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01 - Design to Manufacturing Explained..

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Computer Numeric Control (CNC) Manufacturing of CO2 Cars - An Overview

Stage 1 - Prepare Final Design for Manufacture in Autodesk Inventor (Done by the students)

  • Check design for rules compliance
  • REMEMBER - Your part to be machined must fit within the dimensions of the standard Foam F1 Model block. The dimensions can be found in the Technical Regulations document.
  • Add a machining reference plate to the 3D design. See details by clicking > Here
  • Save your design as a .STL file in Autodesk Inventor and email to F1 in Schools

Stage 2 - Submit a Manufacturing Request to YMC

  • Find the online link (CLICK HERE). Fill the form and upload your car body (with reference plate attached) STL file.
Manufacturing Costs:
  • Standard machining = 350 Dhs per car (this includes all resources and full standard car wheel and axle kit)
  • Additional machining operations = AED 50 each per operation. (Some designs will require additional machining to create detail on the top or bottom of the car that isn't accessible through standard side machining. Don't worry, F1 in Schools will check for this and inform you if it is required)

Stage 3 - Computer Aided Manufacture using QuickCAM Pro (Done by the manufacturing centre)

  • The 3D car model is converted to machining code. This is known as G-Code and includes all of the X,Y and Z co-ordinates that describe the profile of the car along with cutting speed, feeds and other instructions for the machine cutting operation to follow. Click the thumbnail below for an example of what this code looks like.

code-snip.png

Stage 4 - CNC Machining (Done by the manufacturing centre)

  • Cars are machined on a DENFORD 3D CNC Router see this link for more information about these machines - http://www.denfordat...ompact-1000.pdf
  • The Foam F1 Model blank is mounted in a special F1 in Schools Machining fixture
  • Standard Machining, with the car oriented on its side commences via material being removed leaving behind the profile of the car design
  • Here is a video of a typical CO2 car machining operation....
  •  

Stage 5 - We deliver the completed car body/s and wheel kits to your school!

We will be developing more detailed classroom friendly resources that help explain the Design through to Manufacture soon.

If you have any suggestions or comments, please reply to this post...

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Hi,

I am working with a group of students and we have registered our teams for F1 in schools. May I know the submission date for car design and where do we email? Apparently the email address: f1inschools@ymc.ae failed to receive the message due to the server misconfiguration.  

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Hi Nadia - Are you referring to the Formula Ethara competition this May 12? If so, this section you are reading is related to F1 in Schools only. If you are looking for help with F1 in Schools, please email me direct paul.bray@ymc.ae - Thank you!

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