Summary

In this course students build a physical prototype based on their own sketch design for an office façade. Instruction in basic metalworking techniques that students need is given in the structural laboratory.

Course contents

Training in the design of physical objects can be substantially enhanced by a degree of familiarity and experience with manufacturing techniques. A real-life prototype is produced of one element of the students own sketch design of an office façade. To this end basic skills in various metalworking techniques are acquired in the product development laboratory. Direct familiarization with production technology has a number of effects.

• Students learn to design on the basis of existing materials and semi-manufactures.
• Students obtain an immediate impression of what a design means when translated in actual size into physical materials.
• Students obtain insight into what materials can stand.
• Students develop respect for craftsmanship.

The theoretical framework is provided by a book on manufacturing techniques. The knowledge acquired is used in writing a manufacturing report in which the following questions are addressed:

• were the working drawings sufficiently informative?
• was the drawing complete?
• were any elements missing?
• was there sufficient dimensioning information?
• was the list of materials complete?
• to what extent was it it necessary to depart from the planned techniques, and why?
• to what extent does the prototype correspond with the image formed in the scenario?
• what contribution does the prototype make to the development process from scenario to system design?
• conclusion.

This is a group report. It must be submitted at the end of week 16 and is assessed separately.

Study goals

• Knowledge of industrial production and assembly techniques insofar as relevant for the design of manufactured building components.
• Skill in handling various industrial production and assembly techniques in the metalworking practicals and applying these techniques to the production of the prototype. These skills are assessed on the basis of the metalworking practical including production of the real-life prototype.
• Skill in reporting on the physical element of the product development process, the process between the working drawings and the ultimate production of the product. These skills are assessed by means of a report.

Shop drawings: week 11 until 13

In these weeks, the students are working together to provide shop drawings for a material prototype. These shop drawings need to contain all the information about the components elements and the way they are manufactured and assembled to make a working prototype. Every component has its own drawing in at least two flat projections, with all the internal and external sizes. All processes of manufacturing should be represented in the shop drawings. Every whole, mill, bending axis etc. is fixed in size and position. The drawings should contain all the information about the prototype, so that everyone can produce without any clarification. Besides the shop drawings the students also have to hand in a material list. This material list contains all the elements and components and assembly pieces to be ordered to make the prototype.

The student has to take into account there is a limited budget for the prototype to 500 euro including VAT. Increase of this budget is left over to students to look for sponsors from specific industries willing to supply essential components. In the same period of study, the students are brought in contact with production methods by instructions. The instructions are being organized in the BT Lab and contain instructions in several types of welding, machining milling and sheet metal forming. The instructions will help the students to get a clear idea about the manufacturing of the prototype.

Products:

• Shop drawings of material prototype
• Material list
• Budget
• shop drawings report

Making the prototype: week 15 until 18

The students have one week to translate their shop into a real 1:1 prototype. While building, lots of choices have to be made and problems need to be solved. For example changes due to techniques that are not accurate enough, mistakes that have been made during the building process and problems that occur with the assembly of the construction units. By the end of the week each group presents their prototype.

Products:

• A material prototype
• A material prototype
• Prototype report

Final design: week 11 until 22

As a couple you have worked together in the practicals of mechanics, building physics, material science, product development and computer aided design. The result of these practical's as well as the process of the shop drawings and the prototype, have an input in the design process. All these results and experiences are integrated in the final design, they can refine your design to a 1:1 scale. The final design will be presented and examined in week 22.

Products:

• Presentation of the final design:

The presentation contains an overall description of the façade. It shows how the practicals as well as the process of the shop drawings and the prototype have shaped the design. The design will be presented in a 1:100 showing an overview of the façade, a 1:20 showing the relation with the office behind and a 1:5 showing the detailing of the façade. The quality of the drawings should be clear and readable in al aspects of the design. You will be judged on the way the knowledge off all disciplines is translated in an integrated design. How the results of the practicals are translated in the final design and how the process is translated in a complete, clear and readable story.

• Final design report:

The report describes why choices are being made and shows in this way how the scenario has improved as a result of the practical's of building physics, mechanics, material science and computer aided design. At the end you make an evaluation on the final design in comparison with your goals that you have formulated in the beginning of the semester.

Instructors

Peter van Swieten (responsible instructor)