1. 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

2. 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.

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

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

5. 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

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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

12. 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

13. 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

14. 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

15. 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)

16. 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

17. 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

18. Automator | Patent Search
US Patent US 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.

19. Automator | Patent Search
US Patent US 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.

20. Automator | Patent Search
US Patent US 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.

21. 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