P14551 Multi-process 3D Printer Systems Design Review

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1 P14551 Multi-process 3D Printer Systems Design Review Group Members: Jeremy Bennett Austin Chacosky Matt Demm Nick Hensel Chad Rossi Customer: Dr. Dennis Cormier Guide: John Kaemmerlen

2 Agenda Background System Analysis Concept and Architecture Deviation Engineering Analysis Risk Assessment Project & Test Plan

3 Agenda Background System Analysis Concept and Architecture Deviation Engineering Analysis Risk Assessment Project & Test Plan

4 Open Source & 3-D Printing Open source licenses allow hobbyists to afford 3-D printers. RepRap, Makerbot, etc. These printers are single process, usually FDM. Speaker: Matt

5 Benchmark System: Multi-Process 3-D Printing Currently under development Proprietary Large Size Uses Modular Process Heads Expensive (~$150,000) Open source version does not exist Speaker: Matt

6 Problem statement Due to recent leaps open source technology, 3-D printing is set to take off in the coming years. Current open source machines can perform a single process, (e.g. laser sintering, thermoplastic extrusion, routing) leading for the need to buy and maintain multiple machines in order to prototype complex parts. Multiprocess 3-D printers are capable of performing these processes, minimizing capital and maintenance expenses, while simultaneously unlocking the ability to produce multiple substrate parts such a printed circuit boards or other composite materials. Current multi-process printers are not open sourced and have costs well above what the average hobbyist can afford. The goal of the project is to demonstrate a multi-process 3-D printer that is both designed as open source and at an appropriate price range to be marketed to the average hobbyist. This printer will incorporate an interface capable of supporting multiple process heads, which could additive or subtractive in nature, that will operate with minimum setup or training. (i.e. Plug-and-Play) Open sourced or low cost software will be used to control the printer. This project will create a platform that can be expanded upon by future MSD teams. Speaker: Jeremy

7 Customer Requirements Speaker: Austin

8 Engineering Requirements Speaker: Austin

9 Agenda Background System Analysis Concept and Architecture Deviation Engineering Analysis Risk Assessment Project & Test Plan

10 House of Quality Speaker: Austin

11 House of Quality Continued Speaker: Austin

12 House of Quality Continued Key Engineering Requirements: Quantity Subtractive Processes Quantity Additive Processes System Cost Tool Head/Interface Dimensionality Enclosure Dimensions Human Interaction Time During Tool Change Speaker: Austin

13 House of Quality Speaker: Austin

14 Functional Decomposition Speaker: Nick

15 Process Benchmarking Process Name Type Method of Manufacturing Weight Cost (kg) ($) Layer Speed Power Tolerance Size (mm) Safety Concerns (mm/min) (± mm) Req's (Watts) Material Inputs/Outputs Speaker: Matt Material Storage Concerns Process Examples Owner Fused Deposition Modeling Additive (FDM Selective Laser Sintering (SLS) Additive Plaster-based 3D printing (PP) Additive Laminated Object Manufacturing (LOM) Stereolithography (SLA or DLP) Electron Beam Freeform Fabrication (EBF^3) Selective Heat Sintering Vacuuming Air Gun Polishing Sanding Glue Dispense (Solder Paste) Pick & Place (SMT Component Placement Laser Engraving Powder Deposition Additive Additive Additive Additive Cleaning Cleaning Finishing Finishing Finishing Finishing Finishing Preparation Extrudes material through a heating element to form layers Melts powder to form layers via high powered laser Sprays glue on to a powder bed to create layering Thin layers of material are cut to shape by a laser or knife and glued into position. Use UV light to cure photoreactive polymer layer by layer. DLP projects light for a full cross section simulataneously Feeds Wire in a molten pool of metal generated by an electron beam. Once the beam moves away, the pool hardens. Moving the wiring and the beam creates part cross sections Uses direct heat application instead of lasers to melt powder together to form layers Uses vacuum pressure to draw up and away unwanted particles and gases Uses positive pressure to blow away unwanted particles or chips Removes surface scratches from parts, improves surface finish Removes surface material to smooth out faces and edges. Improves overall surface finish and texture Liquid material is dispensed through either a screw driven sryinge or pulled from a basin. Machine using grippers or vacuum to hold SMT componets positions them over solder paste pads in preparation for reflow Uses a laser to burn the surface layer of material, allowing for fast engraving Dispenses Powder into a bed to create a new layer X112X 86 Hot Extruder, Current Draw 50 Plastic Wire Spools of wire 0.1 lasers powder powder bed Austin >2 <= X30X50 Dust Inhalation Powder Powder Bed Jeremy 0.5-2kg "Fast" Mirror N/A N/A 312X245X 483 Hot Roller, Cutting Laser Very hot, machining done in vacuum 350 Adhesive Coated Paper/Foil Matt /laminated-object-manufacturing Rools of specialized paper or foil Matt 3d-printers/matrix-300-plus/ 4800 powdered metal powder bed Austin heat powder powder bed Austin 175 N/A Vacuum Stored External Chad Jeremy < N/A N/A 80X20X40 N/A (Air Supply) Air Air Compressor Jeremy > N/A Nozzle Dependent >10000 Don't Touch the Glue lasers <25 Glue, Solder Paste Onboard Syringe Chad Chad ex.php?title=model_1_1- Syringe_Tool Matt /dispensers.html photopolymer dispense head Preparation Jeremy Milling Moves spinning tool through part, removes Subtractive chips Chad Similar to milling. Used to hollow out wood or Routing Subtractive plastic. Can be use to separate parts from mold Chad Removing material in a continuous fashion by Turning Subtractive spinning a part on an axis using a stationary tool Nick Laser Cutting Uses a high energy laser to cut through Subtractive material lasers Austin Material is removed from the workpiece by a series of rapidly recurring current EDM discharges between two electrodes, separated by a dielectric liquid and Subtractive subject to an electric voltage whatever sparking, heat up to (400A peak and 500V peak)? m.shtml Austin Matt Austin Jeremy

16 Process Benchmarking Process Name?? Type Method of Manufacturing Weight (kg) Cost ($) Layer Tolerance (± mm) Speed (mm/min ) Size (mm) Safety Concerns Speaker: Matt Power Req's (Watts) Material Material Inputs/Outp Storage uts Concerns Fused Deposition Modeling (FDM Additive Extrudes material through a heating element to form layers X11 Hot Extruder, 2X86 Current Draw 50 Plastic Wire Spools of wire Selective Laser Sintering (SLS) Additive Melts powder to form layers via high powered laser? ? lasers? powder powder bed Plaster-based 3D printing (PP) Additive Sprays glue on to a powder bed to create layering >2 <= X30X 50 Dust Inhalation Powder Powder Bed Laminated Object Manufacturing (LOM) Additive Thin layers of material are cut to shape by a laser or knife and glued into position kg "Fast" Mirror Hot Roller, Cutting Laser 350 Adhesive Coated Paper/Foil Rools of specialized paper or foil Vacuuming Uses vacuum pressure to draw up and away Cleaning unwanted particles and gases N/A N/A 312X24 5X N/A Vacuum Stored External Air Gun Uses positive pressure to Cleaning blow away unwanted particles or chips < N/A N/A 80X20X 40 N/A (Air Supply) Air Air Compressor Glue Dispense (Solder Paste) Liquid material is dispensed through Finishing either a screw driven sryinge or pulled from a basin. > N/A Nozzle Depende >10000 nt Don't Touch the Glue <25 Glue, Solder Paste Onboard Syringe

17 Printer Bench Marking Speaker: Matt Printer Name Cost ($) Available Processes Multi Proto Lab 150, ,00 0+ Layer Resolution (in) X-Y Tolerances (in) 3D Dual additive printing (ABS + sacrificial PLA) High-speed precision milling Drop-on-Demand printing of conductive and nano-scale metals Laser-powered soldering Extrusion deposition Adhesive dispensing Pick and place Conformal polymer layer dispensing Printable Area (in) 24"x36"x8" 20"x24"x8" Links for Additional Specifications achine.com/mpl/platform /2-uncategorised/18- platform-standard Fab@Home ~3,000 Solid Free Form Fabrication (Syringe Based Printing) "x8"x8" Fused Filament Fabrication (Dual Plastic Makerbot 2,800 RepRap (Mendel) Deposition) "x6"x8.1" 500-1,000 Fused Deposition Modeling "x8"x5.5" rg/index.php?q=faq m/replicator2x.html endel

18 Agenda Background System Analysis Concept and Architecture Deviation Engineering Analysis Risk Assessment Project & Test Plan

19 Morphological Chart Speaker: Jeremy

20 Morphological Chart Concept 7 - Gene Simmons Selected Speaker: Jeremy

21 System Concepts Concept 1 Concept 2 Concept 3 Concept 4

22 System Concepts Cont. Concept 5 Concept 6 Concept 7 Concept 8

23 Pugh Chart P Multi-process 3D Printer Mutli-Proto Lab Dual Dumper EZPZ Slide'n'Ride Bandaid Dispenser Airmageddon Antebellum America Gene Simmons Ultimate Papercut Judgement Criterion Conceptual Image Cost D - Technical Difficulty A + System Extensibility T - Number of Safety Concerns + S U - Utlizes pre-existing parts - - S S M - Motion Control Precision S + Maximum Number of Processes in Machine S Active Material Storage Volume? + S S Maintenance Frequency? Material Replacement Difficulty? + S S S + + S Number of Actuating Elements ( ) S S - - Ease of assembly/open source capability Visual appeal of system S Power Consumption S - S - Total (+) Total (-) Net Score Speaker: Nick

24 Selected Concept Design Gene Simmons Selected Simple Motion Control Expandable Secure Interface Utilizes existing technology Speaker: Nick

25 Architecture Speaker: Nick

26 Agenda Background System Analysis Concept and Architecture Deviation Engineering Analysis Risk Assessment Project & Test Plan

27 Engineering Analysis Speaker: Nick

28 Agenda Background System Analysis Concept and Architecture Deviation Engineering Analysis Risk Assessment Project & Test Plan

29 Likelihood Severity Importance (L*S) ID 2 Risk Assessment Risk Item Describe the risk briefly Process Head Fall Off Risk Type Identify the type of the risk Technical Effect What is the effect on any or all of the project deliverables if the cause actually happens? Cause What are the possible cause(s) of this risk? Possibly damage print head or Mechanical failure of inside of printer. If protection is not interface. Software sufficient, possibly damage the user. incorrectly releases head. Speaker: Chad Action to Minimize Risk What action(s) will you take (and by when) to prevent, reduce the impact of, or transfer the risk of this occurring? Owner Who is responsible for following through on mitigation? Head connection is active-on M. Demm Machine Acquires Wrong Head Subtractive tool contacts surface other than part Operator gets hurt by machine (Burned, Blinded by Laser, UV Exposure, Cut by tooling, Inhale Powder, Caught in moving parts, etc.) Technical Technical Technical Printer carries out the wrong process, resulting in a bad part and possibly damaging printer Damage to internal of machine (bed/enclosure/etc.) Operator requires medical attention/incurs medical costs Mismanagment of head placement information/head interface issue. Tool motion/path not correct. Bad coordinate referencing Redundant identification system for head N. Hensel Insufficient safety measures Limit motion with robust system feedback/ limit switches. Add hardware limiting elements. Simulate toolpaths to verify accuracy Safety protection components/ document needs and specs of each process N. Hensel A. Chacosky 12 Failure to complete project on time Project Management Failure to implement any processes/address other customer requirements/receive a poor grade Attempt to implement too many processes/take too long with design Maintain good project plan with timing considerations C. Rossi 15 Technical Inability to develop Interface Organizational We fail to meet the most important customer specification Lack necessary skills. Do not put enough resources/time into coming up with a solution Conduct sufficient research and benchmarking Team-wide 22 Customer not satisfied with end result External Customer gives poor review to advisor Chosen design fails to meet customer specifications Maintain good contact with customer C. Rossi 3 Process Head Not Aligned Technical Part printed incorrectly - dimensions of end result incorrect. Mechanical registration failure or of position feedback/software control Software and hardware registration used to verify. Very complex element M. Demm 13 Inability to meet cost goals Organizational Printer cost out of specification - miss customer requirements Receive innacurate cost estimates on components/insufficient BOM detail/need to acquire unaccounted for components Maintain an accurate budget C. Rossi 24 Miss deliverable deadlines Project Management Poor grade/ fall behind on project - might not complete entire project scope/ all nighters/ triage work Poor time management Keep/maintain a detailed project plan C. Rossi

30 Agenda Background System Analysis Concept and Architecture Deviation Engineering Analysis Risk Assessment Project & Test Plan

31 Test Plan Objective Test to compare dimensions in a user created CAD file to system performance output in order to compare system capabilities to engineering requirements Description Created a die by using additive process to create a 1x1x1 cube and subtractive process to create the dots and contour mill edges Measure created part and compare to the CAD file If automated dimensions are not equal to printed part, recalibrate machine and start again Output parameters X-Y resolution of printing Precision Timing Speaker: Chad

32 Project Schedule Speaker: Jeremy

33 Questions?

34 Appendices Video: Lab?goback=%2Egmp_ %2Egde_ _member_ #%21 Benchmarking Site tab=details

35 Appendices File Links: cuments/system%20level%20design/p14551_mor phologicalchart_ xlsx cuments/system%20level%20design/benchmarkin g/p14551_hrmtbenchmarking_ xlsx

36 Concept 1

37 Concept 2

38 Concept 3

39 Concept 4

40 Concept 5

41 Concept 6

42 Concept 7

43 Concept 8

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