3D Printing at The University of Alabama Libraries of Alabama.pdf · The University of Alabama...

3D Printing

at The University of Alabama Libraries

Stanford Prize for Innovation in Research Libraries (SPIRL) Entry

Prepared by Vincent F. Scalfani, Josh Sahib and John H. Sandy

January 2013

SPIRL University of Alabama Libraries Narrative 1

Innovation: 3D Printing Studio

The University of Alabama (UA) Libraries operates a 3D printing studio where members of the UA

community can design and create 3D plastic models. The 3D printing studio at UA Libraries

provides support for 3D users by offering workshops, course training, and personal consultations

which outline the technology, software, and operating procedures required to produce a 3D plastic

object. Briefly, a 3D printed object starts with a computer aided design (CAD), the CAD file is then

converted into a format the printer understands, called a 3D build file. Lastly, the 3D printer utilizes

additive manufacturing technology where the plastic model is constructed by depositing material

layer on top of layer according to the 3D build file.

The technology is highly multidisciplinary as digital design, engineering, and science, are an

integral component of producing a 3D plastic object. As such, the 3D printing studio at UA

Libraries has advanced the outreach, curriculum and research programs across multiple

departments. For example, a 3D user from the Art & Art History department designed and created

an art sculpture plastic model for a design class, while 3D users from the Electrical Engineering

Department designed and created robot parts for a senior design research project. Introduction of

the 3D printing studio has allowed UA Libraries to create new and exciting collaborations between

librarians, faculty, and students.

The University of Alabama Libraries Mission Statement

As The University of Alabama's principal locus of information services, University Libraries strives for excellence in advancing the University's teaching, research, and outreach programs by anticipating information needs, providing access to resources, and promoting effective use of information by students, faculty, and staff.

History of Developing the 3D Printing Studio

The UA Libraries 3D printing studio began as a proposal for the 2010 IMLS Sparks Ignition grant.

We proposed in 2010 that 3D printing would be an innovative technology and would have broad

implications throughout libraries. Our goal was to obtain sufficient external grant funding that

would allow UA Libraries to support a large 3D design and print laboratory complete with support

staff, multiple 3D printers and 3D digital scanners. The proposal was well received, but

unfortunately our proposal was ultimately not awarded funding. Without grant funding, UA

Libraries had to postpone any 3D printing initiatives until other opportunities arose. Fortunately in


2012 our administration graciously provided funds to support the 3D Printing Studio project. The

available funding was more limited than the original grant funds requested, but it was still more

than sufficient to revive the 3D Studio proposal. In fact, we believe our abridged version of the 3D

Printing Studio is a more suitable and more sustainable model for libraries worldwide. In the fall of

2012, UA Libraries purchased a 3D printer and was able to pilot the 3D Printing Studio. The

overwhelming response has validated the presence and need for 3D printing in UA Libraries.

Implementation of 3D Printing Studio

There were three main components necessary for the implementation of the 3D printing studio: 1)

3D printer, materials, accessories, and support facilities; 2) computer workstations with software

necessary for digital modeling and file conversion; 3) policies, training materials and instruction.

The 3D printer was setup in a highly visible area within the UA Rodgers Library for Science and

Engineering as a means to advertise and promote the accessibility. Adjacent to the printer is an

instruction room with approximately 15 workstations. Software for 3D design and 3D printing

(AutoCAD, SolidWorks, Google Sketchup and Axon 2) was installed on all of the workstations.

Training workshops are offered for new users, the workshops provide detailed instruction

pertaining to policies, procedures, and safety within the 3D Printing Studio. The 3D training is

highly interactive; students work together with the instructor and peers to prepare a model for

printing and start a print job on the 3D printer. Trained users collaborate closely with the

Science/Engineering Librarian and support staff when printing independent projects.

Intended Audience and Early Assessment (Fall 2012 Semester)

The 3D Printing Studio is available to all students, faculty, and staff associated with UA. After just

one semester, we have trained 53 users over a series of six workshops, and have five workshops

scheduled for late January 2013, adding an additional 50 new 3D printing studio users. We collect

some basic feedback from our users after the training workshop, which has been overwhelmingly

positive and constructive thus far. However, our ultimate measure of assessment has been the

accomplishments of our 3D studio users in support of instruction and research. For example, the

Rodgers Library 3D Printing Studio services have been integrated into five 3D Design classes in the

Art & Art History Department, which has greatly advanced UA’s instruction. In addition, numerous

3D studio users (~ 10) have designed and created 3D objects for senior design projects and other


independent research. The 3D printing studio has opened new opportunities for research at UA.

We also assess our users dynamically during instruction and consultations. Do our users

understand the basics of the technology? Do they understand how and when to change printing

parameters? In summary, our measures of assessment are methods which show us directly how the

3D studio has advanced our users’ knowledge, instruction, and research.

Principal Players

Vincent F. Scalfani – Science and Engineering Librarian, UA Libraries. Dr. Scalfani is the principal

user and manager of 3D printing operations. His responsibilities include 3D printer training,

organization of support staff, and procurement of consumable materials.

Josh Sahib – Research and Instruction Services Librarian. Mr. Sahib has served as the lead person

with acquiring and adopting 3D printing technology in UA Libraries. He serves as a project advisor

and consultant to the 3D Printing Studio.

John H. Sandy – Head, Rodgers Library for Science and Engineering. Mr. Sandy provides assistance

with project implementation and administration.

Tom Wilson – Associate Dean for Branch Libraries and Digital Student Services. Mr. Wilson

provides administrative and technology support for the 3D Printing Studio.

Materials and Methods: Specifications and Requirements

Few components are required for other libraries seeking to adopt 3D printing technology. The

specifications for the 3D printing studio in UA’s Rodgers Library for Science and Engineering are

listed below. Importantly, there are other suitable printers and software available.

1) Space for 3D printer and workstations. Our setup utilizes an instruction room for the computer

workstations (15), and two work benches for the printer area located in a common lobby area.

2) Bits from Bytes 3D Touch Double Head Printer.

3) Software for 3D modeling – AutoCAD, SolidWorks, Google Sketchup (free) and Axon 2 (free).

4) Consumable plastic material and toolkit for 3D printer maintenance.


3D Printing Media

Photo shows 3D printer and user consultation/sample preparation worktable in Rodgers Library for

Science and Engineering. 3D design workstation computers are located within adjacent Scholars’

Station instruction room (entrance partially shown on left side).

Student designed CAD model of a robot axle wheel mount (left). Printed and mounted ABS plastic

wheel mount (right). The part was designed and printed for an engineering senior design project.


User Documentation

The Rodgers Library for Science and Engineering’s 3D printing standard operating procedures

manual can be found in the supplemental material.

Nominators’ Support Statement

These authors are nominating UA’s Rodgers Library for Science and Engineering for its impact and

contributions made to the library and campus community as a result of supporting a 3D printing

studio, including:

The 3D printing studio was the first open 3D printing service on the University of

Alabama’s campus. The studio was opened for the fall 2012 semester and made freely

available to all UA students, faculty, and staff. Offering 3D printing services has allowed

Rodgers Library for Science and Engineering to provide access to new resources, a critical

component and goal for libraries worldwide.

The 3D printing studio has advanced the University Libraries’ and the University of

Alabama’s teaching and research programs. Users have built models for class projects and

research programs. The 3D printing studio has promoted and sparked independent research,

experimentation and learning throughout the University, all common goals shared between

Universities.

The 3D printing studio has expanded the outreach and collaboration across

departments. Users across numerous departments and of different backgrounds have used

the 3D printing studio. Students, faculty, and staff have collaborated and partnered with

librarians and staff at Rodgers Library for Science and Engineering. Collaboration across

departments is a crucial component to a Universities’ success.

The 3D printing studio is sustainable and adaptable for other libraries. With a limited

budget, Rodgers Library for Science and Engineering has been able to adapt, manage and

operate the 3D studio without the necessity for external grant funding or hiring of new talent.

While external funding can add tremendous value to the initiative, commitment and support

internally are a requirement for the long term sustainability of the service. The 3D Printing


Studio at Rodgers Library for Science and Engineering can serve as a model for other libraries

seeking to adopt new technologies and add value to their University.

Scholarly Work Associated With Innovation

1. Scalfani, V. F. and Sahib, J. Management of 3D Printing in University Research Libraries. 2013, in preparation.

2. Scalfani, V. F. Best Practices for Managing 3D Printing Services in Libraries, Alabama Library Association, Montgomery, AL, April 2013.

Letters of Support and Testimonials

Two letters of support from Andrew Graettinger (UA Civil, Construction and Environmental

Engineering Professor) and Jamey Grimes (UA Art & Art history Professor) have been included in

the supplemental material. Additionally, two student user testimonials have also been included.


Supplemental Material

RodgersLibrary3dPrinting KellenSchroeter

I’maMakemagazinefanatic.Iloveseeingalltheneatthingsthatpeopleare

creatingandusingtheideastocreatemyownstuff.Lastyear3dprintersbecamealltherageamongtheMakecommunity.Naturally,ItriedtolearnasmuchaboutthemasIcould.Theprospectofbeingabletocreateatangibleobjectfromyourmind’screationsiscaptivatingtoanyMaker.WhenIfirstsawtheprinteratRodgersIwassoexcitedtogetmyhandsonit!Atfirstithada“ComingSoon”signattachedtoitandtobehonestIneverreallythoughtitwasgoingtobeopenforgeneraluse.HoweveraroundThanksgiving(muchsoonerthanIhadanticipated!),asignupsheettogetinvolvedwithprintingwasatthecirculationdeskandIjumpedrighton.Thefirstclasswassogreat;itwasawesometohaveahandsonexperiencewithsuchacoolpieceoftechnologyrightoffthebat.

Theprinterhasbeenagreatacademicresourceforme.I’manewmemberofAlabama’sLunaboticsTeamandIinitiallystruggledtofeelusefulamongaverytalentedgroupofmostlygraduatestudentsandupperclassmen.Butthe3dprinterhelpedmetofindaniche.Abigfocusofthecompetitionthisyearison3dprintingandcurrentlyI’mtheonlymemberwiththeabilitytoprintfortheteam.ThankstothissituationIhavebeenabletocompletesomeimportanttasksandhelpcontributetothesuccessoftheteam.FortheLunaboticsteamIhavedesignedandprintedaspurgeartorotateapotentiometerandalsoprintsomekeywheelcomponentsforthegroup’snewdesign.OnapersonallevelIhavedesignedandprintedChristmaspresentsforfamilyandfriends.Ihavealsodesignedandprintedarockclimbinghandholdformypersonalboulderingwallanddesignedandprintedarocketenginehousingthatwillbeusedinanefforttoapplyforsomeprestigiousinternshipsthisupcomingsummer.

I’mverythankfulthatmyschoolhastakentheinitiativetogetontheforefrontof3dprinting.Itwillcertainlybeagreatassetinmyeducationandcareerandisjustatonoffunformypersonaluse.ThestaffatRodgersLibraryhasbeenveryhelpfulandactiveineveryaspectofthe3dprinter.IhavelearnedsomuchfromthemthispastsemesterandIcannotthankthemenoughforallthehelp.

Alex Bradshaw

My interest in the 3D printing came from the need to design and create parts for a robot my

group is making for our senior design project. The robot is a four wheeled platform that must pick up

and deliver multiple blocks to the correct locations based off their size and color. This custom designed

robot needs many parts that are not commercially available. These parts are mainly mounts or adapters

to integrate the many sensors and parts into the actual chassis of the robot. The 3D printer in Rodgers

Library has allowed me to print exactly what I need for the robot. I am able to design parts to our exact

specifications using 3D modeling software and then bring the 3D model to life using the printer. It has

made the design and implementation of the robot much quicker and cheaper. We no longer have to

wait to get custom parts machined, or have to pay to buy parts that are not so readily available.

So far, the use of the 3D printer has given my group and me the best possible chance to

complete our project on time. After taking a one hour class on how to use the 3D printer properly, I was

able to do almost everything I needed using the 3D printer. From start to finish, the design and creation

of the parts we need can take less than a day. This would impossible if the 3D printer were not

available. The scheduling system for the printer gives us an easy way to reserve time to make any parts

we need, however intricate they may be.

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v1.1 V. F. Scalfani 1/2013

Before operating the BFB 3D printer, you must complete a safety training and 3D printing standard operating procedures training course administrated by Rodgers Library.

Contact Vincent F. Scalfani ([email protected]) to sign up for training.

1 STA N DA R D OP E R AT I NG P RO C E DU R E S F OR 3 D P R I N T I NG I N ROD G E R S L I B R A RY

1.1 introduction

The University of Alabama Libraries maintains a Bits from Bytes (BFB) 3D Touch™ Printer (double head) housed in the Rodgers Library for Science and Engineering (located on 1st floor outside of Scholar’s Station). The 3D Touch™ printer is capable of precisely extruding plastic layer on top of layer into a multitude of 3D objects. Briefly, the instrument melt-processes plastic into fine thread and deposits this thread in the melt phase according to a pre-pro-grammed computer-aided design (CAD) drawing.

1.2 policies

1.2.1 Users

The BFB 3D Touch™ Printer is available for use by all current University of Alabama students, faculty and staff.

1.2.2 Operation and Safety Training

A standard operating procedures and safety training course will be required before using the 3D printer. Training will be offered as needed and promptly scheduled for future users. The safety instructions on page two will need to be completed before using the 3D printer.

Figure 1–1. Photo of BFB 3D Touch™ Printer in Rodgers Library.

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The University of Alabama Rodgers Library 3D Safety Training Instructions

After you have read the following safety warnings, please sign and date this form to confirm you understand the 3D printing hazards.

☐ I understand the extrusion nozzles can be very hot (>250 °C, N.B. water boils at 100 °C) during operation and while cooling down after operation. Do not touch the extruders and always assume the extrusion tips are hot.

☐ I understand there are multiple moving parts (XYZ movements of extru-sions nozzles, Z movement of printing stage). Always assume the instru-ment is under operation before attempting to install or remove any printer components or 3D printed objects. Therefore, do not attempt to install or remove anything from the instrument until you have ensured it is not in use (verify by checking status of electronic lcd screen). Be sure to also tie back any long hair or baggy clothing. Do not attempt to make any mechani-cal adjustments to the instrument unless it is off and unplugged from the electrical outlet. Lastly, if the instrument locks up or gets “jammed” during operation, do not attempt to manually move any parts of the instrument. Instead, use the automated controls on the electronic panel to cancel the print job and move the z stage/print heads clear of the obstruction. As a last resort, you may also perform an emergency system shutoff by unplugging the power to the instrument.

☐ I will post a notice on the instrument when it is in use for the safety of others and maintain accurate logs of print jobs in the Rodgers 3D printing logbook.

I, ___________________________, understand and agree to abide by the safety regulations set forth above and any further instructions received from Rodgers Library personnel.

Signature:

Date:

Complete this form after attending the 3D printer

safety training and standard operating procedures course

in Rodgers Library.

Return form to Vincent F. Scalfani

109 Rodgers Library

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1.2.3 Availability And Scheduling Print Jobs

At present, 3D print jobs can be started from 9–6 pm M–F. If demand is high at any given time, original research projects (i.e. you designed the 3D model) will be given first priority for print jobs, while hobbyist print jobs will be second (i.e. printing of stock repository objects).

All are welcome and encouraged to use our 3D printing services. You may schedule print jobs online after you have been trained at https://www.lib.ua.edu/content/selmrbs/. We have 3 hour time slots available at present. Users may book multiple time slots if longer print jobs are necessary. 3D print jobs requiring more than two time slots (>6 hours) can be run overnight and must be scheduled to be started between 3–6 pm M–F. The reasoning is twofold: 1) this will allow other “walkup” users with shorter print jobs to use the instrument for the majority of the day and 2) trained staff will be available for starting your 3D print job.

1.2.4 Cost

3D printing is completely free, enjoy!

1.2.5 Assistance with Print Jobs

After completing the safety and standard operating procedures training course, assistance with starting a print job will be provided by the principal user (Vincent F. Scalfani) or a trained staff member within Rodgers Library. Training materials will be continually updated for your reference. It is fully expected that after a user has successfully used the 3D printing instrument several times and feels comfortable doing so, he or she can then utilize the 3D printer operations independently.

1.2.6 Responsibilities of Users

Users are to follow all operating and safety training administered. It is expected that users will be considerate of others and maintain a clean and safe working environment around the 3D printing operations. Accurate note taking of print jobs should be recorded in the Rodgers 3D printing log book.

See log book form (page 8) for required data logging. The data fields such as material mass an estimated print time are available within the Axon build file report.

The Axon 3D printing conversion software will give you an approximate print job completion time, which will help you schedule the time you need for 3D printing.

You must receive permission by the principal user (Vincent F. Scalfani) or a Rodgers Library staff member to use the 3D printing service independently.

Consider also logging any tips/tricks you have acquired through experience so other 3D print users can benefit from shared knowledge.

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1.3 3D design files and conversion for printing

Our Bits from Bytes (BFB) 3D Touch™ Printer can print 3D models from any CAD software program that is capable of exporting the file as a .stl. The .stl file, however, must be converted to a .bfb build file before printing using the manu-facturers’ Axon 2.1 software.

Rodgers Library PC computers have the Axon 2.1 conversion program and various 3D modeling software installed, including: AutoCAD, SolidWorks, and Google Sketchup.

Whether you choose to design your own 3D model or use one from a 3D repository, you will need to save the model as a .stl file. Once you have a saved .stl file, open the file in the BFB Axon 2.1 software (Figure 1–2). If a red box appears your model is too large and can be scaled down within Axon 2.1 software with the scale function located on the main tool bar. Ensure the printer configura-

You can download stock 3D models

from online repositories such

as Trimble 3D Warehouse or

Thingiverse.

For 3D modeling beginners, we

recommend starting with Google

Sketchup.

Figure 1–2. 3D model (.stl file) opened in Axon 2.1 software

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tion settings are correct by navigating to Settings > Printer Configuration. The printer type is 3D Touch/BFB-3000 bed v2 black and the number of extruders is two. Set the plastic type and color for extruder 1 (left extruder when looking at front of printer) and extruder 2.

Next, start the conversion process by navigating to the build tool path on the main tool bar. Select your layer thickness (0.25 is default recommended), raft material, support material (if needed), and part material. You may also choose to adjust the fill density and fill pattern. The fill density and fill patterns will affect the finished look and mechanical integrity of the object. A 20% fill and random line fill pattern is recommended as a starting point for the first print (Figure 1–3). After you have entered your adjustments, click on build file. Once the process is complete, the software will report build statistics such as the approximate mass of the 3D printed object and the required print time.

Before clicking OK within the build progress window, write down all of the build file statistics so you can record them in the 3D printing logbook. If you forget to record these values, they are also reported on the left hand side of the Axon 2.1 menu under the sub heading “build file”.

Lastly, save your build file using the “save build file” tab. Copy this file (it will now be a .bfb file) to a flash drive under the main directory (i.e. do not put the file in a folder).

Figure 1–3. Build settings in Axon 2.1 (left). Build progress window in Axon 2.1 (right).

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1.4 printing an object

Before printing an object, the 3D printer must be calibrated such that the print extrusion heads are at an ideal distance from a level print bed. The calibration ensures you will not damage the print extrusion head and/or the print board. In addition, proper calibration is required for best results when printing. The calibration file is located on the supplied BFB flash drive. There is one file for checking ABS printing (RaftABS_checkfile) and one for checking PLA printing (RaftPLA_checkfile). The principal user (Vincent F. Scalfani) or a trained Rodgers Library staff member will assist you with calibrating the instrument. Authorized users that have been approved to use the printing services independently may check out the toolkit and logbook from the circulation/reserve desk.

After proper calibration, insert your flash drive into the left USB port located towards the bottom of the instrument front panel. On the touch screen display, press the home button to bring the print heads and print board to the zero (home) position. Next, tap the print button, and select your file to print by double clicking on the file name. The 3D printer will now start heating the extrusion head (only one is heated at a time), and then start printing. Before walking away, watch the print job for ~10–20 minutes to ensure the RAFT print was successful (clean separated print lines) and there are no early errors or problems with the printing. If the RAFT was successful, you can safely leave the print job to complete automatically. If the RAFT print was not successful, cancel the print job immediately and re-calibrate the instrument. The principal user (Vincent F. Scalfani) or a trained Rodgers Library staff member can assist you with the calibration.

When leaving the print job to complete

automatically, place a note on the printer

to let others know the instrument is

in use.

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1.5 maintenance log

10/25 ordered new composite print board.

1.6 Notes

11/20/2012 VFS- polylactide (PLA) material does not like to sit in guide tube for more than a day. If the printer has not been used for more than 24 hours, check for cracks in plastic. If a crack is located, reload PLA feed material.

12/1/2012 VFS- Between commands on touch screen, home the extruder heads. We have noticed the printer may lose it’s position between commands. Sending the extrusion heads to the home position before executing a command solves this firmware bug.

Date

Name/e-mail

Department/UA Status

Advisor (if applicable)

Description of Print Job

Estimated Print Job time

Dimensions

Print material

Estimated Mass (g)

Calibration

Adjustments to Instrument

Outcome/Observations of Printed Object

Errors/Notes

The University of Alabama Rodgers Library 3D Printing Log Book Form

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