Final Detailed Design Review

Transcription

1 Final Detailed Design Review High Temperature Pellet Based 3D Printer Head (P15551) Team Members: Alyssa Palmieri, Ray Ali, James Allen, Kylan Ames

2 High Temperature Pellet Based 3D Printer Head Most current 3D printers use plastic filament as feedstock. Most current 3D printers use plastic filament as feedstock. The goal of our project is to create a 3D printer head that uses ordinary plastic injection molding pellets as feed stock. It should be able to withstand temperatures up to 380 C, which is 100 C higher than max operating temperatures of current printers, and should also be able to print for 10 hours continuously.

3 Review of Customer Needs

4 Engineering Requirements

5 System Function Function Method Storing: Hopper Heater: Cartridge Heater Cooling: Cooling Fan Driving: Auger Screw Stepper Motor Feedback: Thermal Feedback

6 Functional Decomposition

7 Operating Modes Operating Modes: Motor Heater Cartridge Cooling Fans Thermal Feedback Heating ON Cooling OFF Printing Independen t Standby Purging Shut Down

8 Design of Printer Head Current State Future State

9 Print Head Design

10 Print Head Drawing with Components

11 Aluminum Barrel

12 Steel Barrel

13 Auger Screw

14 Mounting Bracket

15 Stepper Motor: Donated Motors: 4218L-01-09, 4 lead, 2.4 vdc, 2A/phase,75 oz.in, 1.2 ohm 2 mh/phase, 17 frame 5618X-24P, 4 lead, 2.8 vdc, 1.54A/ phase, 23 frame, 175 oz-in 5709M-02E, 8 lead, 2.4 vdc, 3.0 A/phase, 23 frame Predicted Torque Required: 75 oz-in

16 Timing Belt Pulley Made of steel Pulleys are flanged with plain bore Furnished with set screw Cost: $22 Alternative 3D print them!

17 Nozzle Adaptor

18 Thermocouple Type-K Glass Braid Insulation Good up to 500 C Color-coded wires Cost: $9.95 Quantity: 2

19 Hopper Design Sits outside of the 3D printer Does not add weight to the printhead Add some sort of high temperature withstanding tubing that is flexible from the hopper to the printhead

20 Hopper Design Dimensions in inches (in) Length of entire hopper excluding the top is around 8 inches The inner diameter of the top part of the hopper is around 6 inches

21 BOM

22 BOM

23 Current Risk Assessment

24 Test Plan: Flow Rate/ Layer Resolution Overview: The main objective of this test plan is to verify that the mass flow rate and layer height of the printed material to make sure it is compatible with current 3D printing capabilities. Testing Configuration: In order to test the flow rate the following materials are required: D Print head Scale to weigh mass of extruded material Stopwatch Data sheet Scissors or tongs to cut filament print time has been reached

25 Test Plan: Flow Rate/ Layer Resolution Test Procedure: Turn 3D print head on and set to appropriate temperature Load 3D print head with pellets Simultaneously, turn print head on and start the stopwatch Print for known amount of time ( Recommend: 30 seconds to a min) Measure the amount of printed material on the scale and the diameter of the printed material and record data Repeat steps 1-5 for at least four trials

26 Test Plan: Flow Rate/ Layer Resolution Pass/fail criteria: Theoretically, the layer height should be the diameter of the nozzle. The pass criteria will be within 5% of the diameter of the nozzle. Another pass criteria will be an appropriate mass and volumetric flow rate. Responsibilities and the approval process: James Allen will be responsible for running and approving the testing results. A secondary opinion will be sought at to further validate the testing results Risks and contingencies: Zero flow rate through nozzle Inconsistent diameter Flow rate too high or low

27 Test Plan: Flow Rate/ Layer Resolution

28 Test Plan: Heater Cartridge Overview: The main objective of this test plan is to determine heating cartridge capabilities, comparing calculated power to experimental power, and determining any thermal expansion. Testing Configuration: In order to test heating cartridge, the following materials are required: Heating Cartridge Beaker (filled with water) Stopwatch Thermocouple (or other temperature measuring device) Calipers Power Supply Multimeter

29 Test Plan: Heater Cartridge Test Procedure: Power: Find rate of power going to heat cartridge Fill beaker with water Power heating cartridge Place heater and thermocouple in the beaker Turn on power supply to a set voltage, begin timing a. record actual voltage and current to obtain power using multimeter Measure temperature over set time interval Vary voltage and repeat steps 1-5. Plot data (Power vs Voltage) with curve fit, compare to actual value calculated in step 4a. Thermal Expansion Analysis: Determine if thermal expansion is negligible or needs to be considered Measure heating cartridge dimensions using calipers Allow heater to reach steady state temperature conditions Measure heated cartridge dimensions and compare to ambient Example of Data sheet:

30 Test Plan: Heater Cartridge Pass/fail criteria: Heating cartridge will fail if the power curve differs significantly from the calculated values. Percent error values of +/- 5% will be tolerable. For thermal expansion, it will be used as a metric for hole tolerances when mounting the cartridge Responsibilities and the approval process Kylan Ames will be responsible for running and approving the testing results. A secondary opinion will be sought at to further validate the testing results Risks and contingencies: gets extremely hot trust manufacturer specs

31 Week 14 Plan

32 Week 15 Plan

33 Week 16 Plan

34 MSD II Plan (Weeks 1-3)