P17551: Sandia Instrumented 3D Printer
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Detailed Design

Table of Contents

Team Vision for Detailed Design Phase

Progress Report

Per the plan discussed in the Preliminary Detailed Design, 10 3D Benchy and 10 tensile specimen are currently being printed and analyzed. The following images depict the 10 completed 3D Benchy prints and 5 green tensile specimen.
Ten 3D Benchy test prints front view - five green, five pink. Print number labeled on image.

Ten 3D Benchy test prints front view - five green, five pink. Print number labeled on image.

Ten 3D Benchy test prints top view - five green, five pink. Print number labeled on image.

Ten 3D Benchy test prints top view - five green, five pink. Print number labeled on image.

Four green tensile specimen.

Four green tensile specimen.

Warping observed on tensile specimen 2. Cause determined to be uneven heating on print bed.

Warping observed on tensile specimen 2. Cause determined to be uneven heating on print bed.

Logbook Rating Standards for Bed Adhesion

Logbook Rating Standards for Bed Adhesion

Logbook Rating Standards for Layer Adhesion

Logbook Rating Standards for Layer Adhesion

Logbook Rating Standards for Stringing

Logbook Rating Standards for Stringing

Logbook Rating Standards for Warping

Logbook Rating Standards for Warping

The logbook can be found here

Moving forward, the team plans to evaluate the effects of various print parameters using a DOE process. The effects determined through DOE will be compared to the benchmarked default print quality and inherent variation. Before the team's design will be implemented with the printer, a prototype will be created using the purchased controller, so as to test the design without damaging the printer. Additional tasks to be completed include:

Prototyping, Engineering Analysis, Simulation

Preliminary design for the selected sensors to be mounted in the printer.

Preliminary design for the selected sensors to be mounted in the printer.

Bracket with mounting array to allow for various sensor locations.

Bracket with mounting array to allow for various sensor locations.

Sensor Mounting

Sensor Network

Of the 14 sensors initially purchased, 9 of them are operational and communication with one another on a breadboard circuit.

There have been some issues with the array sensors as they are difficult to connect to one another on a serial connection. This is being remedied by contacting the manufacturer and talking to their engineering department.

Preliminary Sensor Network.

Preliminary Sensor Network.

Future plans and revisions for the sensor network are as follows and will be done during intersession as well as the first few weeks of MSD 2:

Design of Experiments/Test Plans

In order to set target parameters for the controlled printer, optimized print parameters need to be determined through a designed experiment. A number of factors will be evaluated to find the ideal range in which to print, so that the installed sensors and control system will be able to adjust printing to stay within specifications.

Layout of a two-factor, three-level experiment.

Layout of a two-factor, three-level experiment.

Example data set.

Example data set.

Example data set.

Example data set.

Enclosure Drawings, Schematics

Enclosure on Printer

Enclosure on Printer

Enclosure Front Panels

Enclosure Front Panels

Enclosure Back Panel

Enclosure Back Panel

Enclosure Side Panels

Enclosure Side Panels

Enclosure Top Panel

Enclosure Top Panel

Enclosure Motivation and Description

  1. The room we print is very drafty which could be causing bed adhesion problems
  2. Heating ducts were closed for printing one of the tensile specimens and there were no bed adhesion problems or warping while the other seven prints had these issues.
  3. The printer should hopefully mitigate the majority of warping on the bottom of future prints.
  4. The printer will be easily removable and the two front panels will be on hinges so they can be folded up to easily access inside the printer between prints.
  5. The enclosure materials were ordered and the enclosure will be built over the intersession.

Bill of Material (BOM) and Budget

Budget and Spending as of 12/6/2016

Budget and Spending as of 12/6/2016

Risk Assessment

Updated Risk Assessment document for DDR.

Updated Risk Assessment document for DDR.

Plans for next phase

Gantt Chart

public/Detailed Design Documents/Pictures/Gantt.png

Action Items


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