Build a Scale Model Prototype

Modeling is an important step in the engineering and design process. Before beginning work on a new project, engineers and designers develop models of what they want the product to look like. Models serve as examples both for those involved in development as well as customers.

Assignment: Working with your team, build a 1:1 scale model of the selected birdhouse design.

Part I : Tuesday - Wednesday. A paper template. Work from the sketches and diagrams. Create a paper template with poster board first. Craftsmanship and accuracy are critical.

Trace the template onto the foam board being as efficient as possible with the space and rely on straight edges.

Measure twice - cut once!

TIPS FOR WORKING WITH FOAM

- A new xacto knife with a sharp blade.

- Always cut away from yourself with a craft knife. Turn the piece or the cutting board itself to make this happen if needed.

=Many lighter cutting passes are better than one heavy pass. These lighter passes are easier to control and are less likely to tear the lower surface of the foam board. - A set of spare blades. To replace blunt blades. If it is feels like the foam board is getting difficult to cut, replace the blade (it will have lost its edge, be difficult to control and is more likely to cause an accident) - A metal ruler. Anything less than this will get cut up by your sharp blade! (+ other measuring instruments) - A cutting mat. See above! - A fine point pen / pencil. The finer you can get it, the more accurate you will be... A clutch pencil (mechanical) will keep a fine point and mean you won't have to keep sharpening! It's also easy to erase mistakes!

Marking Out Before making any cuts it is important to mark out the shape you want on the face of the foam board. Use your ruler and other measuring instruments to accurately measure, and your sharp pencil to mark the board. The best tip here is to not apply much pressure. You only need a light line to follow and you do not want to dent the board! Also lighter lines are easier to erase. Use a set square or angle measurer as needed in order to work out accurate angles. I usually mark new lines at angles using a series of dots before grabbing my ruler and joining them all up! Generally speaking you want to try and draw every line in one go to prevent untidy overlaps. It is even easier if you make a template by printing the shape you want onto paper. This is even more advisable if you need multiples of one shape. You can then print and trace the template as many times as needed and will save you lots of time in the long run.

Cutting a Straight Line

• Always place a scrap piece of foam board below the piece you are working on. This protects your tabletop and absorbs any over cuts.

The most basic of things is to cut a straight line. To cut a line you should hold your metal ruler firmly along the marking. Be aware of how the thickness of your blade relates to the thickness of the pencil. Ideally, you should cut ON the drawn line, not one side or the other of it.

Start by holding the blade vertically at the top of the line and piercing the top layer of the foam board. Do not cut at an angle. Do not try to cut all the way through in one go. Take your time and slowly pull the blade down along the line, angling the blade as you go to increase the cutting surface. Do not apply a lot of pressure, the first cut will run through the top layer. You will then repeat this cut so that you go through the foam (and score the bottom layer) whilst a final cut will go through the bottom layer. It is important to keep your ruler still throughout this process.

FoamWerks Tools Guide + Video Demonstration