Have you ever wondered why it takes such a long period of time for NASA to build space exploration equipment? What is involved in manufacturing and building a rover for the Red Planet? During this lesson, students will discover the journey that a Mars rover embarks upon after being designed by engineers and before being prepared for launch. Students will investigate the fabrication techniques, tolerance concepts, assembly and field-testing associated with a Mars exploratory rover.

This course provides students with an opportunity to conceive, design and implement a product, using rapid prototyping methods and computer-aid tools. The first of two phases challenges each student team to meet a set of design requirements and constraints for a structural component. A course of iteration, fabrication, and validation completes this manual design cycle. During the second phase, each team conducts design optimization using structural analysis software, with their phase one prototype as a baseline.

In the past building prototypes of electronic components for new projects/products was limited to using protoboards and wirewrap. Manufacturing a printed-circuit-board was limited to final production, where mistakes in the implementation meant physically cutting traces on the board and adding wire jumpers - the final products would have these fixes on them! Today that is no longer the case, while you will still cut traces and use jumpers when debugging a board, manufacturing a new final version without the errors is a simple and relatively inexpensive task. For that matter, manufacturing a prototype printed circuit board which you know is likely to have errors but which will get the design substantially closer to the final product than a protoboard setup is not only possible, but desirable. In this class, you'll learn to design, build, and debug printed-circuit-boards.

This unit will guide students from basic sheet metal layout and forming through applications and utilization of CNC plasma cutting to develop a better understanding of how this technology is used in industry.  Prior to this unit, students would have an understanding of measurement and the use of the CNC plasma software, interface, and operation through a previous sign making activity.  Students would already have been taught welding (SMAW & GMAW) safety and this unit runs concurrently with welding activities to allow larger classes more access to the welding booths.