Aerospace Component CNC Manufacturing Challenge

Milestones

Complete the Six-Day Aerospace Component CNC Manufacturing Challenge

1. 1
   DAY 1 — Freeze the approved Fusion design revision. Verify that the technical drawing, requirements table, prototype disclaimer, stock plan, tool list, setup sheet, and inspection plan all reference the same revision.
2. 2
   DAY 1 — Review the complete Fusion setup, operation order, tools, cutting parameters, heights, workholding clearance, simulation, warnings, and estimated cycle time.
3. 3
   DAY 1 — Post the approved setup using the machine-specific pathway. DMC2 Mini uses the teacher-validated Mach3Mill workflow; FoxAlien uses the exact-model controller and teacher-selected post.
4. 4
   DAY 1 GATE — Complete the Production Readiness Checklist and receive written teacher approval.
5. 5
   DAY 2 — Inspect the assigned machine, stock, tool, collet/holder, workholding, fixture, and emergency-stop access.
6. 6
   DAY 2 — Secure and align the stock using the approved method. Record the stock dimensions and workholding locations.
7. 7
   DAY 2 — Complete the approved reference/startup process, establish the work zero, and verify the tool reference.
8. 8
   DAY 2 — Load the approved NC file and compare the controller preview with the approved Fusion simulation.
9. 9
   DAY 2 — Complete the raised-Z, air-cut, or single-block dry run. Verify direction, extents, depth range, clearances, spindle method, feed override, and final position.
10. 10
    DAY 2 GATE — Obtain authorization to begin material cutting.
11. 11
    DAY 3 — Start the program at the teacher-approved reduced feed or first-cut condition.
12. 12
    DAY 3 — Observe continuously from the approved location. Record program start, tool behavior, sound, vibration, chips, pauses, feed changes, interventions, and any nonconformance.
13. 13
    DAY 3 — Stop immediately for loose workholding, incorrect direction, excessive vibration, tool damage, unexpected depth, collision risk, or any unclear condition.
14. 14
    DAY 3 — Complete the approved shutdown, part removal, machine cleaning, and tool inspection.
15. 15
    DAY 4 — Deburr and finish only with approved tools. Preserve all features needed for inspection.
16. 16
    DAY 4 — Inspect every critical feature using the specified measuring tool. Record target, lower limit, upper limit, measured value, error, and pass/fail status.
17. 17
    DAY 4 — Repeat selected measurements to check consistency and identify any result close to a tolerance limit.
18. 18
    DAY 4 — Create a nonconformance report for every failed feature instead of altering or hiding the result.
19. 19
    DAY 5 — Complete the airframe-interface, payload-interface, fastener-access, and cable-clearance fit tests using the educational fixture.
20. 20
    DAY 5 — Compare predicted mass, machining time, and dimensions with the physical results.
21. 21
    DAY 5 — Identify whether the most important improvement belongs in the CAD design, drawing, CAM strategy, setup, machining procedure, inspection plan, or operator workflow.
22. 22
    DAY 5 — Revise the digital manufacturing package without remachining unless a second production run is approved.
23. 23
    DAY 6 — Prepare the final design review with the mission, requirements, CAD, drawing, CAM, NC code, setup, physical part, inspection, fit test, nonconformances, revision, and recommendation.
24. 24
    DAY 6 — Each student completes an individual reflection identifying personal contributions, technical learning, safety decisions, and evidence-based improvements.
25. 25
    DAY 6 — Archive the final Fusion file, drawing PDF, NC file, setup sheet, production log, inspection report, fit-test report, presentation, and reflection in the manufacturing portfolio.

Required File Traceability

• Fusion design file and version
• Fusion Manufacture setup name
• Tool library revision
• Post processor name and revision
• Posted .tap filename and date
• Mach3 DMC2 Mini profile
• Stock and tool identification
• Work offset used
• Approved production checklist
• Machining log
• Inspection report
• Fit-test report
• Revision record