Course description
This course is an introduction to mechanical design, fabrication, and prototyping. Students will acquire hands-on experience with tools used in modern mechanical workshops through completion of project work on the development and construction of mechanical prototypes. Topics include the mechanical design and prototyping process, computer aided design (CAD) in mechanical prototyping, introduction to fabrication processes, basic machining operations, rapid-prototyping tools, and machine shop best practices.
Course content
- The Mechanical Design and Prototyping Process:
- engineering design process
- modelling
- fabrication
- testing
- iteration
- evaluation
- Computer Aided Design (CAD):
- sketching: dimensions and tolerances, working drawings
- 3D Modelling: surface and solid modelling, parts and assemblies
- import of CAD models to computer aided manufacturing (CAM) software
- Rapid Prototyping Technologies:
- 3D printing
- laser cutting
- water jet cutting
- computer numerical control (CNC) milling
- Machine Shop Safety:
- personal protective equipment (PPE)
- machine operation best practices
- Machining Tools: description, safe operation, basic machine theory and usage of:
- hand tools
- Vernier-calipers
- lathe
- milling machine
- drill press
- band saws (vertical and horizontal)
- shear
- arbor press
Learning activities
Lectures, demonstrations, and hands-on lab work to apply techniques discussed in lecture.
Means of assessment
Assessment will be in accordance with the Douglas College Evaluation Policy. The instructor will present a written course outline with specific evaluation criteria at the beginning of the semester. Evaluation will be based on the following:
Quizzes: 0% - 20%
Group project: 0% - 15%
Individual student projects (minimum of 3): 65% - 90%
Total: 100%
Learning outcomes
Upon successful completion of the course, students will be able to:
- explain and follow the procedures for working safely in a modern mechanical workshop;
- explain the operating principles of rapid prototyping tools and machining tools found in a modern mechanical workshop;
- safely operate rapid prototyping tools and machining tools found in a modern mechanical workshop;
- apply basic machining theory to work with machining tools found in a modern mechanical workshop;
- use rapid prototyping tools, such as 3D printers, laser cutters, and waterjet cutters, toward the construction of a physical object or mechanical device;
- apply the engineering design process to generate, evaluate, modify, interpret, and revise conceptual design ideas for a mechanical prototype;
- select an appropriate rapid prototyping and/or machining process/tool for prototyping, based on component requirement specifications and technology limitations;
- produce a mechanical prototype of a design using rapid prototyping tools and machining tools found in a modern mechanical workshop;
- test and evaluate the performance of a mechanical prototype;
- produce documentation, including notebook sketches and CAD deliverables, of the design process and iterations involved in the fabrication of a mechanical prototype.
Textbook materials
Consult the Douglas College Bookstore for the latest required textbooks and materials. Example textbooks and materials may include:
- Machine Shop Trade Secrets: A Guide to Manufacturing Machine Shop Practices by James Harvey, current edition
- Makers: The New Industrial Revolution by Chris Anderson, current edition
- The Engineering Design Process: An Introduction for Mechanical Engineers by Ostafichuk, Hodgson, Fengler, current edition