CAD and 3D printed models. During early iteration, it became clear that just because parts in SolidWorks can pass collision simulations doesn't necessarily mean the parts will be move together seamlessly outside simulation. Similarly, unpredictable tolerancing with 3D printed parts introduced challenges with component alignment and friction. During prototyping stages, variation in printing layer line thickness or location of tree supports often led to concentric hole misalignment and shaft binding. The team learned that unlike computer models, making real parts will always result in small imperfection regardless of  how they are created. 

Designing for Manufacturability

Another key takeaway the importance of designing machined components with ease of manufacturability in mind. Although the track was intended to be CNC machined, it's design was not optimized for manufacturabilty which ultimately prevented it from being manufactured. First, the track design heavily relied on a Spline feature which can be very difficult to calculate a toolpath for in CAM software. Secondly, the team did not check that the required tools to make the track grooves were available—the Machine Shop did have a ball-nose endmill with the required depth of cut length. In this example, the team learned to be more conscious of manufacturability and available tooling when planning to make machined componnets.