Rapid Design through Virtual and Physical
Prototyping
Rapid Design through Virtual and Physical
Prototyping
Once you have created the sheets that will comprise the prototype, the next step is to built it. You will notice two holes at the top of each page in the corners. These are called the registration holes; one is circular and the other is oval in shape. These are used to line up the sheets when building the prototype.
Step 1: For the sheet
titled MASK, remove the blocks that have been cut by the plotter. You
will probably need an X-acto knife for this. Also remove the
registration sheets.
Step 2: With the two
metal pins placed in the corner pegs of the board, place the first
sheet on these pegs with the material (foam and paper) on top. Tape
the sides to secure it in place.
Step 3: Place the
sheet called MASK over the pegs, covering Sheet 1. Spray adhesive
over the sheets so that the area that is revealed on Sheet 1 is
covered with adhesive. Remove the MASK.
Step 4: Take Sheet
2. Peel off the blocks around the slice that encloses it, leaving
only the slice. Also, peel of the areas of the slice that are not part
of the prototype. For example, holes in the middle of your part Place
this sheet with the smooth side up over the pegs. If done correctly,
the registration holes will match up with Sheet 1. Press firmly on
Sheet 2 and slowly lift it off, making sure that the slices come off
completely. Repeat this process for every sheet except the last one.
The only difference is that there are no enclosures on sheets 3-?
unless you have enclosed them manually.
Step 5: One sheet has
minor registration holes in the upper right hand section, much like
Sheet 1. This is usually the last sheet of the model, but not always.
If you have manipulated the number of slices per page then there could
be other sheets after the sheet described. Also, if you have included
more than one subpart in your slice model or inverted building order
then there will be more than one sheet with a section with minor
registration holes other than the first sheet. Place this sheet over
the registration posts and press down as you did with the previous
sheets. Take an X-acto knife and while the sheet is still on the
building area, carefully cut the section with the minor registration
marks out. (The plotter has already made cuts to guide you.)
Step 6: Remove the
sheet while making sure that the section you just cut around REMAINS
IN PLACE. This section is starting section A.
Step 7: After you
have finished all of the sheets, you are ready to put the sections
together. Remove the sheet with the completed sections from the
registration posts.
Step 8: Label the
Starting, A. Flip the sheet over (making sure to not accidentally
remove a section) and label the remainder of the sections as denoted
below. After labeling, cut the sections apart into squares following
the lines cut by the plotter.
Step 9: Move one of
the registration posts to the appropriate minor registration hole on
the board. Remove the small square sheet covering the starting
section that does not have registration holes in it. Place the section
over the registration holes using the holes with the section FACING
UP.
Step 10: Orient
Section B such that the section is FACING DOWN. Place this section
on the registration posts. Make sure that the registration holes
match (oblong over oblong, circle over circle). Press down and remove
the square with the registration holes. (It is sometimes easier to rip
the square at the registration hole for removal.)
Step 11: Repeat Step 10
for all of the sections such that section C is next, then D, etc.
Step 12: Remove the new
prototype from the bottom square. Lightly coat it with glue so that
the sides with adhesive exposed are covered.
