Eric Hettler - MEWilliam Gallagher - ISE

Christopher Mieney - MEGregory Ryan - ME

Joseph Cole - EE

FAB AMERICA

Design Review Agenda Project Overview Needs/Specifications Current System Selected Concept Material Delivery System

Drawings BOM Feasibility

Control Electronics Drawings BOM Feasibility

Curing Drawings BOM Feasibility

Risk Assessment Test Plan

Project Overview Fab@Home open-source

architecture Print photo-curable resin Color printing used as a vehicle

to demonstrate multi-material print capability

http://fabathome.org

Systems Overview

Concept Screening/SelectionMaterial Delivery

Micro Valve (solenoid) Ball Point Approach Micro Rocker Valve (solenoid) Inkjet (Thermal) Inkjet (Piezoelectric) Disposable Syringe

Curing Ambient Light

(fluorescent) Mini Halogen Bulbs LEDs Laser Fiber Optics

Motion Control Stepper Motor Servo Motors Pulleys Rack and Pinion Pneumatics

Color Mixing 3 pre mixed reservoirs that

mix in manifold Inject individual inks into

stream of resin Mix inks and inject into

stream of resin Print like an inkjet

(halftoning) Put down resin and print with

inkjet on top

Material Delivery - Manifold

Material Delivery - Manifold

Lee ValvesProposed Design: material delivery nozzles Tube ID: .0075”Proposed Design: Micro Valves

Photos From The Lee Company

Material Delivery - BOMAir Adapter Assembly 10cc Adapter 3ft hose 7012339 EFD 3 $23.25 $69.75Reservoirs Syringe Barrel and Piston Set (10 cc UV Light Block) 7012126 EFD 30 $1.33 $39.78

Solenoid air valve (optional)

Solenoid Valve, NPT Port 1/8 Inch, Coefficient of Volume 0.2, Air Flow 6.9 CFM, Coil 12 VDC, Maximum Operating Pressure 120 PSI, Maximum Temperature 0-180 Degrees Fahrenheit, Actuator/Return Solenoid/Spring, Length 1.32 Inches, Height 2.4 Inches, Width .75 Inch, 3 Way Direct, Body Ported

35A-AAA-DDBA-1BA Grainger 0 $33.30 $0.00

Material TubingTubing, PTFE, All Natural, 1/16th x .040" (1.0mm) ID. Low Pressure, Translucent. 5 Meter Roll. 49210-40

MicroSolv Tech 1 $13.21 $13.21

Material Tubing Covering

Polyvinyl Chloride (PVC) Heat Shrink Tubing - 5 Pack Color: Black Minimum Conductor Range: 1/16 Maximum Conductor Range: 1/8 Length: 6 In. Expanded/Recovered Inside Diameter: 0.125/0.062 65546111 MSC 1 $1.82 $1.82

Material Tubing (second choice)

PTFE Thin Wall Spaghetti Flexible Tubing Inside Diameter: 0.038 In. Outside Diameter: 0.062 In. Wall Thickness: 0.012 In. Material: Teflon Color: Natural White 48703094 MSC 0 $0.20 $0.00

Air Regulator

Air Regulators with Pressure Gauge Type: Dial Air Regulator Port Size: 1/4 Gauge Port Thread Size: 1/4 Minimum PSI: 10 Maximum PSI: 120 Fluid Type: Compressed Air Material: Zinc Width: 1.97 In. 74381435 MSC 1 9.24 $9.24

Hose AdapterNylon Push-To-Connect Fittings - Fractional Tube Outside Diameter: 5/32 Thread Size: 1/4 Material: Nylon 48618565 MSC 1 $5.19 $5.19

3-way air separator Nylon Push to Connect Fittings - Metric Sizes Tube Outside Diameter: 5/32 Metric Tube OD: 4 Material: Nylon 85333789 MSC 1 $10.62 $10.62

Cable Ties

TY-Rap« High Performance Cable Ties Type: General Material: Nylon Maximum Bundle Diameter: 5/8 Maximum Bundle Diameter: 0.625 Package Quantity: 100 Color: Natural Tensile Strength: 18 Body Width: 0.091 54065842 MSC 100 $0.12 $12.43

Air fittings Female Luer to 1/16" barbed connector 11520 QOSINA 0 $0.00 $0.00Air fittings (second choice) Female Luer to 1/32" barbed connector 11733 QOSINA 3 $0.00 $0.00Lee Micro valve Lee VHS P/2 Solenoid Valve INKA2424212H The Lee Co 3 $135.79 $407.37Manifold mount Lee VHS valve manifold mount kit IKTX0322170A The Lee Co 3 $25.03 $75.09Nozzle 0.010" ID MINSTAC nozzle INZA5102514K The Lee Co 1 $38.58 $38.58

Material Delivery - FeasibilityRan preliminary valve test (.0075” ID nozzle)

Valve can deliver consistent small droplets of high viscosity liquid

Valve cannot “jet out” high viscosity liquidFlow rates seem reasonable

Put resin through syringe (.00825” ID nozzle)Could not produce “jet”

Valve Controls

Constant 24 volts for the spike Constant 3.5 volts for the hold 5 volt is pulsed The rising edge initiates the

spike and hold

http://fabathome.org

Control Electronics

R9

4.7k

R2

330

R3

330

R4330

R510k

R610k

R74.7k

R8

1k

C1

C2

C3

C4

D1

D2

D3

D4T3IC2

T1

T2

R1

T4

TB1

IC1

Control Electronics - BOMComponent Specs Item # Supplier Quantity Unit Cost Total Cost

Bulbs6 Watt T5 Fluorescent Black light Miniature Bipin Base F6T5/BL Top Bulb 4 $3.99 $15.96

Light fixtureMicro fluorescent T5 Grounded Light Fixture (6 watt) PSG5-6-xx

Pegasus Associates Lighting 2 $21.90 $43.80

Framing MaterialArchitectural Aluminum (Alloy 6063) (3/4" x 3/4" x 1/16" x 6') 4630T14 McMaster 1 $10.85 $10.85

Reflector Arcadia Aquarium Lighting Reflector T-8 Ebay 1 $0.00

Power CableMicro fluorescent Grounded Flexible L Connector PSG-CC6L

Pegasus Associates Lighting 1 $3.90 $3.90

Curing System

Curing System

Curing System FeasibilityIrradiance at the Bulb Surface: Irradiance at the Work Part:

Total Cure Time:

Assumptions:•The center line of the bulb is considered to be the source of light for purposes of measuring radii•The layer thickness is taken to be 0.01 inches thick•The entire UV output of the bulb (1 watt) is produced at the required wavelength of 355 nmNote:•Cure time may be further reduced through the addition of a reflector

Curing System BOMSpecs Item # Supplier Quantity Unit

CostTotal Cost

Shipping Cost

Price includes shipping

6 Watt T5 Fluorescent Black light Miniature Bipin Base F6T5/BL Top Bulb 2 $3.99 $15.96 Yes

Micro fluorescent T5 Grounded Light Fixture (6 watt) PSG5-6-xx

Pegasus Associates Lighting 2 $21.90 $43.80 Yes

Architectural Aluminum (Alloy 6063) (3/4" x 3/4" x 1/16" x 6') 4630T14 McMaster 1 $10.85 $10.85 No

Micro fluorescent Grounded Flexible L Connector PSG-CC6L

Pegasus Associates Lighting 1 $3.90 $3.90 No

Arcadia Aquarium Lighting Reflector T-8 Ebay optional $0.00 No

Test PlanServe To Verify System Design and Quantify VariabilitySubsystems

CuringValvesMotion ControlColor Delivery

Integration effectsSizeLayerShrinkage/Deformation