Final Project Journal
Project Ideation
- Tell us about the idea of your project. Why do you care about this? What were you inspired by? Include images and videos of similar projects
The idea of my project is a "3D FAB PEN". Small handheld version of 3d printer, designed like a pen, equipped with the ability to build 3-dimensional objects.
complete video of the project.
This particular project works by extruding heated plastic that cools almost instantly into a solid, stable structure, allowing for the free-hand creation of three-dimensional objects. It utilizes plastic thread made of either acrylonitrile butadiene styrene ("ABS"), polylactic acid ("PLA"), or “FLEXY”, thermal polyurethane (“TPU”) that is melted and then cooled through a patented process while moving through the pen, which can then be used to make 3D objects by hand. This is very similar to how a hot glue gun works. The melted plastic is very soft and can be fused onto a surface or worked into any shape that you want. Once the melted plastic leaves the tip, it begins to quickly cool down. After a few seconds, the plastic hardens and holds whatever shape you have worked it into.
Due to my interest in 3D printing field, i came across this latest technology and wanted to have one(as shown in the video) .That was my inspiration in choosing this project as my "Final Project".
By building my own 3D pen, i will not only fulfill my want, but also it will surely empower me to have deep knowledge of each of its components and excel in my desired interest field.
Project Construction
2. Explain the CAD process of your project. How did you use the software to design your project? (List the softwares/tools/materials...etc that you used)
CAD process for my project is as follow:
List:
Fusion360 software.
Microsoft 3D Builder software application. (Customizing ready STL files)
Rectangle tool
Arc tool.
Fillet tool
Offset tool
Extrude tool
Components adding feature
Joining tool
Projecting tool
Extrude cut tool
Shell tool
Mirror tool
Cross section analysis tool
Copy paste tool
Moving tool
Rectangular pattern tool
Exporting as STL/DXF tool
Thees are the step by step guide of the whole process.
1- Open Fusion 360 create new project and save it with desired name.
To start with holder of the extruder kit which was 3d printed.
2- Create a new sketch on xy plane, draw a rectangle from the origin 50x75mm.
3- Draw 180 degrees center tangent arc so that the center point of the arc is placed at the center of any 75mm line(this will be the top part), and the arc will be tangent to the both side line of the rectangle to get a semi-circle shape as shown in the photo
4- By using trim tool remove the line between the arc and the rectangle so that they are merged together.
5- Adding fillet to the bottom 2 rectangle angle to smooth its grip while holding, fillet 10mm radius.
6- Create an offset of 3 mm outer side, to give the thickness for the holder.
7- Finish the sketch by clicking on finish the sketch from top right toolbar, and extruding it by using extrude tool from the toolbar top left side. Extrude it to 1 direction for 32mm (according to the fan length) and make sure to select new component instead of body. And click OK.
8- Now for the screw holes, first need to add extruder kit step file to visualize is better, click on top left menu option a slide command will appear from there click on add/upload a file choose upload from laptop drag the step file on the space where its written “drag and drop your files here” and click upload.
9- Once the upload is done close the upload window and the extruder kit will appear in the slide command, right click on it and choose insert in current project, the kit will appear on the project window, move the kit as desired by dragging the arrows of each axis. And click ok.
10-Now by using join feature by pressing on “J” from keyboard select on the center of the fan and then select on the center bottom point of the new component from the inside, once kit is joined it was moved to any of the side by 5mm so that the other side 2 push buttons has space and does not touch the hot end. At the end, click OK.
11-Hide the kit by pressing on “V” on the keyboard and create a new sketch on that joined inside bottom surface to project the holes of the fan.
12-Press “P” and hide the new component and unhide the kit, drag the mouse on the surface of fan until red line of the entire fan surface is seen right click to project it. Unhide the new component and hide the kit again to use extrude cut command tool. However, first need to click on finish sketch to use that tool.
13- After finishing the sketch click on extrude tool, choose all four holes of the screw and 1 big hole in the middle for the fan. Change the distance to -4mm which will automatically change its mode to cut and red lines will be seen. Click on OK.
14-As for the push buttons it is similar to the fan process so redo all steps from step 8. Only take in consideration that the 2 push buttons will be joined in the middle of side inside (which has more space from the kit).
15-Finishing all steps, just right click on the new component from the left side menu and choose export to STL. A dialogue option will appear click OK. Choose the destination. Give that new component a name like holder by triple clicking on it from the left side menu.
Don’t forget to save it by pressing control + “S”. And voila it’s ready.
Now for the box design (it will be laser cut as the box to be printed on 3d printer will exceed the limit, around total of 250 grams and 8 hours).
16-Create a new sketch choose XY plane, and start drawing simple rectangle from the origin which will be the base of the box 210mm x 108mm.
17- Finish the sketch and extrude it 80mm one side as new component.
18-Repeat the extrude process for the top lid of the box and changing the stings in the extrude command to start from an offset of 80mm, height of 3 mm and as a new component as well(or merge tool can be used but must be done after step 19.
19-Hide the top lid if its new components and use the shell tool thickness of 3 mm to leave the shape as hollow box.
20-Repeat the steps from 8 to 13 for all other components need for the box : power supply , Arduino uno, stepper motor driver control panel, small breadboard, stepper motor, relay module and LCD I2C. if the top lid is merged before this step then cross section analysis tool can be used to view it under the lid and join, project and extrude cut tool.
21-Arranging the components is easy first add power supply and beside it Arduino uno board, behind the Arduino board place stepper motor driver control panel, after that small bread board is placed and on top of it on the lid LCD I2C Is placed. Last but not the least, stepper motor is places behind the bread board so that all the components are parallel to the power supply. Relay module can be placed on the side of the box between Arduino board and stepper motor driver control panel.
22-Once finished create a new sketch on all 3 planes, and project the whole side of the box of that plane, as u drag the cursor on the box red lined box surface will appear right click to project. Redo for all 6 sides.
23-To ease the process of adding screws and nuts, copy all 6 side projected sketches into one sketch and move it every 2 opposite sketch parallel to each other to use mirror command. Also it will be easy to export as DXF from one sketch.
24- If starting with any 2 set front and back for example, delete any one of the border line and draw the T-slots as shown in the picture the measurements can be changed by size of the screws and nuts.
25-Create 2 vertical construction lines one should be placed at the midpoint of the deleted line, other middle of front and back surface sketch. Also add 1 horizontal line at the midpoint of the side border of the deleted line.
26-First mirror the drawn T-slot using the midpoint construction line as mirror line reference. The whole deleted border will appear completed by 2 T-slots. Now delete the bottom border and redo step by selecting all full top border of 2 T-slots and mirror it on the bottom border by using horizontal constructed line as mirror reference.
27- For mirroring it on the other back surface first delete the 2 borders lines and use mirror command on the 2nd vertical constructed line which is placed between the 2 surface sketches.
28-Repeat and redo all steps for each side of the surfaces from step 23 to 26.
29-Remember to place opposite of each T-slot screw opening hole which will be changed opposite of the T-slot line to make it fixable. Here is a small demo on how it will look after all this process and to visualize it extrude command is used and then joined command.
30-For the aesthetic purpose ventilation holes are created on the lid by creating sketch on the top surface and drawing 5mm diameter circle at bottom left end of the box, then by using rectangular pattern tool use the 2 direction Z and X quantity 20 and 17 and choose spacing of 10 mm and click OK, Delete the circles as per design or pattern. In this project its was written “3D FAB PEN” with 2 lines beneath it with the holes. After completing the pattern finish the sketch and use extrude cut tool to make that ventilation on the top lid of the box.
31-After checking all is fitting properly right click on the sketch where 6 sides are pasted and select export to DXF, choose the location and click save.
Don’t forget to save the project at every step.
32- As for the feeder path, there were many ready designs online for 3D printers, i customized one of them on 3D Builder application to suit my need, also was able to emboss writings on STL from this application, i added my project's name "3D FAB PEN" and push button function's "EXTRUDE" & "UNLOAD" on the holder.
Congratulations, designing the whole project is completed.
3. Explain the fabrication process of your project. How did you use the machine to fabricate your project? (List the softwares/tools/materials...etc that you used)
I had used 3 types of fabrication process for my project.
list:
1) For 3d printing:
Prusa i3MK2 3D printer
Cura Slicer software. (similar to Prusa Slicer)
PLA 8gms WHITE/BLUE color
ABS 33 gms WHITE color
Scraper
Pliers
2) For laser cutter CNC:
Lasercutter CNC machine
Laserworks Software.
Removing double line tool
Scan tool/ cut tool
calculation of estimated work time tool
track frame
Plywood sheet 3mm 30x50cm x2
Tape
3) Prototyping assembling:
Screws and nuts – m3 10/5/20
Drill machine
Cutter
Here is step by step guide of the whole process.
1- To start with 3d printing fabrication, open the slicer software, for this project Cura sliccer was used (prusa slicer is recomemded).
2- Import/Open the ready STL file (PEN HOLDER) which was designed on Fusion360.
3- First check the orientation that flat surface is on bed, or needs to be rotated till flat surface is on bed. It can be rotated by the 3rd tab on left hand side which has arrow of rotation. As clicked on it by mouse 3 dimension different color lines will appear around the object, click on any axis line and drag at any of its direction to rotate. For my project X axis rotation was used 180 degrees to set the flat surface at the bottom.
4- Since this design has hollow in the middle, only slight adjustment were needed to move the holder on the bed for avoiding center point(due to printer bed has issues at that particular point). Moving tool is 1st on the left hand side tab, 3 AXIS different color lines will appear, click on any axis line and drag at any of its direction to move. For my project -5 mm on Y axis was moved (just to be sure).
5- Now for the settings, as ABS material was being used to print this part these were the major changes from PLA settings: Infill: 15% , layer height 0.3mm Temperature: bed:90 degrees and hotend:274 degrees, Cooling: fan speed :10% adhesion: Brim was supposed to be used but due to it was not sticking RAFT was used for this part(this resulted in increase of time by 30 minutes). All these settings can be changed from right hand side drop down menu. (This particular setting was set to reach time limit of 1 hour 30 mins to access FAB LAB Egypt time slot)
6- After entering all required settings, Click on slice button which is situated bottom right corner so that estimate time and grams of filament will be used is shown
7- Save to file button will appear at bottom right which will save the g-code (3d printer language), click on it and save it on desktop. At printing time just need to copy that g-code on SD card of the 3d printer from desktop.
8- Upon using the 3d printer gently insert the SD card which was removed to copy g code, till on the screen is visible SD card inserted, press the knob once to see main menu and scroll down to prepare, choose pre-heat abs.( if PLA filament is still mounted first need to unload by preheating PLA and then increasing temperature to abs and load it again). When the 3d printer is heated and ready to use (oozing of filament is the indication of right temperature) press on the knob again, scroll down to reach Print from SD card and press on it, scroll until g code file if found and press again on it to print. (The printer will then check hotend and bed temperature and increase or decrease to reach required temperature, it will then home 3 Axis and start to check bed leveling, after 9 points of bed leveling are checked, it will then start to move to the required place and start extruding)
9- Check the first 5 layers at least for condition of the part printing. Then patience is required till full part is printed.
10- Once 2 hour passed and printed perfectly, scraper was used to remove the pen holder with raft from the bed, as for post processing pliers was used to remove any stringing or any other unwanted filament stands left from the raft.
Voila, The major printing fabrication process is done
11- As for other small remaining parts (filament feeder path + gear) redo all steps from 1 to 10. Only check the settings of PLA: layer height: 0.2/0.3 temperature 215/60 degrees, Cooling 100% since all parts were flat – skirt was used and as for the color filament feeder path was printed in White pla and as for its gear Blue color was used.
12- Secondly Laser cutting fabrication. Open laser work software, and import the .DXF file which is prepared after designing.
13- Move each part to better use of the plywood sheet space.
14- Since for this project all sketches were converted into 1 dxf file, 2 parts (front and back of the box) were removed temporarily as it was not fitting in the 30x50cm sheet.
15- Select all and check for any double lines by clicking remove double lines from top toolbar.
16- Insert Engraving text by using text box from the vertical toolbar on the left , And select on the area where to write, popup dialogue will appear asking to set the fonts settings, select Arial font and write 3D FAB PEN in the text box. After clicking okay adjust the font size by dragging the corner selections to increase or decrease size area.
17- Redo step 16 to add name of the project maker.
18- Also for engraving insert dxf file of any design, Islamic geometrical design was used to give it aesthetic look.
19- Multiple select all engraving parts and from bottom toolbar select the red color as black color by default is for cut.
20- On top right corner double select on red color to view its properties and change its speed and power set the red to be scan mode and speed 300 power 25 output yes. As for cut output yes mode cut speed 22 power 65.
21- Check and track frame digitally by clicking on “preview” from top toolbar. After reviewing the result image and estimated time close the window and click on download (to send the file to the machine).
22- On the machine first turn the button on and set the position of the laser end by arrows and set the as origin, insert the plywood 3mm sheet and adjust it under the tip of the laser cutter. Check the focus settings and if the plywood is curved insert tape on all 4 sides to give it a good grip.
23-Press on file on the machine under the LCD, then choose files and press enter and then press on tack frame( to check the border of the laser cutting fit the plywood.
24-Press run to start the process
25-calculated the total work time on the machine - 15minutes and 20 seconds.
26-After finishing the cutting process check that the cut is done properly, as sometimes the machine efficiency decreases by lot of usage. If still not cut properly redo run again.
video1 , video2, video3 and video4.
That is the end of fabrication process of laser cut.
27- Now for the third part Assembly, it requires patience and lots of time, start by assembling the extruder kit with the holder by minimum of 3 screws so that the holder is attached to the fan and the screw is passed between them and also the heatsink attachment. (for this spiral screws 15mm long is required).
28- Then move to assemble the box, to get the grip of the box attach all four sides on the base and then delicately join with m3 10mm or 5mm screws with m3 nuts to all sides, once all 4 sides are fitted together now fit the base with same screws and nuts. Total of 20 screws and nuts are required till this process
29- Before fitting the lid, fit all components at its place with same size screw and nuts, some components like LCD and stepper motor and power supply will need different size of screws and some without nuts.
(Place stepper motor first at the back corner and screw it, then add power supply and screw it from bottom only, and then add Arduino next to power supply and screw it delicately minimum of 2 screws opposite to each other are must to get a good grip, then stepper motor driver control panel is fitted under Arduino board, also add lcd on the lid and relay module on the side with screws and nuts)
30- Keep driller in handy if any of the screws fitting is wrong, in this project it was only used to drill the filament path feeder screw holes, also to make stepper motor shaft opening bigger.
31- Complete the wiring and test it before closing the lid.
32- At the very end fit the lid with 8 m3 5mm screws and m3 nuts.
check this prototype assembly video and video2
Congratulations on finishing the most irritable part
Project Electronics & Power Management
4. Describe your electronic circuit. What are the input and action components? What is the function of each? How do the components integrate together to form your smart system? (List the softwares/tools/components...etc that you used)
To describe this project’s electronic circuit and integration of components together to form a smart system:
1) To start with connect 220VAC with cable with plug to the SMPS 12V first and second slot from the left which will be written L & N.
2) As for the Arduino board it will be connected by DC jack from second last (positive) and third last (negative) slot of power supply .
3) On the small breadboard, connect from Arduino 5V output to the first column from the left. And also Ground from the board to the 2nd row of the breadboard. To make common ground between all components connect a jumper wire in the 2nd row under pin of Ground from Arduino( column 2) to connect it to the 1st row of the 3rd column, to allow more pins to connect, also reconnect from 3rd column to the 4th column exact way.
4) Stepper motor has 4 pins which is connected to its driver in specific slot, and the driver control panel has 7 pins
D pin = on arduino pin 9
Spin = on Arduino pin 12
E pin = on Arduino pin 10
VCC= on breadboard column 1 row 2
Ground = on breadboard column 2 row 3
Ground = on breadboard column 2 row 4
9V = 9VDC adapter (adapter’s ground is connected to breadboard column 2 row 5)
5) As for the heater it has no polarity so one wire is connected to the last slot of SMPS power supply 12V (positive) and other to the relay module on NC pin
6) Relay module as another 4 pins
Com beside NC = on breadboard column 3 row 3
D+ = on breadboard column 1 row 3
D- = on breadboard column 3 row 4
IN = on Arduino pin 3
7) Fan on the extruder kit has 2 wires
Red (positive) = on SMPS second last slot with Arduino board connection
Black(negative) = on breadboard column 3 row 5
8) NTC temperature sensor has also 2 wires and no polarity
Wire 1 = on breadboard column 30 row 4 (where another jumper wire on same column row 1 = on Arduino A0 pin) just because of clearing the disturbance in reading.
wire 2 = on breadboard column 4 row 2
9) As for clearing the disturbance of the sensor, connect 100kohm resistor between temperature sensor wire and A0 pin = on breadboard column 30 row 2.
The other side of the resistor = on breadboard column 25 row 2
so that the from Arduino board 3.5 V pin = on breadboard column 25 row 3
and as a reference from Arduino board ref pin above 13 pin and ground pin = on breadboard column 25 row 5
10) Push button has 2 pins female to male jumper wire will be connected
pin1 = on breadboard column 4 row 3
pin 2= on Arduino pin 7
As for the other push button
pin1 = on breadboard column 4 row 4
pin 2= on Arduino pin 6
11)Remaining LCD I2C has 4 pins
Ground pin1 = on breadboard column 4 row 4
VCC = on breadboard column 1 row 4
SDA= on Arduino pin A4
SDT= on Arduino pin A5
When the project is powered on the Arduino brain module will read the temperature of the head block(from the temperature sensor) and accordingly allow relay module to power the heater on and off. Also when specific temperature is reached the board will also allow to read input of push buttons and signals the stepper motor driver to move the motor accordingly( if not reached this action will not happen).LCD will display these information at all times. This is how components are integrated to form smart system.
5. What is your power source? How did you select the suitable power source for your project? (List the softwares/tools/components...etc that you used)
Power source of this project are 2:
1) SMPS 12V 10A
2) 9VDC adapter
To select the suitable power source for this project, every component was researched and studied its input and output power requirements as shown in this google sheet below.
Also just to be sure I calculated and made mistakes by using ohms law as shown in the picture for SMPS, the mistake was I was calculating according that SMPS will ONLY GIVE OUTPUT OF 12V 10A but found that that’s the limit, it supplies every components as required.
The adapter is used only for powering the stepper motor driver control panel as it is written on it. All other components limitations are 12V so its powered by SPMS (heater+ Arduino+ fan)
Project Programming
6. Describe the code of your project. How did you program each function of the project?
The code of this project was segmented in 3 parts.
1) Feature 1 stepper motor with stepper motor driver. code
2) Feature 2 temperature sensor and heater with relay module. code
3) Integration of all together. code
As all of my components were new for me I searched for their ready codes from online to understand their function and then customized it as per my need.
For the first segment I searched for stepper motor with stepper motor driver control panel codes, and found this site which helped in understanding the code.
I customized it to rotate with 2 push buttons as shown here this is the code simply added 2 function command to read from any push buttons and move the stepper motor accordingly. The simple way to understand direction change is to change the state of direction pin from High to Low.
For the second segment this codes were very helpful to understand the calculations of the thermistor and give output in degree Celsius. And tested it by using 10K resistor but did not work, after more research I found out that in my project 100K thermistor was being used so, instead of 10Kohms 100Kohms resistor was used and it worked properly.
Then added all the calculations under a function called “void sensor” and tested with heater to run it very minimal around 100 degress. For accessing these calculations simply use function calling feature sensor(temp); and then Serial.println(temp);
The best is yet to come, the integration between them. As the code gets more complicated and requires more and more complex commands as reading the temperature all times with rotation of the motor was very challenging. After discussing and debating for days on this topic new library was introduced to this project for which it helped to meet that requirement which is “Metro” simply replace the delay time of reading temperature with this code. if (serialMetro.check() == 1)
{sensor(temp);
Serial.println(temp);
lcd.setCursor(0, 0);
lcd.print("temp:");
lcd.print(temp);}
This project code is sweet and simple, first upon powering on it will read the temperature by calling the function sensor(temp);
And display it on the lcd, then command to check the temperature below 100 then starts the heater ( heater command also wrapped in function called triggerheater();) and controlling heater by commanding if temp > 100 then trun off heater. Side by side using while loop that if temp > 100 then only check the push buttons else do not check. And if any of the 2 buttons are pressed command the motor to move accordingly.
For safety issues in this project, temperature reading command was given at every stage to avoid any technical issues,
Project Integration & Testing
7. Demonstrate with text and visuals how did you integrate the project’s modules together? What are the testing results? (Include a Demo video separately, showing a proof of functionality)
Integration of modules together for this project was a bit time consuming.
1) Integration of core modules
Brain + user input+ action component+ power management
stepper motor (feature1) with 2 push buttons controlled by the Arduino board. For the stepper motor driver control panel 9V adaptor was specifically used as written on the driver board module. It was a successful attempt but main challenge was to use small push buttons instead of big ones. Furthermore, the push buttons are not attached to the breadboard.
2) Brain + Sensor input+ action component+ Power management
Integrating the temperature sensor with the heater with the control of Arduino board and to power the heater at first 9V was used as 12V was risky. The experiment was successful and due to the small voltage the heater was increasing slowly but worked. (video2 for power the heater)
3) Brain + User Input + Sensor Input + 2 action components + power management.
A trial integration of all electronics components together with one Arduino code and using 2 power supplies 9V for the stepper motor driver control panel and SMPS 12V 10A to power the rest (Arduino + Heater+ Fan)
4) Last but not the least integrating construction parts module with the above full integrated electronic circuit. The 3d printed holder and laser cut box was integrated and tested all before closing the lid motor side to fix the filament feeder path.
complete video.
Sharing & Collaboration
8. Did you ask for feedback? What are the ideas that others have contributed or suggested? What was someone else’s idea that you built upon? How did you help your peers? How did your peers help you?
Yes, i asked for feedback from my peers and especially from my instructors regarding my project. I was blessed by positive responses but also careful warnings which would make me worried also.
Many ideas were contributed such as Assistant director Ahmed Saeed gave his feedback on my design and guidance for making it better, when I was stuck in designing. I built upon it to make my own cutom design for extruder holder.
Also in writing the code Instructor Menna and Assistant Ahmed Saeed gave an idea to use library for stepper motor, I built upon it to use different approaches but still had no luck..
Also was able to help my fellow peers also by giving suggestions and feedback throughout the sessions. Nevertheless by helping them out in any way possible online/offline session.
As one of my peer had hard time choosing his idea for the final project I suggested making it similar of what is thinking but making it more customized.
Also one of them needed idea to put water in the project but as ply wood was being used my peer was afraid of ruining the wood, I suggested in online session that plastic container can be used to prevent any leakage.
My peers also are kind enough to help me out throughout my project journey by giving me support and feedback like one of my peer made time for me when I was rewiring (troubleshooting) my circuit diagram and was really patient to check each wiring even when it was mess.
I want to take this opportunity to thank all of my instructors and my peers specially my group “Group D” for believing in me and supporting me to reach at this level. It really felt like being around family members which helped in my journey of the diploma specially accomplishing my project very wonderful memories. It is truly a blessing to have them with me.
Overcoming Challenges
9. When you got stuck, what/who did you turn to? At what point did you have to pause to research or learn more before moving on? What are some mistakes, pitfalls, or challenges that others can avoid if they were doing this project?
During “journey of my project”, I was facing challenges throughout every single step, here are some of my major experiences..
1) To start with designing: (unless someone is expert in designing) no one can create/design as they think also as prefect as it should be. As in my project I downloaded electrical components from grapcad (step file) to visualize it in designing process. Still my prototype had many flaws.(wrong screw holes, fitting of encloser, very small….etc) I was stuck in such a way that I couldn’t even change a thing unless another flaw appears. By using golden rule of trouble shooting as instructed by my instructors every time is to start over again. So I decided to use another approach instead of designing for laser cut, I designed according to 3d printing which seemed faster and easier way in designing. I advise anyone making this project again recheck every size even after using step file of components there may be a flaw in that design as no one is perfect.as this silly mistake costed me my prototype to be very bad.
2) As for writing Arduino code, I had major challenge in understanding stepper motor in small time frame, so I had to stop and surf in the internet for answers, but still as beginner I couldn’t find what I needed. So in the end I turned to my Instructor Menna and Assistant direct Ahmed Saeed for seeking guidance, they were so kind to give ample of time troubleshooting with me also suggesting required library which I was searching from beginning. In my code I had to maintain displaying temperature at all times also in the same time ordering stepper motor to work continuously side by side, so for that Metro library was suggested. which helped me to command 2 features all at the same time. My advice for anyone making this project again is to test every feature alone and then combine it smartly which will give you more successful result, also will help in troubleshooting a lot.
3) In wiring electrical components: I repeatedly had issues with stepper motor as may be I was using it for first time, sometimes it worked properly and other didn’t work at all. I had to stop and re wire it all again from the start and check it by ready example files to see if the code has the problem or wiring has issues. Also needed to change some wires and also like one of my push button didn’t work as It was damaged. I would strongly advice anyone making this project again to maintain patience and never expect that you are right, double triple check every wire, as I did with my peer Haneen, she was kind enough to give time and rewire all with more sophisticated and cleaner way, which resulted in working properly. Also I would advise to test all components under supervision as experimenting with heater is very risky.
4) Another encounter in designing my project that I wanted to design pen shape encloser but due to size of the components and also weight of the stepper motor I could not make it happen, as being stuck and getting no answers I turned to my Instructor in in offline session at FAB LAB Egypt where I discussed with her in details so that the problem is presented clearly than online session, my main challenge was to fit the extruder kit on the wood and give it tight grip which keeps it from falling. I was then suggested to change my design in a whole new one that solved this issue. So I would advise anyone making this project again to be open to new ideas and accept it with open heart. The goal of the project is the ability to conceptualize, model, and create a medium-fidelity prototype of a smart device or solution for satisfying a personal need. Not making it as any other user need product.
5) Major challenge also was to use the big power supply, as it was SMPS 12Vdc 10A, so misunderstood that at every output it gives this value, so was not able to calculate resistor value for each components. I stopped and asked my Instructors on the whatsapp final project group, they were kind enough to make me understand that the value given on the power supply is not constant but it is the maximum limit which can be reached. Moreover, they rest assured me that nothing will get burned J. So I strongly advice to anyone making this project do not make this silly mistake and research on every component given properly.
6)ABS was not sticking on the bed even after using brim, FAB Lab specialist ENG Noha was a live saver to check and maintain continuously recommending to change settings for better result. The solution was to make a raft instead of brim to keep it adhesive on the bed.
7) Extruder feeder on motor shaft could not able to unscrew it and place it to required position, i had to stop and retuen to instructors for help due to lack of time, ENG Mohannad gave his full effort to make the shaft hole bigger than it was originally cut.
8) Problem in the machine that laser cut was set to required settings but still did not cut perfectly. I was instructed by the Fab lab specialist and my instructor to cut it with cutter so that it would finish cut and remove from plywood sheet. I want to advice anyone making this project again to that due to this problem small surface area parts does not turn out do be as should be, so its better to avoid small scaling design in laser cutting.
All in all silly mistakes, pitfalls or challenges are nothing compared to how dedicated you are in fulfilling this project. Be strong Be happy .
Future Work
10. If you had more time, what is one thing you would change/ Do next in your project?
If I had more time I would have added “controlling/changing temperature feature” by installing 2 additional push buttons below the lcd.
functions of push buttons are as follow:
1)temperature increase or decrease.
or
2)changing material mode i.e: PLA or ABS
so that this 3D PEN can be used with many materials.
Also if I had more time I would have expanded my research just to get acquainted with other components that are relatively small than the ones I am using now(i.e very small LCD / Arduino nano), so that I can actually build small encloser that looks like a normal pen.
