1. Mustafa Alkhulaitit – Project Manager Gregorio Rios – 3D Modeling Jessica Salazar – 3D Manufacturing

2. Our main objective is to improve Sasha, a 3D printer, by applying different upgrades and technologies while taking into consideration costs and time. MISSION OBJECTIVES

3. precision/Accuracy – precision of Sasha must be within 2% error between theoretical and actual results Reliability – consistency of printed objects. Decrease the number of trials to accomplish the desired shape (Exact number of trials TBD) Cost – total cost must be within $300 - $500 range Schedule – expected completion before May 7, 2014 LEVEL 1 REQUIREMENTS

4. Frame Heat Bed Auto Bed Leveling Dual Extruder Heads LCD Panel/SD Reader All Metal Hot End Surface Toning IMPROVEMENTS OVERVIEW

5. The printer is made of 3mm laser cut steel making a strong structure. Pros: 1.steel is 10 times cheaper than aluminum 2.laser cutting steel is easier and cheaper than cutting aluminum 3.steel is stronger than aluminum Cons: 1.Steel is 3 times heavier than aluminum The design of this structure was made with a lot of carvings in order to reduce weight. These carvings, holes, tab and rounded corners where made to accommodate parts while providing a good fit. FRAME

6. ACTUAL FRAME

7. The smart Controller is easily able to connect to your ramps board using the smart adapter Contains an SD-Card reader, a rotary encoder and a 20-character x4 line LCD display Benefits: - PC is no longer needed - G-code design stored - Allows actions like calibration and axes movements LCD/SD SMART CONTROLLER

8. A Bowden extruder is part of a printer where theres a flexible tube guiding a filament from the extruder motor also known as the cold end is located and the nozzle also called the hot end. Differences: - Typical Extruder-gear motor pulls the filament, extruder is right above the hot end - Bowden extruder-stepper motor separated from the hot end BOWDEN EXTRUDER

9. E3D HOT END NOZZLE No PEEK or PTFE Reach Extremely High Temperatures - 300ºC with supplied thermistor - >400ºC with thermocouple (additional electronics may be required) CNC Machined Parts - High precision - High quality surface finish - Aesthetically Pleasing Prints almost every material (including PLA) Short Thermal Transition - Improves extrusion accuracy - Reduces 'blobbing - Lowers extrusion force - Less retraction required The all metal hot end can withstand temperatures that surpass the thermoplastic extrusion levels.

10. AUTO BED LEVELING What is Auto bed leveling? Auto leveling is the process of analyzing several points on the platform and from that data calculates the plane that the print bed actually sits on. The printer is then adjusted so that it prints perpendicular to the bed thats not even. Auto bed leveling does NOT actually level the bed, just helps compensate for the bed not being leveled.

11. Takes multiple adjustments to get an even platform, which can be tedious and time-consuming Get one corner Just right, and another corner goes just a little out of adjustment, and youre making another round to make sure nothing else moved DIFFICULTIES WITH MANUAL LEVELING

12. sanding Acetone Vapor Bath Sandblasting SURFACE TONING

13. Sanding and polishing kits also help with the sanding process Start with a 100/150 grit paper and end with 220, 320 fine, 500 super fine, and finish with the micron-grade grits to eliminate sanding marks. Skipping to different grit papers will not be an advantage. Too fine or too fast will go over the ridges without flattening them. After sanding a surface, a heat gun can be used to erase many of the smaller scratches and restore the original printed color SANDING

14. Its a common way to treat ABS 3D printed objects Pros: Cleans up surface imperfections, fuses together outer layers for a tighter seal. Cons: Part becomes soft during acetone vapor bath and it may slightly distort the shape; short baths tend to minimize this. ACETONE VAPOR BATH

15. Walnut shell as a blasting media for use on soft surfaces like plastic. Walnut shells alone leave a dull finish Plastic pellets might be soft to smooth out prints Different combination with walnut shells, plastic pellets and grit might work better. Too soft material being sandblasted on the printed part might not give enough smooth finish Too hard materials where would deform the printed material SANDBLASTING

16. Dual extruder heads will remove shape restriction Uses dissolvable support structure such as HIPS and PVA When operated by the RAMPS 1.4 and MEGA 2560 we have smoother, higher quality prints DUAL EXTRUDERS

17. Heated beds improve quality of printed objects Heated beds work by keeping the object warm during the whole printing process which keeps the material at or above heat-deflection temperature, meaning the object will remain flat on the surface PCB heat bed is the most common model PCB Advantages: - Even heat distribution - Simple implementation - Small space required - Lightweight - More expensive than the Aluminum Clad Resistors - Has two sides: top side is safer, while the bottom side is more effective and heats up quicker HEATED BED OVERVIEW

18. PCB heat bed platform No heat bed installed, ugly!

19. SYSTEM DESIGN

20. #PartPrice Range (Each) 1.Heated Bed Upgrade$30 - $50 2.All Metal Hot End$100 3.Surface ToningTBD 4.LCD Panel$50 - $70 5.2x NEMA 17 Stepper- Motor $20 6.2x M2.5x12mm Bolts$0.64 7.M2.5 Nuts$0.60 8. TowerPro SG-90 Mini Servo $3.49 9. OMRON SS-5 Micro switch $1.75 Approx. Total= $270 DETAILED COSTS

21. SCHEDULE