For this week’s task, we created two identical versions of the diamond shape with a pattern cut in the middle using a waterjet cutting machine. The diamond must be created using Adobe Illustrator (5 in. x 3 in.) and imported into ProtoMax layout as the first stage in this procedure. In order for the waterjet cutting device to choose the starting point, the design is converted into a digital file. The dimensions, angles, and any other intricate elements of the pattern are specified in this digital design, which is saved into ProtoMax Make before cutting begins. Because the piece of the diamond might shift if we cut the outer form first, we chose the start point toward the middle pattern to ensure the cut went well.
Following the directions, We cut with a water jet machine and discovered that there are numerous scratches on the metal surface caused by debris. As a result, we employed a sandblaster to eliminate any flaws that the waterjet cutting procedure may have left behind, such as burns or inconsistencies. Sandblasting has the ability to give the metal a certain texture or finish, so it produces a smooth, homogeneous surface for the following process. This not only improves the material’s look but also its ability to adhere to a powder coating.
We used a vinyl cutter to cut elaborate shapes from sticky vinyl material, specifically a star and a heart. Then, as masks, these vinyl cutouts are carefully adhered to the diamond’s right and left metal surfaces. Each heart has a beginning and a side measurement of 1 inch. We intended to use powder coating to give the diamond its desired color and protective layer because the metal components appeared to be already smooth and clean. After pumping to 10 psi, an electrostatic pistol adds a fine, dry powder to the diamond’s sandblasted surface. To ensure equal covering, the positively charged powder particles are drawn to the grounded metal. The coated metal item is then baked for 18 minutes at 400F in the oven. The powder melts, flows, and chemically interacts during this process to produce a hard, long-lasting finish that is immune to chipping, cracking, and fading. I have two identical metal parts, one of which has a single layer of coating and the other two. I can see the differences in color after baking. Evidently, the two-layer coated metal has a darker, more substantial appearance. Additionally, one of the metal pieces’ sharp corners accidentally brushed the oven’s inside wall when I put them in the oven, causing the powder to fade slightly and become almost invisible.
Cost analysis table:
| Cost Type | Cost | Price | Source | Quantity | Total |
| Materials | 0.0179in stainless steel | $18.47 | Home depot | 1 piece | $18.47 |
| Labor | waterjet operator
sandblaster labor vinyl cutting labor powder coating labor |
$17
$18 $16 $15 |
ZipRecuiter | 1 h
10 min 30min 30min |
$17
$3 $8 $7.5 |
| Prototyping Engineer (You!) | $38 | ZipRecruiter | 1 h | $38 | |
| Overhead | Facility Cost | $21/h | Techniwaterjet | 1h | $21 |
| Quality Control | $41 | ZipRecuiter | 0.5h | $20.5 | |
| Design | Engineering and Development | $0 | N/A | N/A | $0 |
| Iterations | N/A | N/A | N/A | $0 | |
| Misc. | Waste and Scrap | $1.64/piece | Verichek | 0.5 piece | $0.82 |
| Total | $134.29 |
