Modelling and Fabrication Techniques

Master's Level Course by FabLab Rwanda

Explore advanced techniques in modeling, design, and fabrication processes for modern engineering and manufacturing applications. Offered to UR-ACEIoT students.

In partnership with UR-ACEIoT
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Course Overview

Digital fabrication links digital design and physical production through computer-controlled tools such as CNC machines, laser cutters, and 3D printers. It evolved from manual craft and industrial manufacturing to enable rapid prototyping, precision, iteration, and hybrid workflows, transforming fabrication into an accessible process for innovation, education, and localized production.

Course Topics

Day 1 – Foundations of Modeling & Fabrication

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  • Role of modeling in advanced design and fabrication
  • Analog vs digital modeling approaches
  • Design workflow: concept → model → prototype → fabrication
  • Introduction to fabrication labs and makerspace ecosystems
  • Rapid physical prototyping techniques
  • Workshop tools, safety, and best practices

Day 2 – Digital Modeling for Fabrication

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  • Precision modeling and scale control
  • Design for Manufacturing (DFM) principles
  • Fabrication-ready geometry and tolerances
  • CAD workflows for fabrication
  • File formats for digital fabrication (STL, DXF, STEP)
  • Preparing digital models for production

Day 3 – PCB Milling Techniques & Fabrication Process

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  • PCB fabrication methods and comparison
  • PCB design fundamentals for milling
  • Trace width, clearance, pads, and vias
  • Design rules for PCB milling (DFM)
  • PCB milling machines, tools, and calibration
  • Gerber generation and toolpath preparation
  • PCB milling, drilling, and board profiling
  • Post-processing, soldering, and testing

Day 4 – Materials & Fabrication Methods

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  • Material properties and selection strategies
  • Wood, plastics, metals, and composites
  • Subtractive vs additive fabrication methods
  • Material behavior during fabrication
  • Sustainability and material efficiency
  • Cost, durability, and lifecycle considerations

Day 5 – Digital Fabrication I: CNC & Laser Cutting

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  • CNC machining principles
  • Laser cutting workflows and constraints
  • Toolpaths, kerf, feeds, and speeds
  • 2D and 2.5D fabrication strategies
  • File preparation for CNC and laser machines
  • Assembly methods for flat-fabricated parts

Day 6 – Digital Fabrication II: Additive Manufacturing

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  • 3D printing technologies and workflows
  • Print resolution, orientation, and supports
  • Design constraints for additive manufacturing
  • Material selection for 3D printing
  • Post-processing and surface finishing
  • Functional vs aesthetic printed parts

Day 7 – Digital Fabrication III: CNC Router Milling & Cutting

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  • CNC router systems and components
  • Cutting tools and material compatibility
  • CAM workflows and toolpath strategies
  • Sheet nesting and material optimization
  • Design for CNC router fabrication
  • Tolerances, joinery, and press-fit design
  • Assembly and structural evaluation

Day 8 – Molding & Casting Processes

  • Principles of molding and casting
  • Mold types and mold-making strategies
  • Silicone, plaster, and resin mold materials
  • Casting materials and safety considerations
  • Design for molding and casting (DFMC)
  • Master pattern fabrication
  • Casting, demolding, and quality control

Day 9 – Final Fabrication, Documentation & Presentation

  • Design iteration and refinement
  • Multi-process fabrication integration
  • Final assembly and finishing techniques
  • Fabrication documentation standards
  • Technical drawings and digital file organization
  • Final project presentation and critique
  • Reflection on process, materials, and outcomes

Course Schedule

Day 1
  • Intro to documentation
  • Intro to Digital Manufacturing
  • Intro to CAD software
  • Practicing time
Day 2
  • Intro to CAM & Tool path
  • Intro to CNC Router & CNC Plasma
  • Practicing time
Day 3
  • Intro to Computer Controlled Cutting using Laser cutter & Vinyl
  • Laser cutter configuration and maintenance
Day 4
  • Intro to PCB designing
  • Intro to PCB milling process
  • Setting up a PCB milling machine
Day 5
  • Machine operation Practice day
Day 6
  • Machine Operation Practice day
Day 7
  • Machine Operation Practice day
Day 8
  • Machine Operation Practice day
Day 9
  • Intro to Molding and Casting
  • Mold design and machining
  • Casting process

Learning Outcomes

By the end of the course, students should be able to:

✓

Translate concepts into digital and physical models

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Select appropriate materials and fabrication techniques

✓

Operate digital fabrication tools

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Understand design-for-fabrication constraints

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Produce a fabricated prototype with proper documentation

Prerequisites

Students should have a solid foundation in:

  • Engineering fundamentals and basic design principles
  • Basic knowledge of CAD software (recommended but not required)
  • Understanding of materials and manufacturing processes
  • Mathematical and analytical skills

Required Software Downloads

Students must download and install the following software before the course begins:

🖥️

FreeCAD

Alternative: SolidWorks, Fusion360

📐

OpenSCAD

🎨

Inkscape

Alternative: Adobe Illustrator, CorelDraw

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KiCad

Alternative: Eagle PCB, EasyEDA

🔧

Vectric Aspire