Mechanical Implementation Services for Rapid Prototyping

ABSTRACT Inspired by the MOSIS project, CyberCut is an experimental fabrication testbed for an Internetaccessible, computerized prototyping and machining service. Client-designers can create mechanical components, generally using our web-based CAD system (available at http://cad.berkeley.edu), and submit appropriate files to the server at Berkeley for process planning. CyberCut then utilizes an open-architecture, CNC machine tool for fabrication. Rapid tool-path planning, novel fixturing techniques, and sensor-based precision machining techniques allow the designer to take delivery of a component machined from high-strength materials with good tolerances, e.g. +/0.002 inch (0.05mm).There are also instances where the component’s complex geometry cannot be prototyped on our 3-axis machine tool. For these components we use Solid Freeform Fabrication (SFF) technologies such as Fused Deposition Modeling (FDM) to build a prototype of the design. Based on our experience with this testbed, we have developed a new characterization of types of relationships, or “couplings,” between design and manufacturing using the following three classifications: 1) loose, repetitive, 2) stiff, one-way, or 3) strong, bidirectional. These three couplings represent different trade-offs between “design flexibility” and “guaranteed manufacturability.”