Eric Hettler - ME William Gallagher - ISE Christopher Mieney - ME Gregory Ryan - ME Joseph Cole - EE FAB AMERICA

Design Review Agenda Project Overview Needs/Specifications Current System Selected Concept Material Delivery System Drawings BOM Feasibility Control Electronics Drawings BOM Feasibility Curing Drawings BOM Feasibility Risk Assessment Test Plan

Project Overview open-source architecture Print photo-curable resin Color printing used as a vehicle to demonstrate multi-material print capability

Systems Overview

Concept Screening/Selection Material Delivery Micro Valve (solenoid) Ball Point Approach Micro Rocker Valve (solenoid) Inkjet (Thermal) Inkjet (Piezoelectric) Disposable Syringe Curing Ambient Light (fluorescent) Mini Halogen Bulbs LEDs Laser Fiber Optics Motion Control Stepper Motor Servo Motors Pulleys Rack and Pinion Pneumatics Color Mixing 3 pre mixed reservoirs that mix in manifold Inject individual inks into stream of resin Mix inks and inject into stream of resin Print like an inkjet (halftoning) Put down resin and print with inkjet on top

Material Delivery - Manifold

Lee Valves Proposed Design: material delivery nozzles Tube ID:.0075”Proposed Design: Micro Valves Photos From The Lee Company

Material Delivery - BOM Air Adapter Assembly10cc Adapter 3ft hose EFD3$23.25$69.75 ReservoirsSyringe Barrel and Piston Set (10 cc UV Light Block) EFD30$1.33$39.78 Solenoid air valve (optional) Solenoid Valve, NPT Port 1/8 Inch, Coefficient of Volume 0.2, Air Flow 6.9 CFM, Coil 12 VDC, Maximum Operating Pressure 120 PSI, Maximum Temperature Degrees Fahrenheit, Actuator/Return Solenoid/Spring, Length 1.32 Inches, Height 2.4 Inches, Width.75 Inch, 3 Way Direct, Body Ported 35A-AAA-DDBA- 1BAGrainger0$33.30$0.00 Material Tubing Tubing, PTFE, All Natural, 1/16th x.040" (1.0mm) ID. Low Pressure, Translucent. 5 Meter Roll MicroSolv Tech1$13.21 Material Tubing Covering Polyvinyl Chloride (PVC) Heat Shrink Tubing - 5 Pack Color: Black Minimum Conductor Range: 1/16 Maximum Conductor Range: 1/8 Length: 6 In. Expanded/Recovered Inside Diameter: 0.125/ MSC1$1.82 Material Tubing (second choice) PTFE Thin Wall Spaghetti Flexible Tubing Inside Diameter: In. Outside Diameter: In. Wall Thickness: In. Material: Teflon Color: Natural White MSC0$0.20$0.00 Air Regulator Air Regulators with Pressure Gauge Type: Dial Air Regulator Port Size: 1/4 Gauge Port Thread Size: 1/4 Minimum PSI: 10 Maximum PSI: 120 Fluid Type: Compressed Air Material: Zinc Width: 1.97 In MSC19.24$9.24 Hose Adapter Nylon Push-To-Connect Fittings - Fractional Tube Outside Diameter: 5/32 Thread Size: 1/4 Material: Nylon MSC1$ way air separator Nylon Push to Connect Fittings - Metric Sizes Tube Outside Diameter: 5/32 Metric Tube OD: 4 Material: Nylon MSC1$10.62 Cable Ties TY-Rap« High Performance Cable Ties Type: General Material: Nylon Maximum Bundle Diameter: 5/8 Maximum Bundle Diameter: Package Quantity: 100 Color: Natural Tensile Strength: 18 Body Width: MSC100$0.12$12.43 Air fittingsFemale Luer to 1/16" barbed connector11520QOSINA0$0.00 Air fittings (second choice)Female Luer to 1/32" barbed connector11733QOSINA3$0.00 Lee Micro valveLee VHS P/2 Solenoid ValveINKA HThe Lee Co3$135.79$ Manifold mountLee VHS valve manifold mount kitIKTX AThe Lee Co3$25.03$75.09 Nozzle 0.010" ID MINSTAC nozzleINZA KThe Lee Co1$38.58

Material Delivery - Feasibility Ran preliminary valve test (.0075” ID nozzle) Valve can deliver consistent small droplets of high viscosity liquid Valve cannot “jet out” high viscosity liquid Flow rates seem reasonable Put resin through syringe (.00825” ID nozzle) Could not produce “jet”

Valve Controls Constant 24 volts for the spike Constant 3.5 volts for the hold 5 volt is pulsed The rising edge initiates the spike and hold

Control Electronics

Control Electronics - BOM ComponentSpecsItem #SupplierQuantityUnit CostTotal Cost Bulbs 6 Watt T5 Fluorescent Black light Miniature Bipin BaseF6T5/BLTop Bulb4$3.99$15.96 Light fixture Micro fluorescent T5 Grounded Light Fixture (6 watt)PSG5-6-xx Pegasus Associates Lighting2$21.90$43.80 Framing Material Architectural Aluminum (Alloy 6063) (3/4" x 3/4" x 1/16" x 6')4630T14McMaster1$10.85 ReflectorArcadia Aquarium Lighting Reflector T-8 Ebay1 $0.00 Power Cable Micro fluorescent Grounded Flexible L ConnectorPSG-CC6L Pegasus Associates Lighting1$3.90

Curing System

Curing System Feasibility Irradiance at the Bulb Surface: Irradiance at the Work Part: Total Cure Time: Assumptions: The center line of the bulb is considered to be the source of light for purposes of measuring radii The layer thickness is taken to be 0.01 inches thick The entire UV output of the bulb (1 watt) is produced at the required wavelength of 355 nm Note: Cure time may be further reduced through the addition of a reflector

Curing System BOM SpecsItem #SupplierQuantityUnit Cost Total Cost Shipping Cost Price includes shipping 6 Watt T5 Fluorescent Black light Miniature Bipin BaseF6T5/BLTop Bulb2$3.99$15.96 Yes Micro fluorescent T5 Grounded Light Fixture (6 watt)PSG5-6-xx Pegasus Associates Lighting2$21.90$43.80 Yes Architectural Aluminum (Alloy 6063) (3/4" x 3/4" x 1/16" x 6')4630T14McMaster1$10.85 No Micro fluorescent Grounded Flexible L ConnectorPSG-CC6L Pegasus Associates Lighting1$3.90 No Arcadia Aquarium Lighting Reflector T-8 Ebayoptional $0.00 No

Test Plan Serve To Verify System Design and Quantify Variability Subsystems Curing Valves Motion Control Color Delivery Integration effects Size Layer Shrinkage/Deformation