So now we move on to manufacturing methods, there are six manufacturing processes that are going to allow us to create almost any part. So first of all, we have the milling operation. And this is where a rotating cutting tool moves around to remove material from a block. In order to do this, it's either the table down below or it's the cutting tool up above that's moving, and we can machine or we can mill nearly any shape or angle. So you can see this as an example over to the right. This car with many different angles was machined with that spinning cutting tool above internal features, though, are difficult or impossible.

Holes, of course can also be drilled with this milling operation. And really, you can think of this as starting with a block a rectangular shaped piece of stock material and you can think of this as sculpting your part from that block of the four materials we're dealing with right now. metals, plastics, ceramics and composites can be milled. So all four of them So here you can see a male in operation. And we started with this rectangular piece of metal. And you have the rotating cutting tool above and it's removing material.

As it moves across in this case the table is moving. So here's another part that's been milled. In this case, the material, the stock piece of material is much larger. But you can see that the both the table is rotating and the cutting tool is moving up and down and at different angles. And this allows you to create unique angles in your part. And lastly, here's a piece of plastic that's been milled.

The mill is computer programs. So all of the cutting paths are programmed ahead of time. And you can see this block of plastic we started with rectangular block of plastic and it's been milled away creating some pretty small features here as well. So we move on to our next manufacturing method which would be the lathe which is also called turning. In this case a jaw holds a cylindrical piece of material, both the machine and the material spin while a cutting tool moves in and shapes the part holes can also be drilled in the ends of the piece. You can think of this as similar to shaping clay on a pottery wheel.

So in that case, you would have the clay is spinning on your pottery wheel and you're moving your hands in similar to the cutting tool and move in to shape your part. metals, plastics, ceramics and composites can be turned so all four of our materials here. In this case, here's our stock material. We started with a cylindrical shaped piece of metal and you can see the cutting tools moving And you're able to cut really any shape that you would want from the outside of it. And right here we're drilling into the end of the part. Next we have the 3d printing operation.

Here molten plastic is extruded through a small nozzle. As you can see, this is the small nozzle and this blue plastic is extruded out the end of it to create our part, the plastic quickly cools and hardens. And so in general, the parts are built layer by layer in this process. So we're 3d printing a part here, which is the read material that's being laid down layer by layer. You can see the whole feature on the left here. And here's another example of 3d printing, where the plastic is being extruded out of this Small nozzle and it's created a really unique part.

And that's one of the major advantages of 3d printing. And these you could consider internal features, this would be very hard to produce on a mill. So with 3d printing, one of the weaknesses of it can be that you're laying down this part layer by layer, and so sometimes the layers can separate. But this process is just getting better with time and you really can make some really strong parts with 3d printing. The main advantage of 3d printing is that you can make very complicated parts and you can do it very inexpensively. So once you create your model on your computer, you can straight print it out.

You can actually buy 3d printers and print in your home or you can have a machine shop, print the parts For you, internal features are possible and parts are printed directly from your CAD models. So this is quite a new manufacturing method that's available to us and it has definitely caught on for a reason. And plastic is the primary material that is 3d printed we are commonly 3d printing plastics all the time. We have the laser cutting process. Here a high powered laser cuts 2d parts out of a sheet. The laser is programmed from a computer to cut the max sheet thickness for cutting mild steel would be about one inch so we can cut some pretty thick pieces of material and that's in steel.

And so with other materials we could even go thicker than that material heating though can slightly warp at the edges and we can laser cut metals, plastics, composites, and ceramics and here we have the laser cutting process. So next we move to water jet cutting. And here is where a high pressure water jet cuts two dimensional parts from a sheet so we're again cutting 2d parts from a sheet of material. As with laser cutting the water contains particles of an abrasive so you could think of you know small sand particles for example within the water that are going to give it a higher ability to cut Garnet is the common abrasive that's used. You can cut steel up to a few inches thick so quite impressive with with high pressure water with a with particles in it, you can cut steel up to a few inches thick so this would be thicker than laser cutting, and in this case, there's no damage from material heating.

So this is really a great manufacturing option. If you're cutting two dimensional parts out and starting with a sheet of metal We can waterjet metals, plastics, composites and ceramics all for and lastly we have the bending process. So here is where sheet metal is precisely bent at different angles to form a part a break is used to clamp and bend the parts. A max bending thickness would generally be around a quarter inch or less, and that would be for metal. And this would be common for enclosures, casings, brackets, you can really make a ton of different parts with the bending process as seen. And so commonly you would start with a two dimensional sheet and you can laser cut or water jet cut two dimensional shapes out of it or holes out of it, and then bend your parts and you can create a ton of different parts in this way.

Metal is the primary material that bending is performed on. So with all of the manufacturing methods that we just went through the general ways to shape your part are just a few. We can visualize this in just a few ways. We're starting with a flat sheet of material and cutting shapes from it. And as we said, you can also bend the sheet after cutting. So starting with a sheet starting with a block of material and shaping the block with a cutting tool.

So this would be as in the milling process, you can think of sculpting from a block starting with a cylindrical piece of material and shaping it. So we're either studying with a hollow tube, or we're starting with a solid cylindrical rod. You can think of this similar to shaping clay on a pottery wheel, or we're starting with molten material or liquid and building our part layer by layer so similar to 3d printing. And so when we're designing as you see here, the different methods and materials that we went through, as we're designing, first of all, on the left, we're going to choose our material based on design constraints, we need certain characteristic characteristics of a material we have to meet. We have to choose what stocks material form we're going to start with, so I choose my metal. And then I'm going to start with, for example, a block.

And then on the right, I'm going to shape that block and with a certain manufacturing method, and so all of the different combinations here are going to allow us to create a lot of different parts. So steps in designing a part. First of all, we would define our design constraints, we might need low weight or corrosion resistance, or some of these other design constraints. And so to meet these design constraints, we would ask if a premade part would work. Can we buy something that's already been made mass manufactured that's going to allow us to get our part cheaper? If we can't, we're going to have to design a custom part, you will need to ask what material you should use based on your design constraints that you defined ask what shape of stock material you would start with, and then how are you going to shape that stock material what manufacturing method Are you going to use?

So we've got through the different categories of materials and looked at them, and we've gone through manufacturing methods that will allow us to create almost any parts. Let's go ahead and put our knowledge to the test in a design