P10551 - Nano-ink Deposition SystemSystem Level Design Review

Eric Hettler - MEWilliam Gallagher - ISE

Christopher Mieney - MEGregory Ryan - ME

Joseph Cole - EE

FAB AMERICA

Design Review AgendaProject DescriptionSystem ArchitectureFinal Design SpecificationsProject StatusSummary of Test ResultsGoing ForwardQuestions

Project Overview Fab@Home open-source

architecture Modify an existing Fab@Home

deposition system to mix materials and deposit layer by layer on print surface.

A UV curable resin will be dyed to serve as a medium to demonstrate the printing of multiple materials.

Interface with software

http://fabathome.org

Key Engineering SpecificationsSpecification Description of Metric Unit of Measure Acceptable Value Desired Value

Can Print Multicolor Number of Base Colors # 3 3

Can Print Viscous Material Viscosity of resin cP > 165 > 300

XY Repeatability Mean/standard deviation of XY locations of deposited materials mm TBD TBD

Z Repeatability Mean/standard deviation of layer thicknesses mm TBD TBD

Part Size (XYZ) Mean/standard deviation of Error length/length of desired part mm/mm TBD TBD

Printable area Maximum printable area mm x mm > 50 x 50 > 100 x 100

Minimum Feature Size Resolution in XY plane mm < 0.1 0.0158

Minimum Feature Size Combined Cured Droplet Diameter mm < 0.5 < 0.1

Color Variability Uncombined Uncured Droplet Volume nL < 25 < 10

Color Variability Uncombined Uncured Droplet Volume Precision nL TBD TBD

Low Cost Total Budget $ < 3,000 - Parts < 3,000 - Parts

Curing Time Time to cure a layer of epoxy sec < 180 < 60

Project Development

MSD IIMSD I

1 2 3 4 5

Phase 1: Development• Engineering

Specifications• Concept Development

Phase 2: Design• Systems Level• Detailed Design

Phase 3: Design Confirmation• Design Analysis• Formulate BOM

Phase 4: Fabrication• Order Parts• Fabricate Parts

Phase 5: Testing• Characterize• Capabilities

Systems Overview3D Printer

Software Commands

Uncured Part

Curing

Motion Control

Controller

Controller

Material Delivery Carriage

Z Motor Lead Screw

XY Motors Lead Screws

Light Source

Micro ValvesMaterial

Deposition

Platform Cured Part

Computer

Final Design Concept

BudgetTotal cost must be below $3000 dollars.Preferred cost is below $1000 dollars to

better align with the Fab@Home mindsetOutcome:

Category CostMaterial and Color Delivery $638.19

Curing $55.68

Electronics $13.71

Total $707.58

System Testing ResultsDeposition similar to fountain pen.When multiple colors are printed in same

layer, toothpaste like effect.Edges tend to run over.Thickness is relatively repeatable.

Project Status (Specs Met)Specification Description of Metric Result Acceptable Value Desired Value Spec Met?

Can Print Multicolor Number of Base Colors 3 3 3 Yes

Can Print Viscous Material Viscosity of resin 260cP > 165 > 300 Yes

Z Repeatability Mean of layer thicknesses .24mm TBD TBD -

Printable area Maximum printable area 230mmx150mm > 50 x 50 > 100 x 100 Yes

Minimum Feature Size Resolution in XY plane Tip Dependent < 0.1 0.0158 -

Minimum Feature Size Stream Width Tip Dependent - - -

Minimum Feature Size Combined Cured Droplet Diameter N/A < 0.5 < 0.1 N/A

Color Variability Uncombined Uncured Droplet Volume N/A < 25 < 10 N/A

Color Variability Uncombined Uncured Droplet Volume Precision N/A TBD TBD N/A

Low Cost Total Budget $707.58 < 3,000 - Parts < 3,000 - Parts Yes

Curing Time Time to cure a layer of colored epoxy 240 seconds < 180 < 60 No

Going ForwardFurther design on mixer/manifoldModification of Fab@Home Software

More modular setupModify paths

More Robust ElectronicsLimit switches, wiring panels, motors,

interfaces, etc.Closed Loop

Z –axis positioning

Questions?