Rapid Prototyping Project
ENGR 1182 | SolidWorks Assignment SW_3D | Out of Class Assignment
Overview
Each student will design a customized AEV part that could be manufactured on the laser cutter or 3D
printing. Optionally, the team will then evaluate the designs and choose one design that will be
manufactured for the team’s AEV. Each team is eligible to submit designs for a customized AEV part to be
created on the 3D printers; these parts will only be manufactured if the team’s design is approved by the
instructor. Background information on rapid prototyping and best practices for design are available in the
Rapid Prototyping Details PowerPoint on the course website on Lab 4 web page.
The Assignment
This assignment has two parts: Part A is required, Part B is optional.
Design for Laser Cutting or 3D Printing
Individual Designs –Step1
Individually use SolidWorks to design a part for your team’s AEV that could
be manufactured using the laser cutter or 3D printing. Follow the best
practices outlined in the Rapid Prototyping Details PowerPoint slides when
creating your design. Your part may be functional or decorative, but
providing a functional enhancement is strongly recommended. Write a ½
page explanation of your design and justify your design choices. Print
your explanation and a screen shot of your design to submit in class. This
individual assignment is for credit.
Select a Design Using Laser Cutting or 3D Printing for Manufacturing -Optional
Select Team Design – Step 2
Optional: As a team, evaluate each design and decide which will be the
best for your team’s AEV. Write a ½ page explanation about your team’s
AEV part and justify your team’s design. (i.e., what the part is for, how it will
be used, and why it is the best design for your AEV.)
Instructor Approval – Step 3
Optional: Meet with your instructor, in class or during office hours, to
receive approval on your part. Incorporate any feedback before
proceeding. Approval must be received before submitting your work.
Send to Manufacturing – Step 4 Optional: Submit your files to the appropriate Carmen dropbox. Submit
your original SolidWorks part file and the DWG file for Laser Cutting or your
original SolidWorks part file and the STL file for 3D Printing, and your ½
page explanation. Follow the file naming convention instructions listed on
the Carmen dropbox.
Part Manufactured – Step 5
Optional: Completed part is returned for incorporation into the Team’s
AEV.
ENGR 1182 | Rapid Prototyping Project
Schedule
LAB-01
Presentation of Rapid Prototyping Introduction - Laser Cutting and 3D
Printing
LAB-04
Presentation of Rapid Prototyping Details - Laser Cutting and 3D Printing and
the Rapid Prototyping Project Assignment (SW_3D due SolidWorks_05
Presentation)
Begin Step 1: Each team member creates part design
Class SW-05
Due: Step 1: Individual Designs (for Credit) due at beginning of class.
Submit a printed screen shot of your SolidWorks design & your ½ page
explanation.
Begin Step 2: Optional: Design Evaluation. As a team, choose the design
that will be manufactured for your AEV.
Class SW-08
Due: Step 2: Optional: Team design finished
Due: Step 3: Optional: Team should send design to the instructor and meet
with the instructor to seek their approval on the part design.
LAB-8A
Due: Step 4: Optional: With the instructor’s approval, send to
Manufacturing. Submit your team’s final files as specified under ‘Select a
Design – Step 4 above to the dropbox on Carmen.
LAB-9C
Due: Step 5: Optional: After Spring Break, the completed part is returned
to the Team for use on their AEV.
ENGR 1182 | Rapid Prototyping Project
Material Specifications
Note that both Laser Cutting and 3D Printing create parts that are very close representations of the
specifications, but they not exact reproductions. Since laser cutting may involve melting material, care
should be taken that features like holes are not located close to the material boundaries.
Laser Cutting Specifications
Material Options
You may choose from the materials listed below for your laser cut part, and in your design explanation you
may state a preference for color, but note that it is just a preference and not a guarantee.

Acrylic: Available in 0.25” or 0.125” thick. Colors include clear, black, red, green, yellow, blue

Polypropylene: 0.125” thick milky white material (same as AEV body)

ABS: 3/32” thick black, with texture on one side (same as AEV hangar bracket)

Wood: 0.125” plywood, or .25” thick MDF in black
Laser Cutting File Format
After creating your SolidWorks part you will need to save a ‘.DWG’ file. The DWG file should save only the
single outline of your part profile as explained in the Rapid Prototyping Details powerpoint. You can create
a DWG file from the ‘save as’ menu. It is important to make sure you are viewing normal to your part profile
(see slide 15 in the Rapid Prototyping Details powerpoint) before saving the DWG file. The following blog
shows step by step info on how to do this: https://grabcad.com/questions/how-to-extract-a-dwg-profile-from-a-
model-in-solidworks
3D Printing Specifications
Part Size
When designing your part, make sure that it will fit on our printers, which have a 6” x 6” x11” printing
envelope. You can also consider designing your part to be printed in separate pieces, which can be glued
together after printing.
Material Options
In your design explanation you may state a preference for the color of your 3D printed part, but note that it
is a preference and not a guarantee. Available colors include: black, gray, red, blue, white, green, pink,
purple, and natural (clear-ish).
3D Printing File Format
After creating your SolidWorks part you will need to save a copy as an “.STL” file, which is the file format
required to interface with the 3D printer software. Follow these steps to create an STL file:

Select ‘Save As’

Under ‘Save as type’ choose ‘STL’

Click on the ‘Options’ button

Adjust the sliders for ‘deviation’ and ‘angle’ so that they are about 2/3 of the way to the right.

Click ‘Ok’ and then ‘Save’