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Multi-Process 3D Printer: Detailed Design Review

Multi-Process 3D Printer: Detailed Design Review. Group Members: Jeremy Bennett Austin Chacosky Matt Demm Nick Hensel Chad Rossi. Customer: Dr. Dennis Cormier Guide: John Kaemmerlen. Objective. Obtain feedback to prepare for the gate review

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Multi-Process 3D Printer: Detailed Design Review

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  1. Multi-Process 3D Printer:Detailed Design Review Group Members: Jeremy Bennett Austin Chacosky Matt Demm Nick Hensel Chad Rossi 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. 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) • Fsyield= 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. Higher cost than Arduino Duo Lower clock speed 8 bit operation system May lead to slow system operation Boneyard Inventory: Arduino Mega 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. Insufficient Torque for moving large tool heads May be useful for future teams making powder bed Boneyard Inventory: Lin 3518M Motor Speaker: Jeremy

  29. 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 Boneyard Inventory: MD 23 Motor 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. 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 Boneyard Inventory: Xylotex 3.0 Motion Controller 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 *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 Long Axis Short Axis Speaker: Nick

  35. Bill of Materials - Motors Total:$794.00 Speaker: Jeremy

  36. Bill of Materials – Enclosure Total Cost: $513.72 Speaker: Matt

  37. Bill of Materials – Z-Axis Total: $520.19 Speaker: Matt

  38. Bill of Materials EMHI + Tools Total: $353.87 Speaker: Matt

  39. Bill of Materials - Bed Bill of Materials - Electronics Total Cost: $335.69 Bill of Materials - Storage Total Cost: $329.64 Total Cost: $13.08 Speaker: Matt

  40. Motion Data Control Path CAD Files .stl G-Code files G-Code lines Skeinforge ArduinoSend G-Code lines G-Code lines Electric Impulses Firmware based on TeaCup with G-code interpreter Speaker: Austin

  41. Test Plan Speaker: Austin

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