The document summarizes 3 projects where the author used 3D modeling and 2D graphics to create manufacturing documents. For a client building an ultralight aircraft, the author reverse engineered the design and created assembly instructions. For a client developing aircraft lift kits, the author modeled components and created fabrication and installation drawings. The author also modeled an air duct damper and created shop drawings to help refine the design.

1. Manufacturing Design & Drafting PortfolioFor the following three projects I used a combination of 3D modeling and 2D graphics to create a variety of documents from manufacturing shop drawings, prototype models, patent sketches to assembly and installation instructions.All three clients were not familiar with how 3D modeling could benefit their projects. After successful discussions and the initial images they recognized this would offer more than they anticipated. Staggerlite ultralight aircraft by Desert Aviation

2. Goddard Lift Kit for the Piper Supercub by Airborne Research

3. Inline Duct Damper by ATECSStaggerlite ultralight aircraft This client had built a scaled down ultralight version of a dual stagger winged aircraft popular during the 1920s & 1930s. They worked from crude sketches and trial and error. They hired me to reverse engineer what was completed, create documentation for parts still needed and create the construction and assembly manual.The ultralight was to be built from aircraft grade spruce plywood components cutout by the customer using the manual and included full size templates. Metal components were also fabricated by the customer with the guidance of the included fabrication drawings. All manufactured components such as the gas tank, engine, wheels, propeller etc were indentified in the components list with suggested sources. The skin was cut from aircraft grade fabric. The following examples were selected from a package of over 40 drawings . These show mostly the clarity of the 3D modeling and do not include notesDESERTAVIATIONClient:Created with AutoCAD R14

4. Perspective view of assembled planeShown without fabric skin.DESERTAVIATIONClient:

5. Perspective view of assembled plane from belowShown without fabric skin.DESERTAVIATIONClient:

6. Fuselage side layout drawingCustomers would also receive a full sized drawing in which to layout and assemble each side on.DESERTAVIATIONClient:

7. Fuselage assemblyAll components were keynoted and detailed on the components lists for each section of the plane.DESERTAVIATIONClient:

8. Upper spar stub frame layoutDESERTAVIATIONClient:

9. Upper spar assembly of ribs, webbing & stub framesRibs and webbing fabricated from drawings not included in these examples.DESERTAVIATIONClient:

10. Upper spar attachment detailsDESERTAVIATIONClient:

11. Main landing gear assembly & installationDetailed landing gear fabrication drawings not included in these examples.DESERTAVIATIONClient:

12. Tail wheel gear assembly and installationDetailed fabrication drawings not included in these examples.DESERTAVIATIONClient:

13. Turtle back assembly and jigging board detailA jigging board was required to hold components in place during assembly. Fabrication of ribs and stringers were detailed on other drawings not shown in these examples.DESERTAVIATIONClient:

14. Installation of the turtle back on the rear fuselage section.DESERTAVIATIONClient:

15. Aileron assembly of spars, webbing, and ribsFabrication of ribs and stringers were detailed on other drawings not shown in these examples. DESERTAVIATIONClient:

16. Metal component fabrication detailsDESERTAVIATIONClient:

17. Upper wing assembly of ribs, webbing and stub frames Ribs and webbing fabricated from drawings not included in these examples.DESERTAVIATIONClient:

18. Horizontal stabilizer/elevator assembly & installationFabrication of stabilizer & elevator were detailed on other drawings not shown in these examples. DESERTAVIATIONClient:

19. Vertical stabilizer/rudder assembly & installationFabrication of stabilizer & rudder were detailed on other drawings not shown in these examples. DESERTAVIATIONClient:

20. Goddard Lift Kitfor the Piper SupercubThis client developed and built a lift kit for the Piper Supercub and Piper Pawnee. These kits are installed on the rear of the wings increasing their lift and lowering their stall speed. They constructed the prototypes with preliminary sketches and through trial and error.I was hired to reverse engineer these two prototypes and two additional ones that were gap seal kits also for the same planes. The gap seals are designed to improve the aerodynamics of the wings by sealing the gap between the wing and the aileron. For all four products I created the fabrication, installation, and patent drawings.The following examples were selected from the Piper Supercub lift kit fabrication and installation drawing packages plus the Patent drawings. All solids models were created as individual components which allowed more flexibility in utilization.AIRBORNERESEARCHClient:Created with AutoCAD 2000i

21. Fabrication drawing - Lift kit mounting bracket assembliesAll details are created using the 3D model.AIRBORNERESEARCHClient:

22. Fabrication drawing - Bracket plate detailsThese details were created in 2D because of AutoCAD’s limited model dimensioning capabilities in this version. The 2D graphics were used to extrude 3D parts though.AIRBORNERESEARCHClient:

23. Fabrication drawing – Air foil front attachment bracket detail.As with the prior drawing these details were created in 2DAIRBORNERESEARCHClient:

24. Fabrication drawing – Aileron bay bracket detailsThese details were from the 3D model.AIRBORNERESEARCHClient:

25. Fabrication drawing – Attachment strap detailsThese details were 3D modeled for clarity.AIRBORNERESEARCHClient:

26. Installation drawing 1 of 4 – Installation locationsThe following 4 drawings are issued with the kit to be used by the FFA certified technician installing it. The plane was created in 2D because only one view was required to show the installation locations.AIRBORNERESEARCHClient:

27. Installation drawing 2 of 4All details on this drawing were assembled from the individually modeled components.AIRBORNERESEARCHClient:

28. Installation drawing 3 of 4All details on this drawing were assembled from the individually modeled components. AIRBORNERESEARCHClient:

29. Installation drawing 4 of 4The upper two details were assembled from the individually modeled components. The wing detail is from the first drawing.AIRBORNERESEARCHClient:

30. Patent drawing 1 of 2All of the details shown here were created from the modeled components. The notes were submitted on separate pages.AIRBORNERESEARCHClient:

31. Patent drawing 2 of 2All of the details shown here were created from the modeled components. The notes were submitted on separate pages.AIRBORNERESEARCHClient:

32. Inline Duct DamperThis client supplies patented air control devices to the cleanroom industry. The following example was the first implementation of solids modeling to support the development of a new design for them.From the beginning of ATECS conception I had been providing their design development, fabrication, installation, and marketing drawings in 2D. This project presented it’s self as a good candidate to model. It assisted in clearly illustrating the concept to the team and in refining the design for fabrication. I utilized the model to also create the shop drawings with the need for very few 2D details. I continue to provide ATECS with 3D models for development and illustrations. Recently I’ve been creating new design prototypes as solids models that they’re using for air flow analysis testing in SolidWorks by a third party. This has eliminated the need to build a physical prototype.ADVANCEDTECHNOLOGYEVIROMENTALCONTROLClient:SYSTEMSATECS Inc.Created with AutoCAD 2002

33. Cutaway of the assembled prototype model composed of over 50 individually solids modeled components.ADVANCEDTECHNOLOGYEVIROMENTALCONTROLClient:SYSTEMSATECS Inc.

34. Fabrication drawing 1 of 3Fan blade assembly details created from the solids modeled components . Cutaway is a 2D detail.ADVANCEDTECHNOLOGYEVIROMENTALCONTROLClient:SYSTEMSATECS Inc.

35. Fabrication drawing 2 of 3Fan blade and bracket details from model. Shafts and washers are 2D details.ADVANCEDTECHNOLOGYEVIROMENTALCONTROLClient:SYSTEMSATECS Inc.

36. Fabrication drawing 3 of 3Collar detail s created from solids modeled components. Collar fabrication is a 2D detail.ADVANCEDTECHNOLOGYEVIROMENTALCONTROLClient:SYSTEMSATECS Inc.