Calvin Kwok Cary Sit Colin Wang Jack Ye Steven Norwood Formlabs Automator University of Waterloo Capstone Project Preliminary Design Presentation Calvin Kwok Cary Sit Colin Wang Jack Ye Steven Norwood

Automator | Need Assessment The current labour costs of using Formlabs printers is too expensive for printing in volume. A method to reduce labour requirements is needed.

Automator | Current Process – Printing Starting position Load build platform Lock build platform Start print

Automator | Current Process – Post Processing Remove Build Platform Part removal Wash Cure

Automator | Desired Workflow and Features User sets a queue of .form files (single resin type only) User ensures proper resin tanks and resin is loaded Automator loads build platforms on available printers (up to 4) and starts prints Upon print completion parts are washed in Rosie wash Part is then cured on build platform in Automator cure chamber Part is then removed and stored for pickup New build platform is loaded into printer and new print is started Used build platforms are returned to the storage area User Setup Print and Finish Next Cycle Prep

Automator | Constraints As per Formlabs requirements: Must be able to operate at least four printers Must be able to produce parts with at least one post-processing stage Must be able to operate continuously without human interaction for 72 hours, 4 out of 5 times Must be able to handle maximum build volume parts Must be able to fit within a 12ft × 12ft × 9ft space

Automator | Criteria Minimum cycle time as measured in seconds Minimum material cost (tooling amortized) as measured in dollars Maximum number of printers Maximum number of post-processing stages Greatest success rate of 72-hour run cycles as measured in percent Minimum size as measured in feet (x, y, z) Minimum cost of implementation as measured in hours

Automator | Printer Layout Issue: The printer arrangement must be determined 2 by 2 Square 4 in a Line Radial Arrangement Printer Printer Printer Front View Front View Top View Notes: xyz gantry system needed Gantry to printer clearance issues Size will be 2.2m x 1m x 2m Notes: xyz gantry system needed Size will be 3m x 1m x 1m Notes: Printers on a turn table Only radial and z gantry needed Size will be 2.5m x 2m x 1m

Automator | Design Selection – Printer Layout Criteria Weight 2 by 2 Square 4 in a Line Radial Arrangement Score Sub-Total Component Cost 6 2 12 7 42 Size 8 56 14 Implementation Cost 4 3 9 36 32 Total 17 80 120 88 Rank 1

Automator | Build Platform Handling Issue: There must be a way for the Automator to handle and manipulate a build platform Actuated Pins Hooked Forklift Build platform Build platform Build platform Build platform Side View Front View Side View Front View Fork Features: Good xyz positioning Requires two linear actuators Features: Poor y-axis positioning No extra actuators

Automator | Design Selection – BP Handling Criteria Weight Actuated Pins Hooked Forklift Score Sub-Total Component Cost 6 3 18 8 48 Reliability 10 100 7 70 Implementation Cost 4 1 32 Total 20 122 150 Rank 2

Automator | Build Platform Locking Issue: There must be a way for the Automator to lock the build platform (BP) to the printer Screws Snap Fit Formlabs Lever BP is screwed to carriage Challenges: Driver alignment Minor BP modification Minor carriage modification Designing a BP to carriage snap fit Challenges: Eliminating all free play Modifying printer carriage Modifying BP Actuating the Formlabs Lever Challenges: Modifying lever Modifying BP

Automator | Design Selection – BP Locking Criteria Weight Screws Snap Fit Formlabs Lever Score Sub-Total Component Cost 6 4 24 2 12 8 48 Reliability 10 100 20 80 Implementation Cost 32 Total 132 64 152 Rank 3 1

Automator | Resin Cartridge Capacity Issue: Current resin cartridge capacity is 1L. Need to increase to 3L for continuous printing. Replacing Cartridges Larger Cartridge Central Reservoir Gantry system will replace cartridges The system will need: Cartridge handling provisions Cartridge storage area Cartridge size will be extended to 3L The system will need: Custom modified cartridges Firmware changes to account for increased pressure Single 12L reservoir for all printers The system will need: Custom reservoir Firmware changes to account for increased pressure Piping and valve system

Automator | Design Selection – Resin Capacity Criteria Weight Replacing Cartridge Larger Cartridge Central Reservoir Score Sub-Total Component Cost 6 7 42 5 30 3 18 Reliability 10 60 70 9 90 Implementation Cost 4 1 8 32 24 Total 20 106 132 Rank 1 (Selected)

Automator | Part Washing Issue: IPA level will fall over time due to evapouration. IPA becomes dirty with use, which could lead to insufficiently clean parts. No Additional Systems Fill Only Fill and Drain No additional systems needed if: IPA is dirty after 72 hours IPA loss insignificant If IPA loss is too high, fill is needed The fill system will have: Clean 4L IPA reservoir Pumping system IPA level sensor If the IPA loss is significant and the IPA is too dirty after 72 hours: 16L clean IPA reservoir 12L dirty IPA reservoir Pumping system for fill Pumping system for drain

Automator | Design Selection – Part Washing Criteria Weight No Additional Systems Fill Only Fill and Drain Score Sub-Total Component Cost 6 10 60 36 3 18 Reliability 1 8 80 100 Implementation Cost 4 40 24 12 Total 20 110 140 130 Rank 2

Automator | Patent Search US Patent US 20140288699 A1: 3D printing Vending Machine Abstract: A vending machine for creating a three-dimensional object having an enclosure having an exterior and interior. The interior receives and houses at least one three-dimensional printer. An interface for accepting an instruction associated with an object to be printed and transmitting the instruction to the printer. A storage section for storing a printed object that provides access to the printed part but limits or prohibits access to the interior. https://www.google.ca/patents/US20140288699?dq=applicant%3A3d%20systems&hl=en&sa=X&ved=0ahUKEwiZ34jB_6rPAhUm1oMKHTZxCyQ4HhDoAQhFMAY

Automator | Patent Search US Patent US 20140220168 A1: Automated Three-Dimensional Printer Part Removal Abstract: Three-dimensional printing system with automated part removal. In one embodiment, the system includes a printing surface on which a part is made and a printing device supported for controlled movement with respect to the printing surface to print the part on the printing surface. A blade is supported for motion across the printing surface to release the part from the printing surface. The present printing system according to the invention requires fewer user steps than known in the prior art. https://www.google.com/patents/US20140220168?dq=3D+print+automation&hl=en&sa=X&ved=0ahUKEwivyYK2_arPAhWc14MKHcGQCmAQ6AEIJTAB

Automator | Patent Search US Patent US 8109395 B2: Gantry Positioning System Abstract: A gantry system is provided that comprises a gantry beam having a first section and a second section and first and second motors cooperating to drive the respective first and second sections in parallel directions to position the gantry beam along a linear axis. A flexure is connected between the first and second sections about which the second section is deflectable relative to the first section, which is advantageous to reduce any stresses that may be caused in the gantry system when driving the gantry beam. https://www.google.com/patents/US8109395?dq=gantry&hl=en&sa=X&ved=0ahUKEwi50pq48d_PAhXr5IMKHRE-APYQ6AEIHjAA

Automator | Master Schedule Sept 26 Oct 10 Oct 24 Today Nov 7 Nov 21 Dec 5 Dec 19 Jan 2 Jan 16 Jan 30 Feb 13 Feb 27 Future Oct 24 Preliminary Design Presentation Final Design Presentation Nov 21 Mar 15 Project End Waterloo Deadlines Detailed Design Sept 26 Oct 31 Build Nov 21 Test and Iterate Final exams Dec 5 Dec 23 Test and Iterate ME Jan 13 Detailed Design Sept 26 Oct 31 Build Nov 21 Test and Iterate Final exams Dec 5 Dec 23 Test and Iterate EE Detailed Design Nov 21 Final exams Dec 5 Dec 23 Detailed Design Jan 13 Test and Iterate Software Sept 25 Preliminary Architecture Design Nov 21 Proto 1 Build Complete Jan 13 Design Lock Feb 27 Final Build Complete Jan 23 Order Final Prototype Final exams Dec 5 Dec 23 System