Unit 4: 3D Design and Printing

Students will understand the practical application of Reverse Engineering and Iterative Design. Specifically, they will learn:
Tolerancing: The concept of "clearance" versus "interference"
Prototyping: The cycle of designing, printing, testing, and refining a product.
Design Constraints: How physical realities (material strength, printer resolution) dictate digital design choices.

Students will engage in a full "Design-Build-Test" engineering loop over 7 days. Activities include:
Reverse Engineering: Using precision measurement tools (calipers/rulers) to analyze a specific bolt's dimensions.
Applied CAD Modeling: Designing a functional wrench in Fusion 360 specifically tailored to their assigned bolt.
Prototyping & Testing: 3D printing their design and physically testing it on the bolt. If the fit fails, they must analyze the error, adjust the CAD model, and reprint (Redesign).
Documentation: Compiling evidence of their process into a formal presentation.

Students will demonstrate mastery through both a functional physical product and a digital portfolio:

• Functional Prototype: A 3D printed wrench that successfully fits and turns the specific bolt assigned to them.

• Project Presentation: A comprehensive slide deck that includes:

• Visual Evidence: Photos of the digital model vs. the physical print.

• Technical Documentation: A generated blueprint of the wrench.

• Reflection: Analysis of the design process, specifically addressing what changed between the first draft and the final product.