The top picture shows the CAD model of the contact cup. The bottom picture shows the physical model machined out of a solid piece of acrylic. It is important to note the difference between the two smaller pieces that are inserted into the larger body in the main assembly. In the CAD model it can be seen that this part is designed to be of a uniform diameter. This is to allow enough room between the two walls inside of the chamber so that there is no interference once the secondary tubing is inserted into the side of the cup. When it came to machining this part of the assembly, problems were experienced during the process of parting from the stock acrylic rod. The very small cross section of the part meant that the acrylic would crack before it would cut, causing a jagged edge on the part that left it unuseable. This was remedied temporarily by increasing the diameter at the parting end of the rod to prevent cracking while leaving the other end unaltered to ensure that the tubing could still fit over the rod. While this larger diameter increases the possibility of interference between the secondary tubing and the inner wall, the team determined that it was suitable for the alpha prototype. However, this dimension being important for the purposes of the beta prototype, the team plans to either experiment with different materials (i.e. metals) that are less brittle than acrylic or utilize a smaller parting tool with a finer edge during the machining process.
In Phase 4, with the second iteration of the alpha prototype, the team decided to look at machining as a new way of manufacturing the contact cup. Machining is advantageous for a number of reasons, such as the ability to use a variety of materials from metals to polymers, as well as the high level of tooling accuracy when it comes to model dimensions. However, the factor that was most important for the team at this point in the project was the need for an airtight prototype. Milling the second iteration contact cup prototype out of a solid piece of acrylic ensured that it could be used in functional testing of the overall system.
A CNC lathe was used to machine the second iteration contact cup prototype. process began by inserting a rod of solid acrylic into the spindle and locking it in place. The motor was then turned on, spinning the spindle with the stock acrylic inside. The acrylic is first turned down to the proper outer diameter with a cutting tool that slowly removes material from the outside of the rod. Once at the proper outer diameter, a bit is used to drill a through-hole into the part at the necessary inner diameter. Finally, a parting tool is used to separate the part from the rest of the acrylic rod.