Systems design review - EDGEedge.rit.edu/edge/P14551/public/SLDR_Documents/P14551...Machine using grippers or vacuum to hold SMT componets positions them over solder paste pads in

P14551 Multi-process 3D Printer

Systems Design Review

Group Members:

Jeremy Bennett

Austin Chacosky

Matt Demm

Nick Hensel

Chad Rossi

Customer:

Dr. Dennis Cormier

Guide:

John Kaemmerlen

Agenda

Background

System Analysis

Concept and Architecture Deviation

Engineering Analysis

Risk Assessment

Project & Test Plan

Agenda

Background

System Analysis

Concept and Architecture Deviation

Engineering Analysis

Risk Assessment

Project & Test Plan

Open Source & 3-D Printing

Open source licenses

allow hobbyists to

afford 3-D printers.

RepRap, Makerbot,

Fab@Home, etc.

These printers are

single process,

usually FDM.

Speaker: Matt

Benchmark System: Multi-Process 3-D

Printing

Currently under

development

Proprietary

Large Size

Uses Modular Process

Heads

Expensive (~$150,000)

Open source version

does not exist

Speaker: Matt

Due to recent leaps open source technology, 3-D printing is set to take off in the coming years. Current open source machines can perform a single process, (e.g. laser sintering, thermoplastic extrusion, routing) leading for the need to buy and maintain multiple machines in order to prototype complex parts. Multi-process 3-D printers are capable of performing these processes, minimizing capital and maintenance expenses, while simultaneously unlocking the ability to produce multiple substrate parts such a printed circuit boards or other composite materials. Current multi-process printers are not open sourced and have costs well above what the average hobbyist can afford.

The goal of the project is to demonstrate a multi-process 3-D printer that is both designed as open source and at an appropriate price range to be marketed to the average hobbyist. This printer will incorporate an interface capable of supporting multiple process heads, which could additive or subtractive in nature, that will operate with minimum setup or training. (i.e. Plug-and-Play) Open sourced or low cost software will be used to control the printer. This project will create a platform that can be expanded upon by future MSD teams.

Problem statement

Speaker: Jeremy

Customer Requirements

Speaker: Austin

Engineering Requirements

Speaker: Austin

Agenda

Background

System Analysis

Concept and Architecture Deviation

Engineering Analysis

Risk Assessment

Project & Test Plan

House of Quality

Speaker: Austin

House of Quality Continued

Speaker: Austin

House of Quality Continued

Speaker: Austin

Key Engineering Requirements: • Quantity Subtractive Processes

• Quantity Additive Processes

• System Cost

• Tool Head/Interface Dimensionality

• Enclosure Dimensions

• Human Interaction Time During Tool Change

House of Quality

Speaker: Austin

Functional Decomposition

Speaker: Nick

Process Benchmarking Process Name Type Method of Manufacturing

Weight (kg)

Cost ($)

Layer Tolerance (± mm)

Speed (mm/min)

Size (mm) Safety Concerns Power Req's (Watts)

Material Inputs/Outputs

Material Storage Concerns Process Examples Owner

Fused Deposition Modeling (FDM

Additive Extrudes material through a heating element to form layers

0.4-1 70-250

0.1 40 125X112X

86 Hot Extruder, Current Draw

50 Plastic Wire Spools of wire http://dx.com/p/heacent-et01-k-extruder-w-j-head-for-reprap-3d-printer-black-233527

Matt

Selective Laser Sintering (SLS)

Additive Melts powder to form layers via high powered laser

0.1 lasers powder powder bed Austin

Plaster-based 3D printing (PP)

Additive Sprays glue on to a powder bed to create layering

>2 <=.05 125 30X30X50 Dust Inhalation Powder Powder Bed http://pwdr.github.io/ Jeremy

Laminated Object Manufacturing (LOM)

Additive Thin layers of material are cut to shape by a laser or knife and glued into position.

0.5-2kg 100+ 0.05 "Fast" Mirror Hot Roller, Cutting

Laser 350

Adhesive Coated Paper/Foil

Rools of specialized paper or foil

http://www.custompartnet.com/wu/laminated-object-manufacturing http://www.mcortechnologies.com/3d-printers/matrix-300-plus/

Matt

Stereolithography (SLA or DLP)

Additive Use UV light to cure photoreactive polymer layer by layer. DLP projects light for a full cross section simulataneously

Chad

Electron Beam Freeform Fabrication (EBF^3)

Additive

Feeds Wire in a molten pool of metal generated by an electron beam. Once the beam moves away, the pool hardens. Moving the wiring and the beam creates part cross sections

0.05 - 0.2 Very hot,

machining done in vacuum

4800 powdered metal powder bed Austin

Selective Heat Sintering Additive Uses direct heat application instead of lasers to melt powder together to form layers

heat powder powder bed Austin

Vacuuming Cleaning Uses vacuum pressure to draw up and away unwanted particles and gases

5 40+ N/A N/A 312X245X

483 175 N/A Vacuum Stored External

http://www.shopvac.com/wet-dry-vacs/vac-

details.aspx?vacId=324&vacSKU=589-51-00

Jeremy

Air Gun Cleaning Uses positive pressure to blow away unwanted particles or chips

<2 5-30 N/A N/A 80X20X40 N/A (Air Supply) Air Air Compressor Jeremy

Polishing Finishing Removes surface scratches from parts, improves surface finish

Chad

Sanding Finishing Removes surface material to smooth out faces and edges. Improves overall surface finish and texture

Chad

Glue Dispense (Solder Paste)

Finishing Liquid material is dispensed through either a screw driven sryinge or pulled from a basin.

>1 80-160

N/A Nozzle

Dependent >10000

Don't Touch the Glue

<25 Glue, Solder Paste Onboard Syringe

http://www.fabathome.org/wiki/index.php?title=Model_1_1-Syringe_Tool http://www.manncorp.com/smt/cat-61-1/dispensers.html

Matt

Pick & Place (SMT Component Placement

Finishing Machine using grippers or vacuum to hold SMT componets positions them over solder paste pads in preparation for reflow

Matt

Laser Engraving Finishing Uses a laser to burn the surface layer of material, allowing for fast engraving

lasers Austin

Powder Deposition Preparation Dispenses Powder into a bed to create a new layer

Jeremy

photopolymer dispense head Preparation Jeremy

Milling Subtractive Moves spinning tool through part, removes chips Chad

Routing Subtractive Similar to milling. Used to hollow out wood or plastic. Can be use to separate parts from mold Chad

Turning Subtractive Removing material in a continuous fashion by spinning a part on an axis using a stationary tool Nick

Laser Cutting Subtractive

Uses a high energy laser to cut through material lasers Austin

EDM Subtractive

Material is removed from the workpiece

by a series of rapidly recurring current

discharges between two electrodes,

separated by a dielectric liquid and

subject to an electric voltage.

0.01 - whatever sparking, heat

up to 200000 (400A peak and

500V peak)? http://www.engineersedge.com/edm.shtml Austin

Speaker: Matt

Process Benchmarking Process Name?? Type

Method of Manufacturing

Weight (kg)

Cost ($)

Layer Tolerance (± mm)

Speed (mm/min)

Size (mm)

Safety Concerns

Power Req's (Watts)

Material Inputs/Outputs

Material Storage Concerns

Fused Deposition Modeling (FDM

Additive Extrudes material through a heating element to form layers

0.4-1 70-250

0.1 40 125X11

2X86 Hot Extruder, Current Draw

50 Plastic Wire Spools of wire

Selective Laser Sintering (SLS)

Additive Melts powder to form layers via high powered laser

? 300+ 0.1 ? lasers ? powder powder bed

Plaster-based 3D printing (PP)

Additive Sprays glue on to a powder bed to create layering

>2 <=.05 125 30X30X

50 Dust

Inhalation Powder Powder Bed

Laminated Object Manufacturing (LOM)

Additive

Thin layers of material are cut to shape by a laser or knife and glued into position.

0.5-2kg 100+ 0.05 "Fast" Mirror Hot Roller,

Cutting Laser 350

Adhesive Coated

Paper/Foil

Rools of specialized

paper or foil

Vacuuming Cleaning

Uses vacuum pressure to draw up and away unwanted particles and gases

5 40+ N/A N/A 312X245X483

175 N/A Vacuum Stored

External

Air Gun Cleaning Uses positive pressure to blow away unwanted particles or chips

<2 5-30 N/A N/A 80X20X

40 N/A (Air Supply)

Air Air

Compressor

Glue Dispense (Solder Paste)

Finishing

Liquid material is dispensed through either a screw driven sryinge or pulled from a basin.

>1 80-160

N/A Nozzle

Dependent

>10000 Don't Touch

the Glue <25

Glue, Solder Paste

Onboard Syringe

Speaker: Matt

Printer Bench Marking

Printer Name Cost ($) Available Processes Layer Resolution (in)

X-Y Tolerances (in)

Printable Area (in)

Links for Additional Specifications

Multi Proto Lab

150,000+ 100,000+

3D Dual additive printing (ABS + sacrificial PLA) 0.001 0.001

24"x36"x8" 20"x24"x8"

http://rapidprototypingmachine.com/mpl/platform/2-uncategorised/18-platform-standard

High-speed precision milling Drop-on-Demand printing of conductive and nano-scale metals

Laser-powered soldering

Extrusion deposition

Adhesive dispensing

Pick and place

Conformal polymer layer dispensing

Fab@Home ~3,000 Solid Free Form Fabrication (Syringe Based Printing) 0.001 0.004 8"x8"x8"

http://www.fabathome.org/index.php?q=faq

Makerbot 2,800 Fused Filament Fabrication (Dual Plastic Deposition) 0.004 0.0004 9"x6"x8.1"

http://store.makerbot.com/replicator2x.html

RepRap (Mendel)

500-1,000 Fused Deposition Modeling 0.012 0.004 8"x8"x5.5"

http://reprap.org/wiki/Mendel

Speaker: Matt

Agenda

Background

System Analysis

Concept and Architecture Deviation

Engineering Analysis

Risk Assessment

Project & Test Plan

Morphological Chart

Speaker: Jeremy

Morphological Chart

Speaker: Jeremy

Concept 7 - “Gene Simmons” Selected

System Concepts

Concept 1 Concept 2

Concept 4 Concept 3

System Concepts Cont.

Concept 5 Concept 6

Concept 7 Concept 8

Pugh Chart

P14551 --- 1 2 3 4 5 6 7 8

Multi-process 3D Printer Mutli-Proto Lab Dual Dumper EZPZ Slide'n'Ride Bandaid Dispenser AirmageddonAntebellum

AmericaGene Simmons Ultimate Papercut

Conceptual Image

Judgement Criterion

Cost - - + - - - - D -

Technical Difficulty - - + - - - - A +

System Extensibility + + - + + - + T -

Number of Safety Concerns + S + - - - - U -

Utlizes pre-existing parts - - S - - - S M -

Motion Control Precision + - - + + - S +

Maximum Number of Processes in Machine S - - + + - + -

Active Material Storage Volume ? + S - - + + S

Maintenance Frequency ? - + - - - - -

Material Replacement Difficulty ? + S S S + + S

Number of Actuating Elements (↓) S - + - - S - -

Ease of assembly/Open source capability - - + - - - - +

Visual appeal of system + + - + + + + S

Power Consumption - + - + S - S -

Total (+) 4 5 6 5 4 3 5 0 3

Total (-) 5 8 5 8 8 10 6 0 8

Net Score -1 -3 1 -3 -4 -7 -1 0 -5

Speaker: Nick

Selected Concept

Design “Gene

Simmons” Selected

Simple Motion Control

Expandable

Secure Interface

Utilizes existing

technology

Speaker: Nick

Architecture

Speaker: Nick

Agenda

Background

System Analysis

Concept and Architecture Deviation

Engineering Analysis

Risk Assessment

Project & Test Plan

Engineering Analysis

Speaker: Nick

Agenda

Background

System Analysis

Concept and Architecture Deviation

Engineering Analysis

Risk Assessment

Project & Test Plan

Risk Assessment ID

Risk Item Describe the risk briefly

Risk Type Identify the type

of the risk

Effect What is the effect on any or all of

the project deliverables if the cause actually happens?

Cause What are the possible cause(s) of this risk?

Like

liho

od

Seve

rity

Imp

ort

ance

(L

*S)

Action to Minimize Risk What action(s) will you take (and by

when) to prevent, reduce the impact of, or transfer the risk of this occurring?

Owner Who is

responsible for following through on mitigation?

2 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. 3 3 9 Head connection is active-on M. Demm

1 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.

2 3 6 Redundant identification system for head N. Hensel

8

Subtractive tool

contacts surface

other than part

Technical Damage to internal of machine

(bed/enclosure/etc.)

Tool motion/path not

correct. Bad coordinate

referencing 2 3 6

Limit motion with robust system feedback/

limit switches. Add hardware limiting

elements. Simulate toolpaths to verify

accuracy

N. Hensel

10

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 2 3 6 Safety protection components/ document

needs and specs of each process A. Chacosky

12 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 2 3 6

Maintain good project plan with timing

considerations C. Rossi

15 Technical Inability to

develop Interface Organizational

We fail to meet the most important

customer specification

Lack necessary skills. Do

not put enough

resources/time into

coming up with a solution.

2 3 6 Conduct sufficient research and

benchmarking Team-wide

22

Customer not

satisfied with end

result

External Customer gives poor review to

advisor

Chosen design fails to

meet customer

specifications 2 3 6 Maintain good contact with customer C. Rossi

3 Process Head Not

Aligned Technical

Part printed incorrectly - dimensions

of end result incorrect.

Mechanical registration

failure or of position

feedback/software control 3 2 6

Software and hardware registration used to

verify. Very complex element M. Demm

13 Inability to meet cost

goals Organizational

Printer cost out of specification -

miss customer requirements

Receive innacurate cost

estimates on

components/insufficient

BOM detail/need to

acquire unaccounted for

components

3 2 6 Maintain an accurate budget C. Rossi

24 Miss deliverable

deadlines Project

Management

Poor grade/ fall behind on project -

might not complete entire project

scope/ all nighters/ triage work

Poor time management 3 2 6 Keep/maintain a detailed project plan C. Rossi

Speaker: Chad

Agenda

Background

System Analysis

Concept and Architecture Deviation

Engineering Analysis

Risk Assessment

Project & Test Plan

Test Plan Objective

Test to compare dimensions in a user created CAD file to system performance output in order to compare system capabilities to engineering requirements

Description Created a die by using additive process to create a

1x1x1 cube and subtractive process to create the dots and contour mill edges

Measure created part and compare to the CAD file If automated dimensions are not equal to printed part,

recalibrate machine and start again

Output parameters X-Y resolution of printing Precision Timing

Speaker: Chad

Project Schedule

Speaker: Jeremy

Questions

?

Appendices

Video: http://www.uqast.com/Nationalnano/Multi-Proto-

Lab?goback=%2Egmp_1914824%2Egde_1914824_member_

198149628#%21

Benchmarking Site

http://www.3ders.org/pricecompare/3dprinters/?a=DIY%20kit&

tab=Details

Appendices

File Links:

https://edge.rit.edu/edge/P14551/public/WorkingDo

cuments/System%20Level%20Design/P14551_Mor

phologicalChart_20130919.xlsx

https://edge.rit.edu/edge/P14551/public/WorkingDo

cuments/System%20Level%20Design/Benchmarkin

g/P14551_HRMTBenchmarking_20130919.xlsx

Concept

1

Concept

2

Concept

3

Concept

4

Concept

5

Concept

6

Concept

7

Concept

8