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Multi-Process 3D Printer: Final Review. Group Members: Jeremy Bennett, Austin Chacosky , Matthew Demm , Nicholas Hensel , Chad Rossi Customer: Dr. Dennis Cormier Guide: John Kaemmerlen. Agenda. Project Background System Architecture Customer Needs Engineering Specs

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Multi process 3d printer final review

Multi-Process 3D Printer:Final Review

Group Members:

Jeremy Bennett, Austin Chacosky, Matthew Demm, Nicholas Hensel, Chad Rossi

Customer: Dr. Dennis Cormier

Guide: John Kaemmerlen


  • 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
Project Background


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 Lab

Open Source CNC Mill

Single Process 3D Printer

Speaker: Chad

System architecture
System Architecture

  • System Architecture layout from MSD I

  • Accurate assessment of content we focused on for the project

Speaker: Nick

Review of customer needs
Review of Customer Needs

  • 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

Process head storage
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
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
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


  • 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
Project Evaluation



Survived trip to Imagine

1st 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
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
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


Special thanks: Dr. Cormier, Professor Kaemmerlen,

CJ Winegar, Mike Buffalin, John Bonzo,

ME Machine Shop Staff,

Various Subject Matter Experts