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The page "Additive Manufacturing Projects" from my portfolio showcases a series of my 3D printing projects. These projects were printed to present my knowledge of additive manufacturing and also for fun, I liked experimenting with the limits of our TPU filament.
Featured Projects:
Featured Projects:
Flexible TPU Manta Ray: I designed and printed a flexible manta ray using thermoplastic polyurethane (TPU), highlighting the material's flexibility and suitability for dynamic forms.
Flexible TPU Hedgehog: Following the manta ray, I created a hedgehog model using the same TPU material, further exploring its properties.
AMLA Puzzle: I printed the puzzle I designed for the 2D challenge at the beginning of the year and put it together, showcasing creativity and problem-solving in additive manufacturing.
Hinged Coffin Box: A more complex project involving the creation of a hinged coffin box designed to hold cards and dice. Printed using Selective Laser Sintering (SLS) on a sand-based printer, this project emphasized the challenges of post-processing, including the meticulous cleaning required to remove excess powder.
Multifilament Challenge with PETG and PLA: For a multifilament challenge, I attempted to create an AMLA Lego sign using both PETG and PLA, facing issues due to differing printing properties. I had to adjust nozzle speeds and temperatures to achieve successful prints after initial failures. Despite making adjustments, the final designs still had fitting issues, leading me to abandon the project.
4-Axis Project Page
The project involved designing and machining "Totems of Undying" from "Minecraft" using a 12x2.5x3.5 aluminum block. I used Fusion 360 for sketching and designing the totems, focusing on fitting them within the block dimensions.
Design Process:
Initial sketches outlined the block and totem placement.
Facial features like nose and eyes were added to the sketches.
The design included detailed measurements for length and width of the totems.
I used thin tabs to hold the parts in place towards the end of machining. The tabs help to keep the part in place while also making it easy to remove at the end of the program.
CAM Process:
The CAM process involved simulating tool paths for machining using face mills and flat endmills.
I used different tools for cutting silhouettes and detailing facial features.
Adjustments were made to the code settings for optimal machining performance. Adjustments being in the post processing step of CAM, I had to uncheck "use DWO" which was trying to enable dynamic work offsets which lets you set the zero somewhere other than programmed. I unchecked this box because the machine was registering it as an error message. I also unchecked "force X,Y home positioning on indexing" which was going to force the machine to reset to "home" after each operation which wasted machining time. Finally I checked "use G0" because Fusion's code was trying to use "M298" causing the machine to error out.
Before I get into the execution of machining I want to address what a 4-Axis machine is. A 4-Axis CNC machine is the extension of a 3-Axis machine it adds a rotary axis (A-axis) in addition to the linear ones the three axis has. The 4-Axis also uses a Techni grip to clamp the parts down onto the table.
Machining Execution:
The code was transferred to the machine via USB, we used preloaded tools (tools that were already in the machine) and touched them off for execution.
Despite minor issues with the tool holder running into the clamps, the machining process was completed successfully.
Post-Machining:
Tabs were cut off and parts were deburred for a clean finish.
A vibre burr was used to achieve a polished surface on the totems.
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These are the clamps that hold the part down and that the tool holder ran into.
This is my part on the Techni grip
Recording 2025-06-05 111538.mp4
5-Axis Project Page
This content details the process of designing and machining a 20-sided dice using CAD and CAM techniques on a 5-axis machine.
CAD Process:
The initial step involved sketching a pentagon and creating multiple pentagons to form the shape of the dice.
Construction planes were used to visualize the cutting paths for the CAM process.
CAM Process:
The toolpaths for machining were designed for a tabletop 5-axis machine, the Penta Pocket NC. A five axis machine is a machine that uses linear axis X,Y, and Z combined with rotary axis A, B, and or C. The pocket NC is a tabletop version of a 5-Axis machine.
Machining Steps:
The machining process included multiple toolpaths for roughing and finishing the dice.
Issues arose with feeds and speeds, requiring adjustments to prevent tool damage.
Final Steps:
Manual sawing was needed to part off the dice, followed by deburring to finish the edges.
The final product was a well-crafted 20-sided dice, ready for use.
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Creative Engineering Challenge Project Page
For the creative engineering challenge I was tasked to brainstorm multiple solutions to a problem and pick the one that makes the most sense to create a model in real life. the problem I thought about was not having a good place to put your glasses on your desk, they get pushed around everywhere until you lose them or they break. The solution I chose for this problem was to use my 3D printed Legos to make a glasses stand to put on my desk.
I also considered creating a brand around this concept, I think if the 3D printed Legos worked properly I could create a brand out of this since you can make it into any shape you want or need and really use them for whatever you need.
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