Multi-Process 3D Printer: Final Review

1. Multi-Process 3D Printer:Final Review Group Members: Jeremy Bennett, Austin Chacosky, Matthew Demm, Nicholas Hensel, Chad Rossi Customer: Dr. Dennis Cormier Guide: John Kaemmerlen

2. Agenda • Project Background • System Architecture • Customer Needs • Engineering Specs • Subsystem Construction • Electrical/Mechanical Head Interface • Motion System • Process Head Storage • Enclosure • Project Evaluation • Recommendations for Future Group • Lessons Learned Speaker: Chad

3. Project Background Objective: To develop a 3D printing system capable of executing both additive and subtractive processes through the design and implementation of a unique process head interface system while simultaneously minimizing system cost to appeal to the hobbyist market. Multi – Proto Lab Open Source CNC Mill Single Process 3D Printer Speaker: Chad

4. System Architecture • System Architecture layout from MSD I • Accurate assessment of content we focused on for the project Speaker: Nick

5. Review of Customer Needs • Most of the customer needs are met to some degree • Implemented an enclosed dual process machine with 3-axis motion control capable of implementing more processes and automated tool loading • The degree to which we’ve met the customer needs will be discussed next Speaker: Austin

6. Review of Engineering Specs Speaker: Group

7. Process Head Storage • Stores Process Heads attached to Universal Mounting Blocks. • Currently has space for 3 Process Heads. • Needed additional bracing to increase rigidity. Speaker: Matt

8. Electrical/Mechanical Head Interface • Achieves reliable electrical connection and precise mechanical registration with process heads. • Currently interfaces with a Rotary Spindle Tool & an Plastic Extrusion Head. • Issues that needed correction: • Dowel Pin Pattern • Electrical Pass-through Clearances • Locking Solenoid Design Failure Speaker: Matt

9. Motion System • Lead screws on each of three axes • Dual-driven short horizontal axis • Maximum speed of 15.5 mm/s speed on the long axis • Added hardboard covers to top of each axis as improvement on CAD design • Many issues with getting the axes properly aligned – failure of the design Speaker: Nick

10. Enclosure • Made of spray painted hardboard (Masonite) with clear polycarbonate doors and widows • Includes E-Stop, door switches, vacuum access door, and RGB LEDs • Front single thickness hardboard is flimsy and hand-cut • LEDs are controlled by the Arduino and could be used to indicate build progress, bed and extruded temperature, or current tool in use Speaker: Austin

11. Project Evaluation Successes Failures Survived trip to Imagine 1st place in ARM competition XYZ Movement Semi-functional Open Source GUI Visually Appealing System is expandable Slow speeds Testing not finished No printing at Imagine Incomplete assembly instructions Speaker: Chad

12. Recommendations for Future Groups • Expand the number of implemented processes • Metal additive process head • Measurement process head • Integrate 3D scanner into system • Fully test additive and subtractive processes • Design and add features to more readily align axes • Implement dual y-axis control in user interface • Implement encoder feedback into firmware • Replace front panel with a more solid material • Apply UV and IR blocking plastic film to Polycarb windows Speaker: Jeremy

13. Lessons Learned • Allocate additional lead time for delay due to external factors • Simplify orders for the one in charge of placing them • Lead screw alignment is a tedious and crucial procedure • Don’t underestimate the time requirements for the simpler yet time consuming tasks • Design with unit system utilized by the machining resources of custom fabricated components Speaker: Jeremy

14. Questions? Special thanks: Dr. Cormier, Professor Kaemmerlen, CJ Winegar, Mike Buffalin, John Bonzo, ME Machine Shop Staff, Various Subject Matter Experts