Team Vision for Detailed Design Phase
- Team tested the BCN3D Sigma printer, became familiar with its hardware and software, and finalized the preliminary plan for the sensor layout. Materials were purchased in-order to test the initial sensor design, and a prototype was constructed.
- Several printer tests were run with the exact same parameters in order to understand variance within each print and the common issues associated with printing.
- Additional testing criteria was identified and different 3D printing parameters of interest were identified. These criteria were used to design and experiment to determine optimal settings. Documentation standards for the team's 3D printing jobs was also decided.
Progress ReportPer 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.
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:
- Sensor Installation and Integration: EE Team
- Programming and Testing: Jacob
- Mounting Plans and Part Fabrication: Mike
- DOE Planning and Execution: Justin
Prototyping, Engineering Analysis, Simulation
- The sensors are currently ordered but will not be received till after thanksgiving break.
- The mounting plate with the array will allow to mount the sensors in a variety of different locations knowing there precise location.
- The sensor pins will be used to located the sensor in the mounting plate however tape and/or hot glue will be used to temporarily hold it in place.
- The array sensors have a 60 by 16 degree field of view. The mounting shown in the printer will sufficiently measure the entire print bed.
Sensor NetworkOf 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.
- Transferring sensors to a protoboard; this will make testing easier as the sensors will have more reliable connections. This will also include finding the best way to strain relieve connections from the sensors to the microcontroller, general clean-up of circuit, and research into other common practices for protoboarding.
- Resolving the issues with the array sensors and adding them to the sensor network.
- Reorganization and documentation of code; Code needs to be reorganized and cleaned-up to run more efficiently and lower the probability of error in future alterations and additions. Well written documentation is also needed so that anyone can step through the code and understand what it is doing.
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.
- The team's first goal will be to determine which factors have a statistically significant impact on print quality. An initial two-factor test will be run to evaluate the effect of extruder temperature and bed temperature, as well as any interaction between the two.
- With the installation of additional sensors, an expanded test will be run to evaluate the effects of additional parameters.
Enclosure Drawings, Schematics
Enclosure Motivation and Description
- The room we print is very drafty which could be causing bed adhesion problems
- 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.
- The printer should hopefully mitigate the majority of warping on the bottom of future prints.
- 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.
- The enclosure materials were ordered and the enclosure will be built over the intersession.
Bill of Material (BOM) and Budget
- Updated Risk Assessment with new risks and solutions. Various risks have also been decreased in likelihood and severity as design and progressed.
- Here is the link to the live document.
Plans for next phase
- Before the end of the semester the team will be working on getting the material for our gate review done, this includes our team vision for Imagine RIT in May. We will also continue printing for the DOE which includes printing at +/- 10 degrees C; for both the extruder and the bed temperatures.
- To prepare for MSD II the team will do things over break to make sure we are ready to add them. What each member will be accomplishing will be included in our individual 3-week plans. We will keep communication up through our Slack messaging board.
- Imagine RIT Vision
- Our team vision for Imagine in May is to have the printer displayed in such a way that we can show real time information of the current print. We want to display the bed temperature using a RGB LED array and a display of the other information collected on the sensors including the thermal display from the raspberry Pi. We will show our discovered knowledge on the print and what causes it to fail in our poster as well as talk about our findings and the printing process. We will have the printer and enclosure set up so we can easily print for the crowds of spectators.
- Ryan's Three-Week Plan is here.
- Mike's Three-Week Plan is here.
- Jacob's Three-Week Plan is here.
- Maseo's Three-Week Plan is here.
- Jon's three-week plan is here.
- Justin's three-week plan is here.
- Per the final Design Review, our action items for
Intersession/MSDII include -
- Printing the rest of the Benchy parts for the DOE test.
- Conducting the DOE test and having the results by 2/2/17.
- Continuing development of thermal sensor network.
- Manufacturing the enclosure for the printer.
- Set up camera and thermal camera with Raspberry Pi.