4D Detailed manufacturing methods

Question 1

Time (3D printing)

Answer 1

• commercial scale: very quick and efficient
• school setting: very slow
• time is spent on CAD: to prevent wastage and gain an accurate prototype
• easy to made changes and alterations to existing designs
• training/servicing/repairing equipment (reviewed on at last an annual basis)

Question 2

Cost (3D printing)

Answer 2

• commercial scale: very expensive
• can include: printer/CAD package/servicing/maintenance/regular training/electricity usage/assembling
• school setting: a few 100 pounds

Question 3

Quality (3D printing)

Answer 3

• very high quality
• often seamless
• can be printed with working components inside them
• often used to test models/samples
• unusual shapes can be produced (may be impossible to create by hand)
• quality of the product depends on the printer itself
• compatible with a range of filaments/materials

Question 4

Time (laser cutter)

Answer 4

• quick and easy to use (once training on software has been given)
• easy and quick to make amendments and changes to existing designs

Question 5

Cost (laser cutter)

Answer 5

• commercial setting: can cost hundreds of thousands of pounds (power usage)
• school setting: anything from 20,000 pounds
• the cost of annual maintenance/training needs to be considered
• budget needs to be set aside for machine breakdown/loss of production

Question 6

Quality (laser cutter)

Answer 6

• if correct settings have been selected: quality output will be extremely high
• seals the edges of fabrics: prevents fraying
• if incorrect settings are chosen: materials can burn/ignite/melt (can be left with a black edge and leave a strong smell or residue that can transfer onto other materials/components)
• can cut-out intricate patterns/designs
• can etch patterns/designs into fabrics/materials (depending on depth of cut, materials and settings)

Question 7

Time (knife cutters)

Answer 7

• operates using CNC (computer controlled cutting): CAD designs easily altered/transferred
• produces very quick outcomes: often used to cut multiple layers at once, which saves time in a commercial setting
• commercial: often preferred to laser cutters as it leaves no residue on the edges and it reduces the risk of burning/melting/igniting

Question 8

Cost (knife cutters)

Answer 8

• initial cost: over 100k, but depends on the speed/quality of output and materials
• over time the knife cutter would need regular services and maintenance
• expensive software
• staff training and regular updates are required
• commercial: will gain profit over time as the output is very efficient

Question 9

Quality (knife cutters)

Answer 9

• very high quality
• cut edges are very precise, matching the CAD design
• the software can pick up flaws in the fabric and avoid those areas, making the pieces perfect for use
• much more versatile and easier to use in a variety of settings
• no residue left on pieces
• can cut through multiple layers, but won’t cut through sheer fabrics (inaccurate cut)

Question 10

Time (high powered water jets)

Answer 10

• works quickly (not as quickly as knife/laser cutters)
• water is forced out at a very high speed
• uses CNC: efficient to transfer and change CAD designs

Question 11

Cost (high powered water jets)

Answer 11

• machine: in excess of 100k
• can be bought for as little as 2k (schools)
• they are often not found in schools due to maintenance requirements and size
• depends on the size and power, as well as the materials

Question 12

Quality (high powered water jets)

Answer 12

• very high
• no residue left on material
• may be left damp from the water
• not suitable for highly absorbent fabrics (e.g. wool/cotton): causes shrinking, staining and takes a long time to dry
• can cut through very thick/dense materials with a high-quality outcome (e.g. Kevlar/Nomex/synthetics/metals/plastics)
• multiple layers can be cut at a time