Manufacturing Level 2 - Power Tools, Machining & Digital Fabrication

Learning Objective

Apply Level 1's generic shop foundation to FRC-specific work: master safe operation of power tools and basic machine tools (drill press, band saw, bench grinder), perform fundamental machining operations on a manual mill and lathe with proper setup and tooling selection, produce a real part on a CNC machine with less supervision than Level 1, print functional (not just decorative) 3D printed parts, implement quality control procedures including in-process inspection and documentation, and develop basic fixturing skills. This level is self-guided and typically takes a couple of months; completing it means you can perform most of the basic manufacturing tasks the team needs day to day.

Prerequisites

• Manufacturing Level 1 - Shop Safety & Fabrication Basics
• Mechanical Level 1 - Basic Mechanical Concepts

Primary Resources

• FIRST Manufacturing Worksheet
• FRC Zero -- Machining & Fabrication
• Team 2471 (Mean Machine): Machinery Use and Certification
• Chief Delphi -- Mill Training
• Chief Delphi -- CNC Routers for FRC Robotics
• Design for 3D Printing (FRCDesign.org)

Tasks

1. Power Tool Operations

   • Use a drill press safely and effectively
   • Operate a band saw with proper blade selection
   • Use bench and angle grinders safely
   • Master portable power tool operations

2. Basic Machining

   • Set up and operate a manual mill
   • Perform basic lathe operations
   • Select proper cutting tools and speeds
   • Complete a basic machining project: a part with a pocket, tapped holes, and a bored hole

3. CNC Operation

   • Set up stock and work-zero on a CNC machine with reduced supervision
   • Load and run an existing program to cut a real part, typically on a CNC router
   • Understand basic tool selection and feeds/speeds for CNC cutting

4. Advanced 3D Printing

   • Orient a part to align layer lines with its primary load direction
   • Select wall count and infill appropriate for a functional (load-bearing) part
   • Design and print a part that uses a heat-set threaded insert
   • Print a functional part for actual use on the robot or in the shop

5. Quality Control

   • Perform in-process inspection
   • Document critical dimensions
   • Use go/no-go gauges
   • Maintain quality control records

6. Workholding & Setup

   • Design a simple fixture
   • Use machine vises properly
   • Implement 3-2-1 locating principles
   • Create setup documentation

Level 2 Completion Requirements

• Successfully complete a manual mill/lathe machining project against a given drawing
• Successfully cut a real part on a CNC machine with reduced supervision
• Design, print, and install a functional 3D printed part using a heat-set insert
• Pass a power tool and manual machine safety evaluation
• Create a complete setup and inspection documentation package for the machining project

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