Embedded Files
Fiber-Reinforced 3D Printer using a KUKA 6+1 axis robotic arm
Fiber-Reinforced 3D Printer using a KUKA 6+1 axis robotic arm
Background
3D printing, also known as additive manufacturing (AM), refers to processes that construct three-dimensional objects by depositing or joining material from digital 3D design data. In 3D printing, successive layers of material are formed under computer control to create an object. The object can be almost any shape or geometry, thus making 3D printing an effective method of rapid prototyping. However, the low material strength of common 3D printing thermoplastic prevents it from being applied to most industrial project uses. This project aims to design a mechanism to combine continuous filament with additive manufacturing methods to improve the strength of 3D printed objects.
Objective
The goal of this project is to design, build, and document a 3D printing mechanism that adop
ts the basic concept of 3D printing and uses continuous fibers to strengthen the material properties of printed objects. This prototype should be designed to attach to the end of a Kuka KR 30 High Accuracy 6-axis industrial robot arm and capable of dispensing continuous filament and fiber in multiple orientations.
Final Design
The final design consists of three major components. The first is the spool/component mount, which holds the spools of carbon fiber and plastic filament, a 12V power supply, a stepper motor, and an Arduino UNO microcontroller. The second component is the extruder, which consists of a standard J-head Bowden extruder, an extruder adapter to connect to the milling head’s ER-40 collet, and a custom made extruder tip with a hole on the side for carbon fiber entry.The last component is the electronic components. An Arduino UNO controls multiple components including a stepper motor driver, MOSFET for the heating element, as well as reading data from the thermistor. The linear circuit component distributes the 12V power supply to the cooling fan, located on the J-head Bowden extruder, as well as sending power to the Arduino UNO through a 5V voltage regulator.
The spool/component mount fits well on the head of the KUKA. With a slight inward bend, it allows the mount box to be held with friction. Additional M8 machine screws secure the mount box from the top, attaching directly to mounting threads located on the milling head. The spool/component mount can withstand the full motion and speed of the KUKA robot arm during fast travel. The electronics, including the heating element and stepper motor, all work well in conjunction and are able to extrude the PLA filament at appropriate speeds. The extruder was easily integrated due to the ER40 quick change collet. The tip is concentric with the axis of the milling motor, allowing the PowerMILL path software to use the tool without needing to input exact geometry.
Page updated
Report abuse