Advanced 3 D Printer Group Meron Reda Project

Advanced 3 D Printer Group Meron Reda (Project Manager) Brian Calinaya (System Engineer) Lennon Nguyen (Power Train) Moheb Youssef (3 D Printing) Peter Flores (Manufacturing Division Manager and Controls)

Extruder Carriage

Melting Point � Changed the Extruder Carriage to account for melting point limitations. � Old PLA carriage had melting point of 185° C. � New ABS has melting of 230° C.

Increased Resolution

Requirements � Have the best print quality possible � Use parts that are ubiquitous � Reduce and minimize chance of backlash ◦ However some backlash may be present to prevent jamming, allow for lubrication, etc.

Changing the Belt

Changing the Pulleys � We chose a smaller pulley to increase resolution and to fit with the new belt � To fit the smaller pulley, we made the Y-Axis motor attachment thinner

Results

Air Scrubber

Requirements � Design an air scrubber that eliminates all toxic fumes and smells. � Must adhere to Sasha’s dimensions and allows flexibility. We chose 27 x 24 x 20 inches. � The cost must not exceed $200.

Sasha Box

Sasha Box � Currently testing the box for dead zones and temperature concerns. � Testing with ABS plastic and adjusting the filter tubing size accordingly

Carbon Air Filter

Possible Future Implementations � Retractable floor tray that the 3 D printer sits on in the box for easy access. � Add light sources in the box (Color LEDs)!

New 3 D Printer: Maker Society � We have completed the Ramps Board section of building the new 3 D Printer and are currently working on the exoskeleton.

New 3 D Printer � We are currently at the exoskeleton stage of our build process. � After, we will be working on the hotends and x-bars.

CNC Design

What Is CNC? �A "subtractive" method for processing raw material with a drill-like rotating cutter through a set of computer-driven movements of the cutting head. � Benefits: Fast, high accuracy, efficient

Objective � Design a CNC machine using a Dremel or similar rotary type tool head and Folda. Rap structural base made of aluminum and printed PLA plastic brackets.

Requirements LEVEL 1 � Complete CNC design � Portable � Uses printable parts � Compact ◦ 335 x 348 x 318 mm LWH +21 mm for handle � Cost Effective ◦ Under $600 � Durable ◦ Aluminum structural support LEVEL 2 � Counter resistance of different types of materials during operation � Dremel tool head is used for subtractive method � Stepper motors to move axes in place of belts and pulleys; less resistive

Design � Unlike other CNC designs that use wood for the structure, we chose to use the Foldarap as the outer frame since it is made out of extruded plastic, which we can print, and aluminum which is sturdy and durable. � This design would be efficient because the aluminum can hold up for years. Using stepper motors to drive up the axes would be less resistive and last longer. Printing the hinges and brackets saves us money. � We based our CNC design on both the Prusa Mendel and the Foldarap 3 D printer

Base Assembly � Assemble the Foldarap Base as seen in build instructions manual � Can also find instructional videos online

X-Axis Assembly � X-Axis: Assemble as seen in the Foldarap Build Manual except instead of 2 smooth rods, use 1 smooth rod and 1 threaded rod. Attach a stepper motor to one side with the shaft facing horizontal. The stepper motor will be driving the threaded rod.

Y-Axis Assembly � Assemble Y-Axis, with two smooth rods and one threaded rod in the middle to drive the printed plate. A stepper motor will be attached to the threaded rod.

Z-Axis Assembly � Z-Axis: Assemble as seen in the Foldarap Build Manual. Add stepper motors to the top of the zaxis screw drives.

Dremel Assembly � We will be attaching a Dremel in place of the extruder carriage, enclosed in a printed holder, similar to the one shown in the picture.

Dremel 4000 � Multi-speed from 5 K to 35 K RPM � Quieter than other models � Inexpensive at around $80 � Lightweight: 18. 8 oz � Equipped with multiple attachments for the changing out the tool head

Software � Use Replicator. G (http: //replicat. org/) to convert gcode or stl file � Use RAMPS board version 1. 4, as in the Prusa Mendel, to control the stepper motors that are controlling the x, y, and z axes. � Use Marlin Firmware

Arduino Mega 2560 Ø Ø This board is the brain of our CNC machine and serves as the main interface to the computer. The Arduino board is programmed with a modified Reprap Gcode interpreter and the 3 axes motion.

RAMPS Shield RAMPS is a shield board that needs to be connected to an Arduino MEGA 1280 or 2560 board. Ø The Image shows a RAMPS board mounted on a Arduino MEGA board with four Pololu stepper motor controller boards installed Ø

End Stop (Limit Switch) Ø The switch and little debounce circuit is, at minimum mounted at one end of each axis. Ø Provide a home location for the machine.

CNC Parts List Qty. Product Description Product Number/SKU RAMPS Rep. Rap Arduino Mega Pololu Shield 1 electronics 1 AVR ARDUINO MEGA 2560 REV 3 3 x Mechanical Endstop 3 D printer, reprap, prusa, 1 mendel, makerbot 6 6 mm Diameter x 300 mm Length Smooth rod 2 6 mm Diameter Threaded rod 1 meter 4 NEMA 17 stepper motors Printed Parts for structure 5 20 x 20 beam 6 mm slot 1 meter 1 Dremel 4000 A 000067 Source http: //www. ebay. com/it m/RAMPS-Rep. Rap. Arduino-Mega-Pololu. Shield-electronics-assd -Pololus-kit-PCB/261105171806 http: //www. mouser. co m/Product. Detail/Arduin o/A 000067/? qs=g. Moq Xxk%2 F%2 F 5 ap. EOl. L 63 o O 8 Q%3 D%3 D&gclid=CL uhw. Ku 2 yr. MCFWlx. Qgodi 2 UA 7 g http: //www. ebay. com/it m/3 -x-Mechanical. Endstop-3 D-printerreprap-prusa-mendelmakerbot/150922395345? pt=LH _Default. Domain_2&has h=item 2323 acfed 1 Salvaged from old printers/scanners http: //www. screwfasten ers. co. uk/threadedrods-0/stainless-steel 0/threaded-rod-a 2 stainless-steel-din-975 -0/tige-filetee-m 6 inox-a 2 -din-975. html Ebay 3 D Printed http: //www. aluminiumprofile. co. uk/acatalog/ Aluminium_Profile_with _6 mm_Slot. html#a. KJN_ 20992_20888 Amazon Unit Price Total Price $7. 40 $38. 95 $14. 90 $0. 00 $3. 72 $10. 00 $7. 44 $40. 00 $4. 60 $79. 00 $23. 00 $79. 00 $210. 69

Future Design � To get better efficiency and avoid calculating the resistance of each printed material, look into switching a Dremel tool head with a laser cutter.

Cost/Materials Qty. Product Number/SKU Source 1 OPTIX 18 in. x 24 in. x. 093 in. Acrylic Sheet 241610 Home Depot $9. 78 2 OPTIX 11 in. x 14 in. x. 093 in. Acrylic Sheet 241302 Home Depot $4. 24 $9. 48 1/2 in. x 2 ft. x 4 ft. Medium Density 2 Fiberboard Handy Panel 279388 Home Depot $8. 97 $17. 94 22078553622 Home Depot $1. 83 201426 Home Depot $11. 48 1 92 mm fan N/A Scrap parts N/A 0 2 80 mm fan N/A Scrap parts N/A 0 N/A 3 D Printed N/A 0 $30. 00 N/A 0 Product Description Unit Price Total Price Air Scrubber 1 Liquid Nails Projects 10 oz. 1 GE Carbon Replace Filter 2 -Pack Filter printed parts Resolution Upgrade 1 GT 2 Pulley & Belt Set http: //store. trinitylabs. com LM-GT 2 PB /gt 2 -pulley-belt-set/ Extruder Carriage Upgrade 1 New Printed Extruder Carriage N/A 3 D Printed $80. 51

Schedule