Group Members: Jeremy Bennett, Austin Chacosky, Matthew Demm, Nicholas Hensel, Chad Rossi Customer: Dr. Dennis Cormier Guide: John Kaemmerlen Multi-Process 3D Printer: Final Review

Agenda Project Background System Architecture Customer Needs Engineering Specs Subsystem Construction Electrical/Mechanical Head Interface Motion System Process Head Storage Enclosure Project Evaluation Recommendations for Future Group Lessons Learned Speaker: Chad

Project Background Objective: To develop a 3D printing system capable of executing both additive and subtractive processes through the design and implementation of a unique process head interface system while simultaneously minimizing system cost to appeal to the hobbyist market. Multi – Proto LabSingle Process 3D PrinterOpen Source CNC Mill Speaker: Chad

System Architecture Speaker: Nick System Architecture layout from MSD I Accurate assessment of content we focused on for the project

Review of Customer Needs Customer Rqmt. # ImportanceDescriptionCategory CR11Uses software available to hobbyists (free or inexpenisve)Software CR23Ease of manufacturing/kittableManufacturability CR39Universal Interface for HRMTsEase of use CR43Able to fit on a lab benchEase of use CR59Total system cost between $2000 and $5000Cost CR61Develop an easy to use GUISoftware CR73Utilize existing hardware components available at RITManufacturability CR89E-stops and other saftey sensorsSafety CR99At least two (1 Additive and 1 Subtractive) processPerformance CR109Automated Tool LoadingEase of use CR113Motion Control Subsystems requires X,Y,Z MotionPerformance CR129System EnclosureSafety CR139Robust system architectureEase of use CR143Motion Control Repeatability and ReliabilityPerformance CR153Motion control can support and effectively move any HRMTPerformance CR169Compact Tool/Interface setupPerformance Most of the customer needs are met to some degree Implemented an enclosed dual process machine with 3-axis motion control capable of implementing more processes and automated tool loading The degree to which we’ve met the customer needs will be discussed next Speaker: Austin

Review of Engineering Specs rqmt. #ImportanceSourceFunction Engr. Requirement (metric)Unit of MeasureMarginal ValueIdeal Value S19CR1CostCost of System Operating SoftwareUSD 0 S21CR3PerformanceUseability Time% Up Timelowhigh S33CR3PerformanceTool Change TimeSecondshighlow S69CR4PerformanceEnclosure Dimensions (LxWxH)Inches S79CR2, CR5CostSystem CostUSD ≤ 5000≤ 2000 S81CR7CostQuantity of Recycled Parts S93CR3,CR9PerformanceQuantity of Implemented Additive Processes 1 S103CR3,CR9PerformanceQuantity of Implemented Subtractive Processes 1 S113CR11PerformanceManipulatable (Print/Remove) Part VolumeInches 12"x8"x8" S129CR12SafetyAbility to physically interact with parts during operationUser ScoreVery HardImpossible S139CR13Ease of Use Development Extensibility (Improvement by Future MSD Teams)User Score S149CR8SafetySystem halt on physical interventionBooleanFALSETRUE S151CR6PerformanceIntuitive InterfaceUser Score S169CR3,CR10Ease of UseHuman Interaction Time during tool changeSeconds ≤ 100 S179CR15PerformanceMaximum Tool Head Weight SupportableKilogram ≥2≥2≥5 S189CR11,CR14PerformanceMotion Control Accurately zeroesmm ≤ 0.25 ≤ 0.1 S193CR11,CR14PerformanceMotion Control Consistently zeroes% ≥ S203CR11,CR15PerformanceMotion Control Translation Speed at maximum loadmm/second ≥ S219CR16PerformanceTool Head/Interface Dimensionalitycm ≤10 x10x20 S223CR2Ease of UseTime Required to Remove access panelMinutes ≤5≤5 ≤0.5 S239 PerformanceMaterial Output Line Thicknessmm Nozzle Diameter + Die Swell mm Nozzle Diameter + Die Swell mm Speaker: Group

Process Head Storage Stores Process Heads attached to Universal Mounting Blocks. Currently has space for 3 Process Heads. Needed additional bracing to increase rigidity. Speaker: Matt

Electrical/Mechanical Head Interface Achieves reliable electrical connection and precise mechanical registration with process heads. Currently interfaces with a Rotary Spindle Tool & an Plastic Extrusion Head. Issues that needed correction: Dowel Pin Pattern Electrical Pass-through Clearances Locking Solenoid Design Failure Speaker: Matt

Motion System Lead screws on each of three axes Dual-driven short horizontal axis Maximum speed of 15.5 mm/s speed on the long axis Added hardboard covers to top of each axis as improvement on CAD design Many issues with getting the axes properly aligned – failure of the design Speaker: Nick

Enclosure Made of spray painted hardboard (Masonite) with clear polycarbonate doors and widows Includes E-Stop, door switches, vacuum access door, and RGB LEDs Front single thickness hardboard is flimsy and hand-cut LEDs are controlled by the Arduino and could be used to indicate build progress, bed and extruded temperature, or current tool in use Speaker: Austin

Project Evaluation SuccessesFailures Survived trip to Imagine 1 st place in ARM competition XYZ Movement Semi-functional Open Source GUI Visually Appealing System is expandable Slow speeds Testing not finished No printing at Imagine Incomplete assembly instructions Speaker: Chad

Recommendations for Future Groups Expand the number of implemented processes Metal additive process head Measurement process head Integrate 3D scanner into system Fully test additive and subtractive processes Design and add features to more readily align axes Implement dual y-axis control in user interface Implement encoder feedback into firmware Replace front panel with a more solid material Apply UV and IR blocking plastic film to Polycarb windows Speaker: Jeremy

Lessons Learned Allocate additional lead time for delay due to external factors Simplify orders for the one in charge of placing them Lead screw alignment is a tedious and crucial procedure Don’t underestimate the time requirements for the simpler yet time consuming tasks Design with unit system utilized by the machining resources of custom fabricated components Speaker: Jeremy

Questions? Special thanks: Dr. Cormier, Professor Kaemmerlen, CJ Winegar, Mike Buffalin, John Bonzo, ME Machine Shop Staff, Various Subject Matter Experts