Computer aided design (CAD) and Computer aided manufacture (CAM)

CAD software is a very useful tool for any designer. It can allow you to try and test different designs or components without having to build expensive models.

Using the CAD software, you can even put your product into real world situations. Allowing you to test both your chosen materials and the design. The computer simulates the stresses and strains that the product is likely to go through and can help you identify any weaknesses.

When using CAD software your first step should be to sketch out the general shape of your design.

Everything in the CAD program is defined in space. You will therefore be required to choose which plane you want to work on. For this project we will choose the top plane.

When beginning your sketch it is also helpful to start from the origin point at the centre of the screen.

Once you have your general shape you will need to define it. This will ensure that the sketch is drawn to the correct size. You can do this using smart dimensions. Selecting each line allows you to enter the exact value you require. Once this has been done for each edge the outer lines of the shape will turn black. This shows it has been fully defined and is ready to extrude.

To turn our flat 2D shape into a 3D model you will need to extrude it. In the features tab select the extruded boss/base option. Then define how much you want to extrude your shape. We now have a 3D shape.

Our next step should be creating the studs on the top of the model. Simply sketch out the general shapes of the studs. You can use smart dimensions to resize the shapes and define where they are placed. This will allow you to make sure they are all a uniform size and distance from the edge. Once you are happy that everything is in place, you are ready to extrude the studs.

Now we have our 3D design, our next step is to hollow it out. This can be done using the shell function. You just need to select the face you would like to shell from and input the value for how thick you would like the edges.

Our last step for the design is to smooth out some of the edges. This can be achieved using the fillet feature. You simply select the fillet tool and then select the edges you would like to fillet. Enter the value for how much you would like to fillet. The program will give you a preview to visualise this before confirming.

And there you have it, your finished model.

Computer aided manufacture (CAM) involves using computers to control machines to undertake the production of goods.

Some examples of different CAM machines are 3D printers, laser cutters as well as different milling machines.

There are a number of advantages to CAM. For example: It achieves a much faster and accurate production; Machines can run constantly on repetitive tasks without getting bored or mes; it's great for producing on mass or on a production line; finally, there is also less wasted material, which should help keep your costs down.

There are however also some disadvantages to using CAM. For example: it can be quite expensive to set up; the machines themselves can be quite expensive; you will also require a skilled workforce of engineers to keep the process running; there is some downtime required for maintenance; and lastly, machines and computers can unexpectedly fail.

Laser cutting is the use of a high-powered laser to cut, etch and engrave your material.

Before we get started here are a few things you might need:

A choice of materials for cutting

Your design

Access to a laser cutter and CAD software

Lasers cut by burning through the material and are incredibly precise.

They can be used on cardboard, paper, wood, foam, acrylic plastics as well as on some metals and glass.

It's useful to that it's possible to cut out and etch within the same project.

The first thing you need to do is to create your design.

Your CAD drawing has to be a vector file, which is different from an image file, as it can be resized without losing resolution and the lines remain smooth.

You can use 2D CAD programmes to make your vector file.

Lasers follow the design lines just like paths so they need to be perfectly smooth.

A CAD drawing usually consists of three colours.

The laser cutter can then be told to do different things with each colour.

The first colour should be used for the shapes that have to be cut out.

This is called 'vector cutting'.

The second colour should be used if you want to engrave sharp lines or outlines into the material.

This is called 'vector engraving'.

While it does cut into the material it doesn't cut all the way through.

The third colour is used for any designs you want to etch into the surface.

This is known as 'raster engraving' and works much like a regular laser printer.

For faster engraving, the laser cutter makes multiple es across the surface of the material.

Once you've finalised your design, you will need to send it to the laser cutter.

There are two main variables to think about: the power of the laser and the speed it moves across the material.

The denser or thicker the material, the more power you will need to cut it.

The speed and power will also have an impact on how deep into the material the laser cuts.

With experience, you'll find which settings work best for different materials and thicknesses.

For now your teacher and the guide for the machine will give you an idea of where to start.

So now the machine is set up, it's time to get cutting.

Laser cutters get extremely hot, so as it cuts, the machine cools the material by blowing compressed air.

Depending on the material, laser cutting can create smoke and fumes so it's important to make sure the extractor hood is turned on.

Watching the laser cutter bringing your design to life is the best bit, so enjoy it!

Laser cutters are incredibly precise, so the final product or component needs very little finishing.