Unit 13 Lesson Plan: Design your Own Part (optional)
Grade Level:
9-12
Prerequisites:
9th Grade General Math & Science
Concepts Addressed:
Engineers and designers use a variety of tools and techniques, ranging from freehand pencil sketches to sophisticated digital modeling, to explore ideas and communicate concepts and technical directions to others. The design development process can be expedited through the use of virtual prototypes and rapid prototyping. The development of a custom product feature for a robot requires careful consideration for how it will be integrated into the entire robotic system.
In this optional unit, students will use Autodesk® Inventor® and/or Autodesk® Fusion 360™ software to design and model their own custom part for addition onto their robot. If possible, students will utilize rapid prototyping (3D printer, laser cutter, CNC milling machine) to create their part and implement it onto their robot before testing its efficiency.
Learning Objectives:
- The students will be able to analyze an existing product (VEX robot) to identify potential areas for innovation that might include improvements relative to performance or cost, among other factors.
- The students will be able to explain how physical sketch models, 2D sketches, and 3D digital models can be used as visualization tools for design ideation.
- The students will be able to use Autodesk Inventor and/or Autodesk Fusion to create, render and animate custom 3D models.
- The students will be able to describe the importance of documenting and annotating a design in the design software.
- The students will be able to physically create a custom part from a virtual prototype using Autodesk Inventor and/or Fusion.
STEM Connections:
A key aspect of design innovation involves the ability to analyze existing design solutions to determine areas for improvement. This unit offers students a chance to engage in new product development by exploring ways to develop additional components to enhance or expand the capabilities of the VEX® Classroom Lab Kit. They will employ design visualization through digital design software technology in conjunction with engineering math formulas to create and animate their 3D models. Geometry and algebra calculations will be made with respect to forces and power requirements, engineering tolerances, degrees of freedom, finite element analysis, strength-to-weight ratios and kinematics.
Materials Needed:
- Unit Guide
- Internet Access
- Dictionaries
- VEX Robotics Kit
- Online Resources
- Computer with Autodesk® Inventor® or Autodesk® Fusion 360™ software (Note: software is available on the Autodesk Education Community at no charge to students, instructors and schools. Visit www.autodesk.com/educationto download required software at least a day before before your class begins.)
Key Terminology:
- CAD stands for computer-aided design.
- CNC stands for computer numerical control for machines, which enables a machine to be programmed to quickly make parts.
- Constraints in Autodesk Inventor and Fusion are used to determine how parts are attached to each other in an assembly and generally limit the degrees of freedom for a part.
- Degree of freedom is a value that represents the number of different ways a component or object can move.
- Design constraints are limits that the design must stay within to remain viable.
- Orthographic view sare used to view a three-dimensional object as a two-dimensional drawing. When multiple orthographic views are used and are situated at right angles to each other, it is known as a multiview drawing.
- Prototype is a physical or virtual model used to evaluate the technical or manufacturing feasibility of a particular 3D design product concept, technology, process, end item, or system.
- Rapid prototyping is a term that refers to creating a prototyped part with a 3D printer, laser cutter, or another fast means of making a part; for example, with a CNC milling machine.
- Tolerances are used to constrain the amount that a feature can deviate from its desired dimension.
- 3D printer is a device that can literally print in all three dimensions and is commonly used for rapid prototyping.
Note: There are two separate Day to Day Lesson Plans available: one for Parametric Modeling with Autodesk Inventor and one for Free Form Modeling with Autodesk Fusion. You may pick one or both to suit the needs of your class.
· Parametric Modeling with Autodesk Inventor covers:
o Unit 13.2 for basic skills videos
o Unit 13.4 for the project – designing a battery clip
· Free Form Modeling with Autodesk Fusion covers:
o Unit 13.3 for basic skills videos
o Unit 13.5 for the project – designing a wheel
Lesson Plan for Parametric Modeling with Autodesk Inventor
Day to Day Lesson Plan:
Lesson 1:
Introduce this optional unit with an overview of the basic commands used to design a custom component in Autodesk Inventor. Students will familiarize themselves with these commands as they review the videos. These tutorials are meant as an overview, and the student is not expected to duplicate the work being done in the videos. These videos are also a great refresher if the student has not used the software in a little while. The following videos should be viewed in Unit 13.2:
1. 2D Sketches
2. Part Browser
3. Line and Fillet Tool
4. Geometric Constraints
5. Dimensional Constraints
6. Part Basics
7. Creating Parts 1
Note - If the student is already familiar with Autodesk Inventor, have them demonstrate their knowledge of these features and move on to Lesson 3.
Lesson 2:
Students will continue to review the basic commands of Autodesk Inventor. Encourage students to assist each other in learning the software. They should view the following videos in Unit 13.2:
1. Creating Parts 2
2. Creating Parts 3
3. Work Features
4. Pattern Features
5. Part Properties
6. Creating Drawings
Lesson 3:
Students will use Autodesk Inventor to create a custom battery Clip in Unit 13.4. The Overview video will give them an idea of what is expected of them in this project. The files required for this activity must be downloaded, and data sets in Imperial and Metric units are available. Metric equivalents are given throughout the text. Find the files in Unit 13.4, located after Video 1 in the text.
The data sets provided will work for Inventor version 2013 onward. Download and unzip these files and save them into a new project folder. Also download the 3D print files for this activity, located with the data sets in Unit 13.4.
Students should watch the following videos in Unit 13.4 to learn how to begin modeling their battery clip:
- Overview
- Video 1: Create a New Part and Sketch
- Video 2: Model the Battery Clip
Lesson 4:
Students should watch the following videos in Unit 13.4 to learn how to efficiently build a battery clip and add features like mounting holes and engraving text to the battery clip:
- Video 3: Mirror the Battery Clips
- Video 4: Add the Holes
- Video 5: Engrave the Battery Holder
Lesson 5:
Students should watch the following videos in Unit 13.4 to assemble the custom battery clip onto the Clawbot:
- Video 6: Assemble the Battery Holder
- Video 7: Assemble the Battery Holder to the Robot
Lesson 6:
Students should watch the following videos in Unit 13.4 to learn how to document their new design, make an IDW drawing with all the associated views and annotation, and review the assembly to prepare the model for 3D printing:
- Video 8: Document the Part
- Video 9: Modify and 3D Print Battery Holder
- Summary Video
Students then watch the Summary video and reflect on what they have accomplished in their engineering notebook.
Engineering Notebook “Seed Questions”:
1. What other custom parts could be designed for the Clawbot?
2. How many different methods of Rapid Prototyping are there?
3. Can you name some rapid prototyping techniques?
4. How can the model information from Autodesk Inventor be used to produce a real prototype of your design?
5. Take it one step further: The design process used to create a new part for a VEX robot is greatly enhanced through the application of virtual modeling with Autodesk Inventor and rapid prototyping with technologies such as 3D printing. There are a variety of 3D printing technologies on the market that vary with respect to cost and performance. Investigate these technologies and develop a matrix that compares factors such as speed, precision, printing material used, part durability, post-processing requirements, and volume of work envelope.
Final Presentation (optional):
To prepare students for future success in school, careers, and life in general, organize students into small groups to then make a presentation to the class. Ask the students to reflect on what they learned creating the battery clip, and brainstorm on ideas for other custom parts for their VEX robot. Have them consider what kind of additional parts could be created to enhance the performance of the robot, and record what the part is and how it would improve the robot’s functionality. Have students sketch out ideas and work with their groups to get creative. Depending on availability of time, consider having students sketching 2D ideas on paper or on the Autodesk Sketchbook app if students have mobile devices.
Instruct the students to prepare and conduct small group presentations that capture the important aspects of designing a custom part in Autodesk Inventor. Ask students to demonstrate how this project has helped them expand and enhance the four Cs of their learning and innovation skills: critical thinking, communication, collaboration, and creativity.
Stress the importance of using software tools to visualize, animate, and present the same way real professionals do every day. Remind students that many colleges, universities, and employers place high value on digital portfolios that convey how a student thinks, how they work with others, how they can generate creative solutions, and how they communicate their ideas and knowledge through a variety of written, visual, and oral formats. By investing effort into this project, your students will be one step closer to their goal for careers and/or college.
Lesson Plan for Free Form Modeling with Autodesk Fusion
Day to Day Lesson Plan:
Lesson 1:
Introduce this optional unit with an overview of the basic commands used to design a custom component in Autodesk Fusion. Students will familiarize themselves with these commands as they review the videos. These tutorials are meant as an overview and the student is not expected to duplicate the work being done in the video. These videos are also a great refresher if the student has not used the software in a little while. The following videos should be viewed in Unit 13.3:
- User Interface
- Dashboard
- Data Panel
- Start an Empty Design
- Use Mirror Symmetry
Note - If the student is already familiar with Autodesk Fusion, have them demonstrate their knowledge of these features and move on to Lesson 3.
Lesson 2:
Students will continue to review the basic commands of Autodesk Fusion. Encourage students to assist each other in learning the software. They should view the following videos in Unit 13.3:
- Draft Command
- Fillet and Chamfer
- Insert Edge
- Insert Point
- Subdivide
- Press Pull
Lesson 3:
Students will use Autodesk Fusion to create a custom wheel for the Clawbot in Unit 13.5. The Overview video will give them an idea of what is expected of them in this project. The files required for this activity must be downloaded, and data sets in Imperial and Metric units are available. Metric equivalents are given throughout the text. Find the files in Unit 13.5, located after Video 1 in the text.
The data sets provided will work for all versions of Fusion, and Inventor version 2013 onward. Download and unzip these files and save them into a new project folder. Also download the 3D print files for this activity, located with the data sets in Unit 13.5.
Students should watch the following videos in Unit 13.5 to learn how to begin modeling their custom wheel:
- Overview
- Video 1: Create a New Design
- Video 2: Assemble the Wheel Tread and Rim
Lesson 4:
Students should watch the following videos in Unit 13.5 to learn how to upload the Clawbot frame, set up connections and constraints, and assemble the wheel to the main robot frame:
- Video 3: Assemble the Frame
- Video 4: Assemble the Frame and Wheel
Lesson 5:
Students should watch the following videos in Unit 13.5 to render and animate the assembly, share a Fusion project, and prepare the file for 3D printing:
- Video 5: Render and Animate the Frame
- Video 6: Manage the Project and 3D Print
- Summary Video
Students then watch the Summary video and reflect on what they have accomplished in their engineering notebook.
Engineering Notebook “Seed Questions”:
6. What other custom parts could be designed for the Clawbot?
7. How many different methods of Rapid Prototyping are there?
8. Can you name some rapid prototyping techniques?
9. How can the model information from Autodesk Fusion be used to produce a real prototype of your design?
10. Take it one step further: The design process used to create a new part for a VEX robot is greatly enhanced through the application of virtual modeling with Autodesk Fusion and rapid prototyping with technologies such as 3D printing. There are a variety of 3D printing technologies on the market that vary with respect to cost and performance. Investigate these technologies and develop a matrix that compares factors such as speed, precision, printing material used, part durability, post-processing requirements, and volume of work envelope.
Final Presentation (optional):
To prepare students for future success in school, careers, and life in general, organize students into small groups to then make a presentation to the class. Ask the students to reflect on what they learned creating the custom wheel, and brainstorm on ideas for other custom parts for their VEX robot. Have them consider what kind of additional parts could be created to enhance the performance of the robot, and record what the part is and how it would improve the robot’s functionality. Have students sketch out ideas and work with their groups to get creative. Depending on availability of time, consider having students sketching 2D ideas on paper or on the Autodesk Sketchbook app if students have mobile devices.
Instruct the students to prepare and conduct small group presentations that capture the important aspects of designing a custom part in Autodesk Fusion. Ask students to demonstrate how this project has helped them expand and enhance the four Cs of their learning and innovation skills: critical thinking, communication, collaboration, and creativity.
Stress the importance of using software tools to visualize, animate, and present the same way real professionals do every day. Remind students that many colleges, universities, and employers place high value on digital portfolios that convey how a student thinks, how they work with others, how they can generate creative solutions, and how they communicate their ideas and knowledge through a variety of written, visual, and oral formats. By investing effort into this project, your students will be one step closer to their goal for careers and/or college.