# Sheet Prototyping

<img src='img/ur-rotation-end-effector.png' height=400px>
<img src='img/wiz-and-rotary.jpg' height=400px>

Cutting and folding sheets may be the fastest way to put precision features on multiple planes.  A sheet fabricated prototype can go from design to part in minutes and scale to massive production volumes.

<img src='img/cardboard-1.jpg' height=200px>
<img src='img/cardboard-2.jpg' height=200px>
<img src='img/cardboard-3.jpg' height=200px>

Don't take it from me, listen to the master, Dan Gelbart, in his series "Making Prototypes":
https://www.youtube.com/watch?v=dS5kwdaNhZo


### Materials

* Cardboard
* Paper
* <a href='http://www.itwformex.com/'>Polypropylene</a>
* <a href='https://www.mcmaster.com/#standard-plastic-sheets/=1a6mf16'>Dibond</a>
* Steel
* Stainless Steel
* Aluminum: Must be a formable series, like 1100 or <a href='https://www.onlinemetals.com/merchant.cfm?id=753&step=2&top_cat=60'>3003</a>

### Cutting Tools

* <a href='http://cba.mit.edu/tools/display/?type=tool&id=universal_laser_x2600_laser_cutter#'>Laser cutters</a>
* <a href='http://cba.mit.edu/tools/display/?type=tool&id=omax_2652_waterjet_cutter#'>Waterjet</a>
* <a href='http://cba.mit.edu/tools/display/?type=tool&id=zund_g3_l-2500_digital_cutter#'>ZUND</a>


### Creasing Methods

* Press Brake
* <a href='http://cba.mit.edu/tools/display/?type=tool&id=finger_brake#'>Finger Brake</a>
* <a href='http://www.bbc.co.uk/staticarchive/c674c7d0cbfb7d03e3aacf3f50125a82ff4ed61b.gif'>Vice Bending</a>
* Perforating
* Half-cutting
* Bevel routing

### Design Factors

<img src='img/k-factor.png' width=300px>

* Thickness
* K-Factor
* Relief

### Design tools

* Fusion 360 sheet metal: 
	* <a href='https://www.youtube.com/watch?v=nEjFMYNGY4g'>tutorial (nyc cnc)</a>
	* <a href='https://www.youtube.com/watch?v=1aDN44__L9E'>tutorial (cardboard)</a>
	* <a href='https://www.youtube.com/watch?v=UXNSlxXjzhk'>sheet metal gems part 1</a>
	* <a href='https://www.youtube.com/watch?v=_CPkUqedqhA'>sheet metal gems part 2</a>
* Rhinoceros 'UnrollSrf' Command
* Solidworks sheet metal
* 123D Make
* ExactFlat