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Training/Education 42 MoldMaking Technology —— AUGUST 2016 By Cynthia Kustush Project-Based Learning University education in a shop-like setting helps mold a new generation of enterprising engineers. E ach year, universities everywhere graduate clas ach year, universities everywhere graduate classes of educated students, each of whom presumab of educated students, each of whom presumably has been molded to be a good, productive me has been molded to be a good, productive mem- ber of our society. At Washington State University (W ber of our society. At Washington State University (WSU) in Pullman, Washington, the term molded takes on a in Pullman, Washington, the term molded takes on addi- tional meaning for its mechanical engineering stude tional meaning for its mechanical engineering students. The Cougar Shop, the working "lab" at WSU's Scho The Cougar Shop, the working "lab" at WSU's School of Mechanical and Materials Engineering, has been ru of Mechanical and Materials Engineering, has been run by Robert "Kurt" Hutchinson since 2013. From the beg by Robert "Kurt" Hutchinson since 2013. From the begin- ning, he set out to run a technically advanced shop—o ning, he set out to run a technically advanced shop—one that makes use of CNC machines as well as other, mo that makes use of CNC machines as well as other, more standard equipment like drill presses and band saws t standard equipment like drill presses and band saws that the students would encounter in a real work environ- the students would encounter in a real work environ- ment. The shop now features two Haas Minimill vert ment. The shop now features two Haas Minimill vertical machining centers and two Haas TL-1 CNC toolroom machining centers and two Haas TL-1 CNC toolroom lathes, as well as a Fadal 3016 CNC machine with mor lathes, as well as a Fadal 3016 CNC machine with more capacity, a Bridgeport mill and two other lathes. At the time that Hutchinson took over, students in At the time that Hutchinson took over, students in the Cougar Shop were doing manual data input (MDI the Cougar Shop were doing manual data input (MDI) programming, but the lack of advanced software for m programming, but the lack of advanced software for more refined NC programming limited the sophistication o refined NC programming limited the sophistication of the work they could do. With the support and experti the work they could do. With the support and expertise of Dan Newby, a fellow WSU alumni and educational of Dan Newby, a fellow WSU alumni and educational programs manager for CNC Software, Hutchinson inv programs manager for CNC Software, Hutchinson invest- ed in one seat of Version 5 to take advantage of the ca ed in one seat of Version 5 to take advantage of the capa- bilities of the company's Mastercam CAD/CAM produ bilities of the company's Mastercam CAD/CAM product, including multi-axis programming. Today, the Cougar including multi-axis programming. Today, the Cougar Shop is using Version X9 to not only program multipl Shop is using Version X9 to not only program multiple axes, but also for high-speed machining and dynamic high-speed milling, as well as surface finishing. A Hands-On Education Hutchinson teaches five sections of WSU's junior-level mechanical engineering class, ME 311. Of the 80 students in those classes, he estimates that only 10 to 15 percent have any type of shop experience, and in these cases usu- ally because members of their families own or work at a manufacturing company. For this reason, he starts everyone out working on conventional machine tools Images courtesy of Washington State University. This fully functioning mini injection molding machine was built by mechanical engineering students in Washington State University's Cougar Shop. The machine has been instrumental in providing real-world experiences as students learn about high- speed machining, programming, moldmaking and molding.