User:1sfoerster/enes100/fall2013/p3Plexiglass

=Team Member=
 * Zachary Krell
 * Lucas Brown
 * Chris Snyder

=Problem (Finish Description)= Plexiglass resources such as those giving details on Plexiglass manipulation methods and supplies available to work on or with Plexiglass are minimal at HCC. Given these restrictions, the end result is:
 * Allow student lab access to continue experimentation with plexiglass cutting, bending, and gluing methods.
 * Apply experimentation results to miniature models/applications using existing lab materials and tools.
 * Develop jet engine using 3D printer models and apply plexiglass housing

=Conceive=
 * Evaluate materials and supplies needed to effectively heat and glue Plexiglass
 * Design and build bending table to improve quality and ease of bending Plexiglass
 * Experiment with cutting methods, identifying optimum method for clean cuts
 * Compare and contrast the effectiveness of drilling, cutting, bending methods applied on multiple models
 * Build prototype jet engine model

Resources/Materials


 * Plexiglass

Heating/Gluing:


 * Generic heat gun: no attachments

=Implementation=

Bend Table


 * Initially, we attempted implementation of Option 1 for the heating element. We tried several attempts at connecting the two printer heating elements.  Soldering failed.  Fusing the plastic coupler to the glass rods using a heat gun initially worked; however, once these heating elements were attached to the springs, they broke.


 * We switched to Option 2, using nychrome wire for the heating element which was initially successful. However, our design lack sufficient control of current through the dimmer switch.  Once the dimmer switch was turned up too high, it burned out.
 * When operational, the bend table made bends easier and quicker

Jet Engine


 * Due to time constraints, the development of the Jet Engine never got beyond printing and welding of the components downloaded in the Instructables above. Welding was accomplished using directed heat from the Dewalt heat gun.

=Operation= Plexiglass Models Using Bending Table
 * We evaluated the operation of the bending table as well as cutting, drilling, and heating methods by working on Plexiglas applications
 * The actual operation of the bending table is to turn on the electricity to the heating element and place the Plexiglass on the table with seam of the Plexiglass edge to be bent over the heating element. Heat for at least a minute or until the Plexiglass is bendable.  Fold the hinged, movable, smaller board until the desired angle is achieved.  Maintain this angle until the heating element is turned off and the Plexiglass fully cools.  The bend is complete!

The following are descriptions for each of the models, including the methods employed and any significant design notes and fabrication limitations. All bending was performed using the bending table. All cuts were using the Dremel tool.

Five Sided Box

This is a box cut and bent from a single sheet of Plexiglass. Due to the lack of precision of the heating element, the corners of adjacent bends are not crisp. If crisper corners are desired, future models should be comprised of multiple pieces of Plexiglass glued together.

Pencil holder

This model required straight cuts, using the heat gun to smooth the edges, drilling for the pencil holes, and 90 degree bending.

Book Shelf

This model is composed of multiple cut Plexiglass pieces adhered together with glue gun, due to inability to use adhesives without a brush. There are also 90 degree bends in this piece and smoothed edges via the heat gun.

Book Holder

This model required straight cuts, using the heat gun to smooth the edges, and 90 degree bends.

=Next Steps=
 * Improve circuit design of current through heating elements and switches of bending table
 * Complete Jet Engine development
 * Expand experimentation of glues with acrylic adhesive
 * Experiment with cut and burn designs using laser cutter
 * Improve display cases outside of engineering room and design small ones to put over completed