Pegasus Producer 3D Giovanny Vasquez, EE Roberto Tang, EE Hector Arenas, CpE Goals and Motivation Industry 3D Printers are used in Product Development 3D visualization Rapid Prototyping NASA recognized the potential of 3D printers and has spent millions of dollars in research and development to create a 3D printer that works in space UCF students have recently been in the headlines for creating a cheap yet effective 3D printed prosthetic arm for children 3D printers are revolutionizing major aspects of our society and allowing for the creation of 3D printed food, homes, cars, organic material, prosthetics, and everyday household goods The purpose of the Pegasus Producer 3D is to create an affordable 3D printer which can show the limitless creative potential that 3D printing technology can bring Specifications Size18 (W) x 12 (L) x 15 (H) Weight17 pounds Printing MaterialABS and PLA plastic Printing Speed.90 inch per hour Nozzle Size.4mm Build MaterialPrinted Plastic and Acryclic MicroprocessorAtmega644p Motor DriversAllegro A4893 Micro-step Resolution3200 steps per Revolution Power Requirement100W Project Block diagram Pegasus Producer 3D Control Board G-Code To Motor Movement Interpretation Software Mechanic al CAD to G- Code Motor and Heat Control Firmware Processing DC Output 12V/17A Power Supply Extruder X/Y/Z Axis AC Input 120V/60 hz Creator FreeCAD OpenSource Online Tutorials Easy export to.OBJ and.STL Useful for calibration and testing Translator Cura Open Source Compatibility with.OBJ and.STL Easily rotated View by layers Ability to open multiple files simultaneously Generates the.gcode file Translator Slic3r Better G-Code Less intuitive Not user friendly Difficult to manipulate objects Calibrator RepetierHost Allows manual movements while connected through USB It shows the temperature of the heatbed and extruder Shows fan speed and positioning of the extruder head G-Code Used to set commands to the printer The most common ones are movements Specific set of commands to prepare the printer for initialization and finalization G0: Rapid Movement: G0 F2000 X12.3 Y28.4 Z25.8 E3.4 G1: Coordinated Movement G1 X 12.4 Y 28.7 Z26.0 E3.7 M106: Fan On M106 S25 G28: Move to Origin G28 X0 Y0 Z Power requirements VoltageCurrentPower ( VI ) 5 x Stepper Motors 12V~5A60W Extruder Element12V2A24W Micro-controller5V.5A2.5W TOTAL=7.5A87W Power Supply Transformer Primary: 115V 60Hz Secondary: 18V Size: 3.75in L x 4in W Power Supply TransformerRectifier Primary: 115V 60Hz Secondary: 18V Size: 3.75in L x 4in W Bridge Rectifier Volt (max): 100V Current (max): 20 amps Rated: 252 VA Power Supply TransformerRectifier Voltage Regulation Primary: 115V 60Hz Secondary: 18V Size: 3.75in L x 4in W Bridge Rectifier Volt (max): 100V Current (max): 20 amps Rated: 252 VA LM7812C Regulator Power Supply TransformerRectifier Voltage Regulation Primary: 115V 60Hz Secondary: 18V Size: 3.75in L x 4in W Bridge Rectifier Volt (max): 100V Current (max): 20 amps Rated: 252 VA LM7812C Regulator Control Board Power Supply Schematics Control Board Microcontroller Power Input 12V/5V Motor Control Stepper Motors Hot end USB Interface End Stops Extension Pins Temperature Control 12V ~6A 12V SD Card Control Board Goals for control board: Powerful yet cost effective MCU with multiple I/O pins and DIP package Small in size and easy to replicate using discrete components Power regulation to handle an input of 12V and 7 amps On board micro-step control USB interface for printer calibration Microcontroller choices MCU ATmega328ATmega2560Atmega644pTI AM3358 ARM Cortex A8Freescale MKL25Z128VLK4 Price $3.38$16.55$7.85$23.52$4.63 Processor Speed 16MHz 720MHz48MHz Analog Pins Digital Pins Memory SRAM 2KB EEPROM 1KBFLASH 256KB SRAM 8KB EEPROM 4KB RAM 64KB 2KB EEPROM 4KB RAM RAM 256 MBRAM16KB FLASH 128KB Current Arduino based prototype Control Board Control Board MCU Decision Program Memory Size 64KB (32K x 16) RAM Size4K x 8 Number of I /O 32 Speed16MHz Program Memory Type FLASH EEPROM Size2K x 8 Core Processor AVR Core Size8-Bit Connectivity I2C, SPI, UART/USART Voltage - Supply (Vcc/Vdd) 2.7 V ~ 5.5 V Specifications Easy to solder DIP Package 32 pin I/O for future expandability Easily Replaceable due to $8 price tag Very Similar to Popular AVRs such as the Atmega328p and Atmega2560 Downfalls: No out of the box third party IDE software support, a bootloader must be installed through in-circuit programming to install 3D printing firmware Advantages:Atmegag644p Control Board Overall PCB Schematic Control Board Motor Control Motor Driver with A4983 chip Stepper Motor Our Motor NEMA17 200 steps per revolution; 1.8 per step 12V rated voltage 0.9A max current 20 N*cm torque Stepper motors are used because of their accuracy due to their discrete steps Control Board USB Interface Control Board PCB Layout End Stops Gap between electrical and mechanical functions. Cheaper and practical to implement over optical sensor. Essential for X, Y and Z calibrations. Analog input Allows to move to origin without recalibrating Two pieces of metal, a couple of pull down resistors. Flow Diagram Configuration information will be static non changing written before the code runs There is back and forth flow between the reading and interpreting the data State Diagram Waits for SD card Flows throughout the different stages Reports errors to error.txt Thermistor At the highest point of the resolution the higher the voltage change per temperature change Using a 100 k thermistor assuming that the room temperature is 25C Using look-up tables Extruder Basic Principle Plastic Plastic must be fed at a variable speed, Different printing materials require different temperatures Hot end and cold end must have proper insulation to prevent 3d printed cold end from melting Motor vibrations must be kept to a minimum Nozzle size should remain within.35mm and.4mm to maintain adequate printing resolution Extruder 3D Printed Cold End Special Thread to Reduce Motor Vibrations Motor Rotates a Toothed Pinch Wheel to Force Filament through The Insulator known as A Bowden Tube is stiff enough to pass Plastic and prevent Heat Transfer to Cold End The Brass Hot End has a.4mm Nozzle And can heats up to 250 degrees Celcius Thermistor attached to Hot End to Monitor and Regulate Temperature Filament ABSPLA Temperature to Extrude ~225C~ C Requirements to Print Needs heated bed and passive cooling Heated bed optional Passive Cooling Cooling required for accurate prints Benefits from cooling Possible Defects when Printing Prone to cracking and warping Upward curling of corner Flexibility Very FlexibleBrittle Adhesiveness Can be bonded together with household solvents Requires glue to bond Smell Melting plastic smellSweet sugar" smell Manufacture Process Requires oilPlant based Color Limited range of colors Wide range of colors and opacity Availability Widely available Packaging Coil or spool Diameter (Filament) 1.75mm and 3mm Recycling Partially recyclableFully recyclable Price Per Kilogram (Natural- No color) $18.96$19.19 Spool of ABS Plastic Science behind Melting Plastic: Glass Transition Temperature (Tg)- Temperature when plastic goes from solid to rubbery Melting Temperature (Tm) Melting Temperature, plastic becomes a liquid Temperature between (Tg) and (Tm) is ideal extrusion temperature! Temperature vs Extrusion Speed V max = k (T HotEnd - T plastic ) V max = max velocity of extruder T HotEnd = temperature of hot end T plastic = ideal extrusion temperature (between Tg and Tm) K= nozzle size constant Chassis Base moves in X direction Extruder head moves in Y and Z direction Two motors in for Z axis movement to ensure stability in the frame 4000 steps to move Z 1mm, 782 for Y Budget CategoryQuantityPrice Chassis (Acrylic + Plastic)1$80 Threaded Rods8$10 Smooth Rods4$10 Bearings8$30 Belts2$10 Stepper Motors4 Free Heat-bed1$25 Motor Drivers4$7.50 End Stops3$10 Nozzle with thermistor1$30 M3/M4 Screws, Washers, Nuts32$12 Prototype MCU and Control Board1$30 PCB Components1$42 PCB Manufacture1$65 Power Supply1$70 Total:$432 Projected Spending For Senior Design 1Price Microcontroller and Control Board$220 Entire Chassis and Frame$210 Power Supply$130 MotorsFree Total$560 Questions?