P13552: Projected Image Prototype II


P13552 - Project Summary Project Information

The aim of this project is to continue efforts to produce a projected image 3D printer. The system will use an ordinary overhead projector to project black and white images onto a film of UV curable photopolymer in order to selectively cure/harden the polymer. Students will pick up where last year’s group left off. They will (a) design a movable platform upon which the 3D part is printed; (b) determine the best method of adjusting the image size and focus; (c) create a procedure for generating the sequence of black and white images; (d) research different photopolymers that are available; and (e) design and construct an optics system capable of transmitting light that will cure the selected photopolymer.

For additional project details, please click on the following link for the Project Readiness Package.

Primary Objective

Produce a projected light photopolymer curing system that successfully prints high resolution 3D parts.

Secondary Objective

To produce a system that allows process research and development involving (for example) different light sources, different optics, different photopolymers, etc.

Build in Progress.

Build in Progress.

Project Name
Projected Image Prototyping System
Project Number
Project Family
Printing & Imaging Systems
Start Term
End Term
Faculty Guide
John Kaemmerlen
Primary Customer
Denis Cormier
Printed Parts.

Printed Parts.

Team Members

Name Role Email
Michael DiRoma Industrial Engineer mad6149@rit.edu
Rachel Levine Mechanical Engineer rwl1585@rit.edu
Kwadwo Opong Mensah Electrical Engineer kxo7118@rit.edu
Amy Ryan Industrial Engineer alr4307@rit.edu
Samuel Perry Mechanical Engineer sdp8483@rit.edu

Current Project Summary

One of the goals this team had upon starting this project was to not restrict themselves based on what the previous teams had done. They started by exploring a variety of new and different ideas including a different curing set-up, a different shearing device and a different photopolymer. The biggest problem faced by last year’s team was that when the projector cures through an optical medium onto the build platform, the resin sticks to both the optical medium and the build platform. Despite the implementation of a peeling mechanism that aimed to “peel” the part from the optical medium, the cured resin continued to stick to both the build platform and the optical medium. This resulted in the motor being unable to generate enough torque to raise the build platform.

In exploring ways to overcome this main issue we began by exploring a different method of curing referred to as the top-down method. Previous groups had aimed to put the projector on the bottom and project images through an optical medium into a bath of resin (bottom-up curing). In this method the platform starts at the bottom of the bath of resin and moves up layer by layer. The top-down method, however, puts the projector above the bath of resin. In this method the platform starts at the top of the bath and moves down layer by layer. The top-down method eliminates the need for the optical medium and therefore does not require any shearing or peeling. The team explored this idea thoroughly and after a vote decided that the bottom-up method would be used in order to more closely control the accuracy of the part.

Initially the team decided that shearing laterally was the best method for removing the part from the optical medium. Testing was done to determine the force needed to sheer and after a variety of tests it was discovered that with the correct hydrophobic material covering the optical medium, such as Teflon, the force needed to separate the part from the optical medium was minimal. Therefore with the correct coating or film substrate on top of the optical medium, along with a powerful enough motor to overcome suction forces from the fluid, shearing would not be necessary. During testing a new photopolymer was explored, however, due to strong and potent fumes the team decided to use the same polymer used by previous groups.

Currently the team has completed MSD I design and planning and has ordered parts in preparation for MSD II.

Table of Contents

View images captured throughout the P13552 project in our Image Gallery or view parts that have been built with the machine in the Build Gallery.

Also, watch this video of one of our successful builds!

MSD I: Planning MSD I: Systems Level Design MSD I: Detailed Design MSD II

Project Readiness Package

Background Research

Bottom-Up or Top-Down Curing Method?

Peer Review Tool

2nd Peer Review Tool

Project Plan

Functional Decomposition

Customer Needs

Engineering Specifications

House of Quality

Morph Analysis

Concept Generation

Software Architecture

Motor Control Architecture

Risk Analysis

System Design Review Pre-Read

Projector Capability Experiment

System Overview

Graphical User Interface (GUI) Design

Shearing Test Protocol

Motor Driver & Controller

Resin Bath Design

Build Platform Assembly Design

CAD Drawings

Bill of Materials

Motor Controller Communication

New Risks

MSDII Testing Outline

Detailed Design Review Pre-Read

Detailed Design Review Post-Read

MSDII Project Plan

Integrated Bath Testing

Fully Integrated Testing

Testing Scenario Spreadsheet

Final Presentation

Technical Paper

Project Poster

User Manual

Build Gallery