Rachel Levine ME (Lead Engineer) Sam Perry ME Amy Ryan ISE (Lead Programmer) Kwadwo Opong Mensah EE Faculty Guide John Kaemmerlen Primary Customer Denis Cormier Michael DiRoma ISE (PM)

The primary objective of this project is to create a projected image 3D printer with the ability to produce a three-dimensional part.

Specification Build a 3D Part Built with Photopolymer Layer Thickness Feature Resolution Part Size Dimension Software to control all aspects Yes 25 – 250 Microns Able to report process capabilities Max Size of 3” by 4” Fully Automated Target Value

Photopolymer: Light sensitive resin that cures when light hits it A black and white image or “slice” is a way to selectively cure the resin

Black and white image from DLP projector

Physical Setup Bath glass is covered with Teflon Bath glass is secured between top and bottom bath assembly Bath assembly is attached to the platform Bath filled with resin Build Platform lowered Completely Platform is lowered using the jog buttons

Inputs to LabView STL file Units (millimeters and inches) Slice Thickness – 50 Microns (ideal conditions) Base Speed – 1600 (ideal conditions) Cure Time – 3 seconds (ideal conditions)

Windows Command Line and Slicer Information Gathered 3D Object size (length, width, and height) Functions Performed Object sliced Images background changed to black and core changed to white Images saved to desktop

LabView, the projector, and the Microcontroller Steps to move determined by layer thickness Build Platform moves up to far enough to separate from the Teflon then down to the appropriate distance The image will project for the set cure time then it will display a black screen.

Stepper Motor Lead Screw, Linear Guide Sandblasted Aluminum Build Platform Jog Buttons Resin Bath and Teflon Film

DLP Projector Motion Controller Motion Assembly Macro Lens Optics

Sandblasted Aluminum Build Platform Increased adhesion Teflon Film Decreased adhesion Lead Screw Anti-backlash nut 12.7μm (0.0005”) resolution per step Linear Guide High loading support with low deflection Motion Controller Integration with software

Successes Multiple complete parts produced System fully automated Utilizing past teams materials (projector, case, formula, etc) Inconsistent adhesion to build platform Unable to use different photopolymers Resolution of parts is low Failures

Improve Teflon Film Permanent glass coating Hard limit switches Dedicated software Encoder support Test different photopolymer resin formulas Clean up LabView Programing Code Continue Detailed testing to determine optimal settings

All risks can not be accounted for Unidentified risks, external to the project Overlooked sources of help “Secret formula” found on past teams poster in week 8 of the second quarter Better testing structure earlier in the quarter Manipulate one variable at a time in a controlled manor