Students as fabricators

[Jay H 237]

Our problem is the school limits those students in the metals/machine shop to those that have taken and passed the class in regular school. If you haven't taken any metals classes (or passed) than you can't run the machines in there. Some parts are made by mentors as we may only have 1-4 kids a night that are allowed in there.

This is due to policy and insurance reasons at the high school and no way we can work around it.

[Karibou]

On a 25 student team (my freshman and sophomore year), from what I recall: 22 drill press, 22 bandsaw, 5 mill, 3 lathe, 1 welding. We didn't have a formal training program - if you showed up and were willing to work in the shop at least once, someone would teach you how to use the bandsaw and drill press. The only students who weren't competent with them were the ones who didn't go into the shop at all. Mill/lathe/welding were on a "by interest" basis, or a mentor saying "hey, we don't have any students here today that know how to use this, wanna learn?". We had a very dedicated set of students working those machines (and on the team in general), and they were nearly constantly in use.


Junior and senior year were at a different high school in our district, and our membership numbers and levels of dedication varied. ~40 student team: 30 drill press, 30 bandsaw, 2 welding, 4 mill, 2 lathe. We did have shop training that every student had to go through, and each student was told how to use each piece of machinery and had to attempt a predetermined task (i.e. measuring locations for and drilling 3 holes in a piece of scrap). So everyone knew how to use the machinery, but not everyone was proficient. The drill press and bandsaw are easy enough to pick up, so most students could use them on their own by at least the end of the season. Mill/lathe/welding were once again on a "by interest" basis, though we didn't manufacture as many parts (that required those machines) those years and there wasn't much interest.

[cnepo]

We have a team of 80ish students, but our Robot Ops division (ones who work on the robot itself) are around 30 students. The tools we have in our shop are lathes, a mill, band saws, drill presses, welding stations, plasma cutter and a CNC mill. Since we build everything in-house, all of our R.O. students need to know our basic tools (drill press,band saw, sanders, etc). There isn't a single part on our robot that isn't mostly or completely student built.

Estimates:
Lathe(10), Mill(10), Band Saws(30), Drill Presses(30), Welding Station(2), Plasma Cutter(2), CNC Mill(2)

[safiq10]

You guys are talking about all these fancy tools. Back in our team our best friend is a Jigsaw, a drill, and a hammer. but on a serious note im totally jealous that our team doesn't have some the tools you guys do. But with the limited materials we do have we do alright i mean. 12th at TRR and 24 in what you can call our rookie season this year. (last years team was all seniors and they taught us nothing)

[Seth Mallory]

safiq10, It is less about what tools you have but how well you use what you have. While we have well equipped shop we are regularly beaten by teams that have just hand drills as their only power tools. It is still about using the most important tool you have and that is your brain.

[Peter Matteson]

We usually have have 1 student who is the primary operator for each of our critical tools (CNC Mill, CNC Plasma Cutter, Lathes). This is a junior or senior that has spent 2 years as a minion/apprentice on that piece of equipment. That student is responsible for programming and running that piece of equipment when at meetings. We try to have 2 students learning and as back-ups in case the primary misses a meeting.

Additionally most of the mechanical team, about 20 students, can perform basic operations on the manual bridgeports. (i.e. drilling hole patterns and squaring tube) There are some students who are further trained to do the more complex manual milling jobs, usually 3-5 students.

All the mechanical kids learn to use the drill press, hand drills, riveting, basic sheetmetal bending, horizontal bandsaw, making chain

Generally we don't let student do the grinding operations because of safety concerns with the die grinders. Also broaching is usually done under supervision in our shop.

If it isn't clear from the above our students do most of the fabrication in our shop.

[DonRotolo]

Virtually everything on the robot is student-built. Mentors are really not allowed to do robot work (although we are free to build prototypes early in the season).

That means students need to be proficient with the tools. The only exceptions are the table saw (only adults) and our drivetrain side plates (Made by a sponsor).

Sure, some students use screwdrivers as a chisel, or a hammer. But the mentors try to discourage that... About 2/3 of the team works on the robot, all of them are proficient on most of the tools, and by the time they are Seniors they can use all of them - except that some are still scared of that chop saw (and for good reason). The rest are non-technical, and don't use tools generally.

Only 2 or 3 students learn how to use the lathe, mostly because we don't use it that much. Same with soldering. We don't have a welder.

We have a small lathe, 2 bandsaws, 3 drill presses, a sander (that sees way too much use), 2 chop saws and lots of small power tools, along with 3 sets of hand tools.

My goal in life is to get a few students each year who also understand how to care for and adjust these tools. I'm usually successful.