McKenzie Kil-A-Bytes

Team 1024 has the great benefit of having a Stratasys MAXUM FDM machine. For those unfamiliar with FDM, or Fused Deposition Modeling, it is a process used to make plastic prototype very quickly. Stratasys developed and patented Fused Deposition Modeling which can build accurate, complex parts using a variety of high-performance engineering materials like ABS, polycarbonate and polyphenylsulfone. Our team is able to use the FDM machine housed at our school to make parts for use on the robot.

The process begins with Autodesk Inventor. The student design team is able to create a part in Inventor, make sure it fits by creating an assembly, and then export it as a .STP file. This STP file is transferred to the FDM’s Insight software, where the Inventor files are automatically sliced and oriented to fit within a given system's build envelope. Insight also generates precise extrusion paths for the specified build materials along with any additional support structures.

The FDM machine then builds the piece from the bottom up, layering ABS plastic. This technology has been used by companies such as Adidas, Logitech, and Hyundai and our team is fortunate enough to have the same capabilities. The parts that the students design are able to come to life and be used on the actual robot. Last year, the team designed pulleys to replace the aluminum ones. The ABS plastic parts were nearly 60% lighter, while still being tough enough to handle the wear and tear of a typical match.

This year, our team was able to further utilize the FDM technology. The Omniwheel gearbox is housed in a piece designed and made by the students. We were able to place the motors and gears from the FIRST Virtual Kit of Parts into an assembly and build a plastic block to hold everything. We then exported the file and walked down the hall to have it prototyped. Another key element produced with the FDM was the encoder wheels, which we also designed in Inventor and produced with the Stratasys FDM.

Our team is able to utilize Autodesk Inventor as more than just a modeling tool. We are able to make Inventor a valuable design tool that, when combined with the FDM process, can provide the robot with custom-fit, highly accurate parts that are light-weight, yet sturdy. This also provides the Student Design team was real world experience, as they get to work with new technologies that are rapidly changing the way people design new products and make prototypes.

McKenzie FDM Machine

2004 FDM Pulley

Inventor Block Plastic

Produced Inventor Block Plastic

Encoder Wheels