123.1.1 - 2D Cutting CAD/CAM/CNC

2D Cutting Basics

What is "2D Cutting"?

2D cutting is a manufacturing process that involves cutting flat patterns out of materials using various cutting tools such as plasma, laser, waterjet, etc.
- This process is used to create precise cuts in a variety of materials including metal, plastic, and wood.
2D cutting is important and useful because it allows manufacturers to rapidly create custom parts and components with a high level of precision, from standard sheets/plates of materials.
- Additionally, 2D cutting can also be used for prototyping, allowing manufacturers to test and evaluate designs before committing to mass production.
2D cutting is also used in fabrication, where sheet/plate material is cut into specific shapes and forms to create 3D products.
- The ability to cut precise shapes with minimal material waste and high precision is important in order to save costs.

2D Cutting Processes

There are several different types of 2D cutting processes, each with their own set of characteristics and key distinctions. Some common 2D cutting processes include:
- Plasma Cutting: This process uses a high-velocity stream of ionized gas (plasma) to cut through a wide range of materials, including steel, aluminum, and copper.
  - Plasma cutting is known for its high cutting speeds, low cost, and ability to cut through thick materials.
- Laser Cutting: This process uses a high-powered laser beam to cut through materials such as steel, aluminum, and plastic.
  - Laser cutting is known for its high precision and ability to cut intricate designs. It is also able to cut thin materials with high accuracy.
- Waterjet Cutting: This process uses a high-pressure stream of water to cut through materials such as steel, aluminum, and composites.
  - Waterjet cutting is known for its ability to cut through a wide range of materials without causing heat distortion, and it's also good for cutting materials that are sensitive to heat.
- Flame Cutting/Burning: This process uses an oxy-fuel mixed gas, high-temperature melt & burn to cut through ferrous materials such as steel, cast iron, etc.
  - Flame cutting is known for its ability to cut through extremely thick pieces of ferrous metals, that other 2D Cutting process might struggle with or simply be unable to do.
- Knife Cutting: This process uses a sharp blade to cut through materials such as paper, cardboard, and foam.
  - Knife cutting is known for its ability to cut through a wide range of materials, including materials that are difficult to cut with other methods, such as fabrics and textiles.
- Routers: This process uses a spinning cutter to remove material and create precise cuts.
  - Routers are commonly used in woodworking and sign making, and they can also be used to cut softer materials such as plastics and composites.
These are some examples of the main 2D cutting processes, each process has its own strengths and weaknesses and are suitable for certain applications, so it's important to choose the right process for the job.

2D Cutting Applications

There are many ways you can utilize 2D cutting processes in manufacturing.
- The methods shown below increase the functionality and efficiency of making 2D designs/products, and can either be used individually or combined into hybrid methods for even greater design performance/efficiency

Blank Preparation

One of the most common uses of 2D cutting is to simply get pieces of material into rough shape ("blanks") in preparation for additional manufacturing processes to then be performed to refine or add additional features/geometry to the rough shape, turning it into a finished product. Examples include:
- Turbine Blades
- Gears

Flat Designs

Flat Designs are the simplest application of 2D Cutting processes. Examples include:
- Signs
- Flat Brackets
- Washers
- Gaskets/Bearing Surfaces

Bent/Rolled Designs

Bent/Rolled Designs have been formed from flat shapes into 3D shapes through bending/rolling. Examples include:
- Metal Tubing (Round/Square/other)
- Corrugated Sheets
- Brackets
- Ducting/Transitions

Formed Designs

Formed designs have been formed using pressure and/or heat via a variety of processes (stamping, forging, spinning, hydroforming, etc.) into complex 3D shapes. Examples include:
- Automotive Body Panels
- Aerospace Components

Stiffened Designs

Stiffened Designs utilize formed or attached reinforcements to a part/assembly that provide additional structural support to a component. Examples include:
- Aircraft Wings
- Vehicle Frames

Layer-Stacked Designs

Stacked designs are stacked together to form an assembly. Examples include:
- Multi-layer printed circuit boards (PCBs)
- Forming/Bending/Braking Dies

Tabbed Designs

Tabbed Designs have minimal connections (tabs) that allow for easier & more controlled bent/formed joints to turn a 2D pattern into a 3D structure. Examples include:
- Origami-like "folded" structures
- Brackets

Keyed Products

Keyed Designs have locating features (keys + slots, commonly) that fit together to form an assembly. These products can easily be packaged flat/efficiently for shipping or storage, and then easily assembled or fabricated upon delivery/arrival. Examples include:
- Precision fabrication tables/fixtures
- Interlocking furniture (firepits, end tables, many IKEA designs, etc.)

Assembled Designs

Utilized 2D cut geometries combined with other components via standard hardware, which can include: nuts, bolts, screws, hinges, pins, bearings, etc. Examples include:
- Machinery
- Scissor Mechanisms

Fabricated Designs

Typically involves welding and other processes to create a final product. Examples include:
- Frames & other structural components
- Metal Bumpers
- Boat/Ship Hulls
- Heavy Equipment Frames & Tools (ex: Excavators & Buckets, etc.)

Compliant Mechanisms

Compliant Mechanisms are flexible parts that are designed to bend or deform in a controlled manner, due to the elasticity of certain materials. Examples include:
- Robotic Joints
- Medical Devices
- Microscopic and/or High Cycle-Count Actuators
- Microelectromechanical Systems (MEMS)

1.1✔ CHECKPOINT

2D Cutting Overview

Answer the following prompts/questions in your own words - apply your personal experiences and opinions to the topics covered in this sub-module. Feel free to use multi-media visuals, references, etc.:

What is 2D Cutting, and why are the primary benefits of it as a manufacturing process?
A) If you needed to cut a thick piece of aluminum, what 2D cutting process would you choose, and why?

B) If you needed to cut a thick piece of cast iron, what 2D cutting process would you choose, and why?

C) If you needed to cut a thin aerospace part with extremely precise features, what 2D cutting process would you choose, and why?

D) If you needed to make some affordable metal signs out of thinner materials, what 2D cutting process would you choose, and why?

A) Identify multiple (at least 2) 2D-cut products in your daily activities at work/life/school.

B) What 2D Cutting processes do you think were used to cut the parts out, and why?

C) What applications of 2D Cutting were utilized to make the products?

Page updated

Google Sites

Report abuse