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Setting up for a practical lesson
Setting up for a practical lesson
When manufacturing, the workshop should be set up for manufacture with the well turned over to provide a safe space to store tools and materials as well as other items being stored out of the way. Put ipads and paperwork on the stool and push the stool under the workbench.
You should stand up when using tools as it is safer and more efficient.
Countersinking the torch
Countersinking the torch
Without a countersink on the screwholes trhe machine screw sits in a raised position on the top surface of the torch which is dangerous. It also results in the machine screw not being long enough to reach all 3 layers of the torch and the bottom layer will fall off.
The countersink should go through the thickness of the top layer without making the hole bigger at the bottom diameter. This will result in the head of the machine scre fitting perfectlywithin the top layer and the length of the machine screw reaching the bottom layer.
Tapping the torch
Tapping the torch
A machine screw has a thread on the barrel. The thread is what holds it in place. The laser cut layers of your torch have no thread and are really smooth. You need to add the thread by using a tap.
A tap is the tool that you use to add a thread inside a hole. The process of using the tap is to tap or tapping.
It is confusing - you tap a hole using a tap!
What your torch should look like at different stages of manufacture:
What your torch should look like at different stages of manufacture:
After countersink and tap. Has a countersunk top layer.
After Tapping - inside of both holes has a thread inside.
Assembled torch - laser cut finish
After filing - looks cloudy
Create friction
After wet and dry paper - feels smooth (like your cheek). No scratches.
Create friction to make wet and dry paper work effictively
After polish - Shiny, middle layer should have a more transparent appearance
Adding electronics
Adding electronics
Once your torch has been filed, wet and dry'd and polished, it is time to assemble the electronics inside and add a keychain if you have designed your torch with a hole for a keychain.
Collect the electronic components needed: LED, Battery and Foam
Seperate and clean your layers
Place the LED into the slot with the rim of the bulb placed inside the design feature.
The long leg of the LED is positive (+). It must be in contact with the positive (+) side of the battery. Look for the + symbol on the battery
Cut a small rectangle of foam like the size you see in the picture
Use scissors to make the foam fit in the space for the LED underneath the long leg. The foam will insulate the leg of the LED to prevent flow of electricity
the foam should overlap onto the battery slightly like you see in the picture
Test the pressure sensitivity of the switch. If it is too hard to press then you may want to cut the foam shorter to help.
Once you are happy with the fit of the electronic components, fit the machine screws to hold the layers of the torch together
Now test the design after the machine screws have been fitted.
Now add a key chain or key ring
Take lots of photos of your finished torch in the light box.
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