P17512: Xerox 3D Print Head
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Preliminary Detailed Design

Table of Contents

Team Vision for Preliminary Detailed Design Phase

The team worked to create and finalize early mock-up designs for the various subsystems and began to decide on design strategies going forward. All the documents related to this phase can be found here: Detailed Design Documents

Prototyping, Engineering Analysis, Simulation

The team ran a few tests to verify the feasibility of the X-Axis drive system, and checked the functionality of the other subsystems left by last year's team.
Lead Screw Frame-By-Frame Analysis

Lead Screw Frame-By-Frame Analysis

A preliminary test was run with the lead screw drive subsystem, it was shown to be too slow due to the inertia and friction inherent in this system, hitting a top speed of only .475 meters per second. This figure came from a quick encoder test, and verifies the speed seen in the frame by frame video analysis.
Belt Encoder Test Setup

Belt Encoder Test Setup

Data From Linear Belt Drive

Data From Linear Belt Drive

Linear Belt Drive Top Speed Test

Linear Belt Drive Top Speed Test

The 2 motor tests shown above demonstrate the capabilities of the x axis drive motor with the belt system, and prove that it is fast enough to meet and exceed the engineering requirement for speed

Preliminary design summary

Preliminary designs developed during this phase and presented at the pertinent design review follow.

X-Axis Drive Subsystem

The motor driving the x axis was upgraded, and the subsystem redesigned to accommodate it.
Mounting Plate for New Motor

Mounting Plate for New Motor

Driver for New Motor

Driver for New Motor

Serial Interface for New Motor

Serial Interface for New Motor

Printing Subsystem

Progress was made on redesigning the mounts and parts for the image loader board and associated support circuitry
Image Loader Board Mounting Location

Image Loader Board Mounting Location

Modification to Existing Hardware to Accommodate New Mounting Scheme

Modification to Existing Hardware to Accommodate New Mounting Scheme

Enclosure/Containment Subsystem

The redesign for the enclosure components was modeled, see model below:
Redesigned Enclosure

Redesigned Enclosure

Emergency Stop Safety System

It was decided that the emergency stop subsystem could consist of only a circuit breaker for simplicity, see below:
E-Stop System

E-Stop System

UV Ink Fume Evacuation Subsystem

All parts for the UV subsystem are on hand and easily integrated into the system overall, see pictures of the fume extractor and vent adapter below:
Fume Extractor and Related Equipment

Fume Extractor and Related Equipment

A couple of alternative schemes for securing the print surface were designed in this phase, for later fabrication:
Side Plates for New Mounting Scheme

Side Plates for New Mounting Scheme

Final Assembly of New Mount

Final Assembly of New Mount

Simple Fallback

Simple Fallback

Bill of Material (BOM)

A live document containing the BOM can be found here

Test Plans

Risk Assessment

Our risk assessment has not changed throughout this phase here.

Design Review Materials

A link to the powerpoint presented at the relevant design review can be found here

Plans for next phase

For the next review, the team anticipates having designs complete enough to start work on executing those designs starting after the break for MSD II

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