Manufacturing Level 1 - Shop Safety & Fabrication Basics

Learning Objective

Achieve shop safety certification including hazard identification and emergency procedures, master precision measurement using calipers, micrometers, and layout tools, develop proficiency with basic hand tools for filing, cutting, and finishing, demonstrate proper workholding and material handling, learn to operate a 3D printer from a provided model through slicing and printing, and safely run a pre-programmed job on a CNC machine under supervision. This level is intentionally generic: none of this requires FRC-specific knowledge yet, and it's meant to be self-guided and attainable in a few weeks (a highly motivated student could finish it in a long weekend).

Prerequisites

None

Primary Resources

• FIRST/FTC Safety Manual
• FIRST Common Bolt Sizes, Uses, and Hardware guide
• FRC Zero -- Machining & Fabrication
• FRC Zero -- Machining & Fabrication Safety
• FIRST Prototyping 101

Tasks

1. Safety Certification

   • Pass a comprehensive shop safety exam (90% or higher)
   • Demonstrate proper PPE usage
   • Identify all emergency stops and procedures
   • Show proper lifting and material handling techniques

2. Measuring & Layout

   • Use calipers to +/-0.001" accuracy
   • Read micrometers correctly
   • Perform basic layout with a height gauge
   • Use angle measuring tools accurately

3. Basic Hand Tools

   • File to specified dimensions and surface finish
   • Cut materials with hand saws
   • Use taps and dies properly
   • Demonstrate proper deburring techniques

4. Workholding

   • Use bench vises safely
   • Select appropriate clamps and fixtures
   • Demonstrate proper part support
   • Practice safe material handling

5. 3D Printing Basics

   • Understand FDM 3D printer components and basic operation
   • Prepare a provided model for printing using slicing software
     • Orientation
     • Supports
     • Infill
     • Layer height
   • Select appropriate print material for a given part
     • PLA
     • ABS/ASA
   • Diagnose and resolve a common print failure
     • Warping
     • Poor adhesion
     • Stringing

6. CNC Basics

   • Understand what a CNC machine is and how it differs from manual machining
   • Demonstrate CNC-specific safety practices
   • Load stock and set a work-zero on a CNC machine under supervision
   • Safely run a pre-programmed job on a CNC machine under direct supervision

Level 1 Completion Requirements

• Pass the shop safety certification exam
• Complete a measurement accuracy test using calipers, micrometers, and a height gauge
• Demonstrate proper hand tool use and deburring on a sample part
• Successfully slice and print a provided model without mentor assistance
• Safely load stock and run a pre-programmed CNC job under direct mentor supervision

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