1. Group Members: Jeremy Bennett Austin Chacosky Matt Demm Nick Hensel Chad Rossi Multi-Process 3D Printer: Detailed Design Review Customer: Dr. Dennis Cormier Guide: John Kaemmerlen

2. Objective Obtain feedback to prepare for the gate review Receive confirmation that the design is sufficient Receive approval to order the materials and to start preparation for Multi-disciplinary Senior Design II Speaker: Chad

3. Agenda Project Overview Review Customer Needs Review Engineering Specs Critical Subsystems Mechanical Electrical Head Interface Motion System Hybrid Rapid Manufacturing Tool (HRMT) Storage Subsystem Other Subsystems Enclosure/Safety System Extruder Tool Rotary Tool Machine Bed Bill of Materials Cost Layout Updated Risk Assessment Test Plan MSD II Project Plan Speaker: Chad

4. Multi- Process 3D Printer Multi- Proto Lab Single Process 3D Printers Open Source CNC Mill Speaker: Chad

5. System Architecture Speaker: Austin

6. Review of Customer Needs Speaker: Austin

7. Review of Engineering Specs Speaker: Austin

8. Overall System Design Speaker: Matt

9. Mechanical/Electrical Head Interface Speaker: Matt

10. Mechanical/Electrical Head Interface FEA Results: 70N Load at COG for extruder head Max Stress: 44GPa (bolt) Fs yield = 1.25 Max Deflection: 0.03mm Speaker: Matt

11. Mechanical/Electrical Head Interface Speaker: Matt

12. Mechanical/Electrical Head Interface Maximum Spec Process Head @ 4g Deceleration Taper Pin Under 1g z, 1g y Speaker: Matt

13. Motion System Speaker: Nick

14. Motion System Speaker: Nick

15. Motion System Speaker: Nick

16. Motion System Speaker: Nick

17. Motion System Speaker: Nick

18. Motion System Speaker: Nick

19. HRMT Storage Subsystem Speaker: Nick

20. HRMT Storage Subsystem Speaker: Nick

21. Enclosure/Safety System Speaker: Nick

22. Extruder Tool Speaker: Matt

23. Rotary Tool Speaker: Matt

24. Material Bed Speaker: Austin

25. High Level Electrical Block Diagram Speaker: Jeremy

26. Boneyard Inventory: Arduino Mega Higher cost than Arduino Duo Lower clock speed 8 bit operation system May lead to slow system operation Speaker: Jeremy

27. Microcontroller Selection Arduino Due 32-bit ARM core, Low Power 3.3 Volt System Open Sourced Nature with Many Available Resources 84MHz Clock, 512Kb flash, 54 I/O Pins Speaker: Jeremy

28. Boneyard Inventory: Lin 3518M Motor Insufficient Torque for moving large tool heads May be useful for future teams making powder bed Speaker: Jeremy

29. Boneyard Inventory: MD 23 Motor Model 23MD306S-00-00-00 Much higher torque than required Close to double the cost of more appropriate motor No encoder If used 23MD306S may obscure true system performance May be useful for testing components Can be used as a fallback if selected motors fail Speaker: Jeremy

30. Motor Selection Nema23 Stepper Motors with Integrated Motor Drivers Torque Requirements met by 175 and 262 Oz-in models Speaker: Jeremy

31. Boneyard Inventory: Xylotex 3.0 Motion Controller The use of Nema 23 Motors with built-in controllers make the Xylotex Controllers not needed May be useful for future bed system or if Nema 23 motor controllers fail Speaker: Jeremy

32. Power Supply Selection Enclosed Adjustable 200W Power Supply Up to 8.8 Amps at 24 Volts Internal Current, Voltage and Temperature Protection Speaker: Jeremy

33. Cost Layout Sub SystemCost X-Y Motion $1,258.88 Raw Material* $826.50 Motors $794.00 Enclosure $513.72 Z-Axis $520.19 EMHI+ Tools $353.87 Bed $335.69 Electronics $329.64 Storage $13.08 Total $4,945.57 *Raw materials includes: -10mm support plates for z-axis -Various plates to form EMHI assembly -Framework of the enclosure Speaker: Nick

34. Bill of Materials X-Y Motion Control ItemPart SourceCost PerQuantityTotal Lead ScrewMisumi$79.681 Fixed Side SupportMisumi$58.971 Screw NutMisumi$29.101 Nut BracketMisumi$35.281 Simple Side SupportMisumi$36.691 Shaft CouplingMisumi$46.391 Maker RailInventables$32.841 Carriage PlateInventables$8.002$16.00 WheelsInventables$11.954$47.80 Mount BracketMcMaster$3.884$15.52 Nuts - M5McMaster$0.078$0.59 Bolts - M5x20McMaster$0.428$3.37 80/20 Double FastenerMcMaster$1.098$8.72 Makerslide to 80/20Inventables$3.004$12.00 80/20 Single FastenerMcMaster$0.6416$10.20 Extended M8 - M8x55McMaster$0.284$1.14 M8 NutMcMaster$0.054$0.20 M5x25McMaster$0.404$1.61 M5x16McMaster$0.368$2.85 Long Axis ItemPart SourceCost PerQuantityTotal Lead ScrewMisumi$61.681 Fixed Side SupportMisumi$58.971 Screw NutMisumi$29.101 Nut BracketMisumi$35.281 Simple Side SupportMisumi$36.691 Shaft CouplingMisumi$46.391 Maker slideInventables$21.841 Carriage PlateInventables$8.002$16.00 WheelsInventables$11.954$47.80 Mount BracketMcMaster$3.884$15.52 Nuts - M5McMaster$0.078$0.59 Bolts - M5x20McMaster$0.428$3.37 80/20 Double FastenerMcMaster$1.098$8.72 Makerslide to 80/20Inventables$3.004$12.00 80/20 Single FastenerMcMaster$0.6416$10.20 Extended M8 - M8x55McMaster$0.284$1.14 M8 NutMcMaster$0.054$0.20 M5x25McMaster$0.404$1.61 M5x16McMaster$0.368$2.85 Short Axis Speaker: Nick

35. Bill of Materials - Motors Motor Description Bipolar Torque (oz- in) "L" Length (in) Rotor Inertia (oz-in-sec2) Weight (lbs) Shaft Option Encoder Option Input Polarity Recommended Power Supply Price (USD) Nema 23 1.8° Stepper w/ Driver & Encoder (X-Axis) 2624.940.00682.41Double400 Line Sinking or Sourcing PSAM24V2.7A$208.00 Nema 23 1.8° Stepper w/ Driver & Encoder (Z-Axis) 1754.030.00421.75Double400 Line Sinking or Sourcing PSAM24V2.7A$177.00 Nema 23 1.8° Stepper w/ Driver & Encoder (Y-Axis) 1754.030.00421.75Double400 Line Sinking or Sourcing PSAM24V2.7A $354.00 (Priced for two) Total:$794.00 Power Supply DescriptionPower (W)Voltage (V)Peak Current (A)OutputsInputPrice 350W Enclosed Supply3502414.6(3)V+/(3)V-115Vac/3.5A $55.00 (Priced for two) Speaker: Jeremy

36. Bill of Materials – Enclosure DESCRIPTIONQTY.PRICESUBTOTAL Corner Connector8 $9.55$76.40 80-20 Bench Length4 Included in raw materials total 80-20 Bench Width4 Included in raw materials total 80-20 Vertical5 Included in raw materials total Nut Block12 $0.64$7.65 Front Panel, Enclosure1 $83.65 Side Panel, Enclosure1 $83.65 Back Panel, Enclosure1 $83.65 Door HINGE4 $5.68$22.72 Door HANDLE2 $3.86$7.72 Example E-stop1 $75.92 Door Sensor + Latch2 $16.18$32.36 Various FastenersN/A $40.00 Total Cost: $513.72 Speaker: Matt

37. Bill of Materials – Z-Axis NAMEDESCRIPTVENDORQTYPRICESUBTOTAL 6709K13 20MM LINEAR RAIL CARRIAGEMisumi1117.45 6709K4320MM LINEAR RAIL, 340MM LMisumi100 HFSP6-3030-3413030 EXTRUDED ALUMINUMMISUMI113.09 MCGLC25-6.35-86.35-8 DISC COUPLINGMISUMI131.76 MTSRW12-351-F25- V8-S18-Q8 LEAD SCREW, 12D, 2MM PITCH, 340 TRAVELMISUMI138.54 MRWZ8 FIXED LEAD SCREW SUPPORTMISUMI164.21 MRUZ8LEAD SCREW SUPPORTMISUMI129.61 MTBLR12 ANTI-BACKLASH LEAD NUT, 12MMMISUMI1136.42 BACKPLATE10MM PLATE, MACHINEDMSC (SORT OF)1Included in raw materials total MOTOR MOUNT PLATE10MM PLATE, MACHINED*1Included in raw materials total SUPPORT PLATE10MM PLATE, MACHINED*1Included in raw materials total FIXED SUPPORT PLATE10MM PLATE, MACHINED*1Included in raw materials total Z NUT MOUNT50MM BAR, MACHINED MCMASTER- CARR142.15 92871A707SPACER MCMASTER- CARR43.6714.68 *** NEMA 17 MOTOR (NEEDS SPECCING***10 VARIOUS FASTENERS130 HNTTSN6-4M4 EXTRUSION NUT BLOCKMISUMI40.572.28 Total: $520.19 Speaker: Matt

38. Bill of Materials EMHI + Tools NAMEDESCRIPTIONQTYPRICESUBTOTAL LEDEX-H-2414-029ROTARY SOLENOID1$114.00 LEDEX-C5-270-B-1LATCHING SOLENOID1$8.85 EMHI SIDEMachined 75mmx90mmx10mm2Included in raw materials total UMB SIDEMachined 178mmx110mmx10mm3Included in raw materials total Under BraceMachined 65mmx90mmx10mm1Included in raw materials total Top BraceMachine 45mmx90mmx10mm1Included in raw materials total Female Bracket ConnectorMachined 40mmX60mmX10mm1Included in raw materials total 93600A1758mmX20mm Dowel Pin (5)3$13.00$39.00 93600A1156mm Precision Ground Dowel Pins (25)1$9.42 9292K416mm Hardened Ball Bearing (50)1$5.86 213893-2Female Socket, Flanged, 8 sig, 2 power1$6.09 213906-1Male Plug, Free, 8 sig, 2 power1$11.96 1-66400Signal Pin8$0.40$3.20 1-66399Signal Socket24$0.42$10.08 213847-4Power Socket, 50A2$5.20$10.40 213845-3Power Pin, 50A6$3.28$19.68 LRA6-A42-B20-L40BRACKET Stock FOR MALE CONNECTOR1$11.33 Stepstruder Mk7Extruder Head1$100.00 Black & Decker Rotary toolDremel Head1$35.00 UMHW Rotary Tool Clamps3-D printed plastic mounting clamps2$4.00$8.00 VARIOUS FASTENERSN/A $75.00 Total: $353.87 Speaker: Matt

39. Bill of Materials - Electronics Part NameDistributorMaterial CostQuantityTotal Cost LevelingKnobMisumi$4.714$18.84 LevelingBlockMisumi$18.144$72.56 LevelingPlateMisumi$43.581 BedMountingBracketMisumi$17.724$70.88 HeatingPlateMakerFarm.com$35.001$42.35 GlassPrintPlateMisumi$69.841 Kapton TapeEbay: mxqtech$5.883$17.64 Total Cost: $335.69 Bill of Materials - Bed Part NameCostQtyTotal Microcontroller60160.00 Wiring40.00 Cable Carriers12.610126.00 Carrier Connector9.66438.64 AC Power Strip15115.00 Limit Switch10.00 Position sensors40.00 Total Cost: $329.64 Bill of Materials - Storage PART NUMBERDESCRIPTIONQTY.PRICESUBTOTAL P14551_Storage8020SupportRails_ 20131023 80-20 STORAGE MOUNTING RAIL 4 Included in raw materials total P14551_StorageBracket_20131205STORAGE BRACKET6 Included in raw materials total 5537T164DOUBLE NUT BLOCK12 $1.0913.08 Total Cost: $13.08 Speaker: Matt

40. Skeinforge ArduinoSend Firmware based on TeaCup with G- code interpreter Motion Data Control Path Speaker: Austin

41. Test Plan Speaker: Austin

51. Test: Bed Adhesion Heated Bed Still On Adhesive force per square inch Speaker: Austin

52. Test: Bed Adhesion Heated Bed Off Adhesive force per square inch Speaker: Austin

53. Test: Milling and Drilling Milling XYZ accuracy Drilling XY accuracy Drilling depth accuracy Time to switch rotary tool bit Time to switch from additive to subtractive process Impact of switching from additive to subtractive on repeatability (zero-ing accuracy) Speaker: Austin

54. Updated Risk Assessment Risk Item Describe the risk briefly Risk Type Identify the type of the risk EffectCause Likelihood Severity Importance Action to Minimize Risk Process Head Not Aligned Technical Part printed incorrectly - dimensions of end result incorrect. Possible tool head collision with bed or part Mechanical registration failure or of position feedback/software control 236 Software and hardware registration used to verify. Very complex element changed from 3 to 2 use of sensors for location of storage with limit switches Miss deliverable deadlines Project Management Poor grade/ fall behind on project - might not complete entire project scope/ all nighters/ triage work Poor time management224 Keep/maintain a detailed project plan/ plan to increase the amount and duration of meetings to get back on schedule (pull all-nighters to reciver) Changed from 3 to 2. Team has done well with designing everythign on time and we have constant communication between the group to prevent this from happening Process Head Fall Off Technical Possibly damage print head or inside of printer. If protection is not sufficient, possibly damage the user. Mechanical failure of interface. Software incorrectly releases head. 133Head connection is active-off changed from 3 to 1 due to EMHI design and risk management identification Machine Acquires Wrong Head Technical Printer carries out the wrong process, resulting in a bad part and possibly damaging printer Mismanagment of head placement information/head interface issue. 133 Redundant identification system for head changed from 2 to 1 based on sensors that are implemented to the system, this is designed to never occur Operator gets hurt by machine (Burned, Blinded by Laser, UV Exposure, Cut by tooling, Inhale Powder, Caught in moving parts, etc.) Technical Operator requires medical attention/incurs medical costs Insufficient safety measures 133 Safety protection components/ document needs and specs of each process Enclosure added Failure to complete project on time Project Management Failure to implement any processes/address other customer requirements/receive a poor grade Attempt to implement too many processes/Take too long with design 133 Maintain good project plan with timing considerations / Have biweekly schedule checks to maintain an up to date status Aproaching end of MSD 1 on time( from 2 to 1) Team member disappears Organizational Lose team capability. Responsibility of each team member increases Many possible reasons for member to become absent. Sickness/drop out/etc… 133 Increase the amount of responsibilities per person/ assign "back-up" task-owners on task by task basis who can fill in in the occurance of a member disappearance Changed 2 to 3 on severity because the amount of work wuold substantially increase to a point where it may effect the outcome and completion date of project Reason for Change Speaker: Chad

55. MSD II Project Plan Speaker: Chad

56. Questions/Comments

57. Appendix

58. Motor Torque

59. FEA Force Calculations

60. FEA force calculations

61. FEA Force Calculations

86. Electrical/Mechanical Head Interface(EHMI) Subsystem Pugh Chart P145511234 EMHI Subsystem Tongue and Solenoid with 2 Alignment Pins Shaft and Solenoid with 1 Alignment Pinn Solenoid Driven Locking Arms Ball Bearing/Roller Bearing Alignment Parameter Number Criteria Number Conceptual Image Judgement Criterion 11Linear Alignment (X,Y,Z) DS-+ 22Rotational Alignment AS-+ 33Active-off Mechanical Connection T+++ 44Reliability of Electrical Connection USSS 55Amount of Custom Parts M+-- 66Machining Complexity --- 77Ease of Servicing Unit +-+ 88Complexity of Release Mechanism S-S 99Overall Cost ?-? 10 11 12 13 14 Total (+) 0314 Total (-) 0172 Net Score 02-62 Speaker: Matt

87. Storage Subsystem Pugh Chart P14551123456 Process Head Storage Subsystem Horizontal Pins with Z Motion Horizontal Pins with Spring Loading Solenoid-Driven Pin Locking (Back Plate) Solenoid-Driven Pin Locking (Side Plates) Magentic Storage Vertical Pins with Z Motion Parameter Number Criteria Number Conceptual Image Judgement Criterion 11Required Range of Z Motion D++++- 22Complexity of Storage Area Element A-+-++ 33Complexity of Process Head Element TS-+++ 44Machining Complexity U--S++ 55Estimated Cost M----- 66Added Space Envelope for Storage S---- 77Stablility Without Power SSS-- 88Number of Actuating Elements ---SS 99Precision/Repeatability of storage location -++SS 10 11 12 13 14 Total (+) 013343 Total (-) 055434 Net Score 0-4-21 Speaker: Nick

88. Motion Control Pugh Chart P145511234 Process Head Storage Subsystem Basic Cartesian Ball & Belt Drive Basic Cartesian Lead & Chain Drive Complex Cartesian Ball & Belt Drive Wench - Cable Drive Parameter Number Criteria Number Conceptual Image Judgement Criterion 11Technical Difficulty S-- 22Motion System Cost D+-+ 33Load Bearing Capability S?- 44Accuracy (X) A-S- 55Max Drive Speed (X) +S+ 66Accuracy (Y) T-S- 77Max Drive Speed (Y) +S+ 88Accuracy (Z) U-S- 99Max Drive Speed (Z) ?-S 10 Maintenance Requirements M--+ 11 12 13 14 Total (+) 0304 Total (-) 0445 Net Score 0-4