Multi-Processed 3D Printer: Detailed Design Review
Group Members:Jeremy Bennett, Austin Chacosky, Matthew Demm,
Nicholas Hensel, Chad RossiCustomer: Dr. Dennis CormierGuide: John
Kaemmerlen
Multi-Process 3D Printer:Final Review
AgendaProject BackgroundSystem ArchitectureCustomer
NeedsEngineering SpecsSubsystem ConstructionElectrical/Mechanical
Head InterfaceMotion SystemProcess Head StorageEnclosureProject
EvaluationRecommendations for Future GroupLessons Learned
Speaker: ChadProject BackgroundObjective: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
Single Process 3D Printer
Open Source CNC MillSpeaker: Chad3System Architecture Speaker:
NickSystem Architecture layout from MSD IAccurate assessment of
content we focused on for the project
Review of Customer NeedsCustomer Rqmt.
#ImportanceDescriptionCategoryCR11Uses software available to
hobbyists (free or inexpenisve)SoftwareCR23Ease of
manufacturing/kittableManufacturabilityCR39Universal Interface for
HRMTsEase of useCR43Able to fit on a lab benchEase of useCR59Total
system cost between $2000 and $5000CostCR61Develop an easy to use
GUI SoftwareCR73Utilize existing hardware components available at
RITManufacturabilityCR89E-stops and other saftey
sensorsSafetyCR99At least two (1 Additive and 1 Subtractive)
processPerformanceCR109Automated Tool LoadingEase of useCR113Motion
Control Subsystems requires X,Y,Z MotionPerformanceCR129System
Enclosure SafetyCR139Robust system architectureEase of
useCR143Motion Control Repeatability and
ReliabilityPerformanceCR153Motion control can support and
effectively move any HRMTPerformanceCR169Compact Tool/Interface
setupPerformanceMost of the customer needs are met to some
degreeImplemented an enclosed dual process machine with 3-axis
motion control capable of implementing more processes and automated
tool loadingThe degree to which weve met the customer needs will be
discussed nextSpeaker: AustinReview of Engineering Specsrqmt.
#ImportanceSourceFunction Engr. Requirement (metric)Unit of
MeasureMarginal ValueIdeal ValueS19CR1CostCost of System Operating
SoftwareUSD0S21CR3PerformanceUseability Time% Up
TimelowhighS33CR3PerformanceTool Change
TimeSecondshighlowS69CR4PerformanceEnclosure Dimensions
(LxWxH)InchesS79CR2, CR5CostSystem CostUSD 5000
2000S81CR7CostQuantity of Recycled
PartsS93CR3,CR9PerformanceQuantity of Implemented Additive
Processes1S103CR3,CR9PerformanceQuantity of Implemented Subtractive
Processes1S113CR11PerformanceManipulatable (Print/Remove) Part
VolumeInches12"x8"x8"S129CR12SafetyAbility to physically interact
with parts during operationUser ScoreVery
HardImpossibleS139CR13Ease of UseDevelopment Extensibility
(Improvement by Future MSD Teams)User ScoreS149CR8SafetySystem halt
on physical interventionBooleanFALSETRUES151CR6PerformanceIntuitive
Interface User ScoreS169CR3,CR10Ease of UseHuman Interaction Time
during tool changeSeconds100S179CR15PerformanceMaximum Tool Head
Weight SupportableKilogram25S189CR11,CR14PerformanceMotion Control
Accurately zeroesmm0.250.1S193CR11,CR14PerformanceMotion Control
Consistently zeroes%95100S203CR11,CR15PerformanceMotion Control
Translation Speed at maximum
loadmm/second50100S219CR16PerformanceTool Head/Interface
Dimensionalitycm10x10x20S223CR2Ease of UseTime Required to Remove
access panelMinutes50.5S239PerformanceMaterial Output Line
ThicknessmmNozzle Diameter + Die Swell +- 0.2 mmNozzle Diameter +
Die Swell +- 0.05 mmSpeaker: Group
Process Head StorageStores Process Heads attached to Universal
Mounting Blocks.Currently has space for 3 Process Heads.Needed
additional bracing to increase rigidity.
Speaker: Matt
Electrical/Mechanical Head InterfaceAchieves 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
PatternElectrical Pass-through ClearancesLocking Solenoid Design
FailureSpeaker: Matt
8
Motion System
Lead screws on each of three axesDual-driven short horizontal
axisMaximum speed of 15.5 mm/s speed on the long axisAdded
hardboard covers to top of each axis as improvement on CAD
designMany issues with getting the axes properly aligned failure of
the design
Speaker: NickEnclosureMade of spray painted hardboard (Masonite)
with clear polycarbonate doors and widowsIncludes E-Stop, door
switches, vacuum access door, and RGB LEDsFront single thickness
hardboard is flimsy and hand-cutLEDs are controlled by the Arduino
and could be used to indicate build progress, bed and extruded
temperature, or current tool in use
Speaker: AustinProject EvaluationSuccessesFailuresSurvived trip
to Imagine1st place in ARM competitionXYZ MovementSemi-functional
Open Source GUIVisually AppealingSystem is expandableSlow
speedsTesting not finishedNo printing at ImagineIncomplete assembly
instructionsSpeaker: ChadRecommendations for Future Groups Expand
the number of implemented processes Metal additive process
headMeasurement process headIntegrate 3D scanner into systemFully
test additive and subtractive processesDesign and add features to
more readily align axesImplement dual y-axis control in user
interfaceImplement encoder feedback into firmwareReplace front
panel with a more solid materialApply UV and IR blocking plastic
film to Polycarb windows
Speaker: JeremyLessons LearnedAllocate additional lead time for
delay due to external factors Simplify orders for the one in charge
of placing themLead screw alignment is a tedious and crucial
procedureDont underestimate the time requirements for the simpler
yet time consuming tasksDesign with unit system utilized by the
machining resources of custom fabricated components
Speaker: JeremyQuestions?Special thanks: Dr. Cormier, Professor
Kaemmerlen, CJ Winegar, Mike Buffalin, John Bonzo, ME Machine Shop
Staff, Various Subject Matter Experts
