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Session 3438

Reverse Engineering and Rapid Prototyping: A Senior Level Technical Elective for Mechanical Engineering Technology Students and Much More. David R. Forsman Penn State Erie, The Behrend College

Abstract

Students in the Mechanical Engineering Technology (MET) program at Penn State Erie, the Behrend College are highly versed in application oriented computer techniques for problem solving. Nine years ago, a senior level technical elective was developed that would allow students with an interest in CAD modeling and design extending beyond the nine credits of required CAD classes to further their knowledge of the latest technology. This course would also introduce students to aesthetic and ergonomic design issues, which, while touched upon in traditional design courses, have never been a major factor in the overall design process. Over time this course has evolved to one that also covers advanced surface modeling CAD strategies for geometry creation, both additive and subtractive methods for rapid prototyping and different methods of reverse engineering existing products. In addition, the acquisition of this technology and equipment has come to benefit both students in other courses and departments within the College. It has also become a resource for faculty doing research and local industry as well. This paper will describe the scope and layout of this class, student projects, and the equipment used, associated costs of running a laboratory and lessons learned as well as the impact on other faculty, departments and local industry.

Course Overview

METBD 410 (Rapid Prototyping, a technical elective) has the following Goals/Objectives: 1. Understand the advantages and disadvantages of different additive processes currently on the market. 2. Reverse engineer a product by digitizing geometry, importing the data into Pro/ENGINEER and creating a solid model from surfaces. 3. Build the model (Objective 2) on the Z-402 3-D printer and re-digitize the prototype using a non-contact scanner to verify the geometry against the CAD model. Iterate through Objective 2 and 3 as needed. 4. Create CNC tool paths for three axis milling operations including volume, local, conventional, contour and trajectory, using Pro/MFG on the CAD model. 5. Check tool paths for accuracy using Pro/NC-CHECK. 6. Post process all tool paths and execute them on a three axis CNC router.

Proceedings of the 2005 American Society for Engineering Education Annual Conference & Exposition Copyright © 2005, American Society for Engineering Education

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Forsman, D. (2005, June), Reverse Engineering And Rapid Prototyping: A Senior Level Technical Elective For Mechanical Engineering Technology Students And Much More. Paper presented at 2005 Annual Conference, Portland, Oregon. 10.18260/1-2--15219