Research

Abstract

3D printing and additive manufacturing is an up-and-coming industry that is becoming vital to the workflow of many engineers, hobbyists, and entrepreneurs. As the scale of 3D printing increases, such as in farms, servicing printers – like having to manually clear the print bed – becomes a major productivity loss. Some companies have tried to solve these issues with an automation solution for their printers, such as Prusa Research or Mosaic Manufacturing, with the Prusa AFS and the Array, respectively (Prusa Research, n.d.; Mosaic Manufacturing, n.d.). The target audience for these solutions is large businesses; they’re not practical for small businesses. This paper aims to develop the mechanical components of an automation system built for affordability and consistency by utilizing some of the best-in-class printers on the market, the BambuLab X1C and P1S printers, to provide an automation system at a price more affordable than solutions by other companies. These mechanical components for this automation system were broken down into three individual assemblies – an X-axis gantry, a Y-axis manipulator, and an end effector assembly – which were tested and scrutinized for individual success. Concluding the development of these assemblies, these components were created using affordable and consistent materials and techniques, allowing for the later innovation of these parts and a software system behind them to be developed into a finished product. However, further work would need to be done in the bed replacement and clearing system(s) for the automation system to be automatic which would need a software system developed behind it.

Keywords: CoreXY, i3 or Bedslinger, CAD, CNC, FDM

Research Map

Rationale

Summarized Findings

Through the development of the three mechanical components of the automation system conceptualized in this study, seven iterations were created across the three components. A subassembly methodology was taken in the development of these three components, developing foundational parts prior to developing end assembly parts.

Using hand-drawn technical drawings and the Autodesk Fusion360 CAD suite, possible solutions were drawn, developed, and considered before selecting the best fit and designed digitally in the CAD software. These assemblies were jointed (digitally connected in software to allow for digital motion) and scrutinized for mechanical, electrical, and software errors or oversights. Then, unless major errors were found in the part before being assembled by peer and expert review, the parts were printed, purchased, and/or assembled for prototyping to determine if the part complied with the measure of success.

Drafts/Technical Drawings

Various technical drawings were drafted for the concepts and initial dimensions for the various parts of the assemblies. Often, these were drawn to scale based on actual physical dimensions of known measurements, such as the size of the 3D printers or industrial shelf. These technical drawings allowed for the investigation of several different motion systems and transmission pathing, as well as structural and aesthetic designs. This allowed for several concepts to be ruled out as potential solutions due to issues found within the drawings, making it easier to move directly into the CAD software with structural concepts and motion systems thought through.

X-axis Carriage

Several technical drafts were drawn in the Fusion360 drafting workspace to provide professional visuals for the various assemblies. The X-axis carriage developed can be seen above.

Y-axis Manipulator

The Y-axis manipulator developed can be seen above. This design used an offset mount design to allow wide range-of-motion and a double reverse virtual four bar (DRV4B) to allow for compact linear motion with compliance.

End Effector

The end effector developed can be seen above. This design used a trapezoidal profile for the bed guide, which allowed for potential misalignments. Two solenoids, when actuated, would lock the bed in place.

Cost Analysis

Overall, the affordability goals were achieved by reducing the amount of purchases needed for the automation system. In the figure to the right, I managed to reduce the costs of the mechanical assemblies to about $340 for the actuators and barebones hardware alone, and I estimate a door-actuator assembly and bed-clearing system would cost about $30 and $200, respectively. For hobbyists, engineers, or small businesses, an automated system for the cost of about $500-$600 (excluding the costs of the printers themselves) is quite reasonable. This is much less than other solutions offered, which can cost upwards of $49,999.

Research Paper

Cody Goh - Research Paper.pdf

Legacy

Although the individual systems achieved their success measures, other assemblies are still required for a fully functional automatic 3D printing system, as well as a software system capable of managing a 3D printing queue workflow with logic to manage files and occupied/vacant printers. The assemblies developed in this study can be used for future development in an automation system based on the concepts in this study. Though this particular system used a DRV4B for a Y-axis manipulator, a better solution may prove more effective due to the constraints of the project within the internship it was developed. Additionally, a better solution for end-effector locking may be more consistent than the trapezoidal guide solenoid lock system implemented here. Finally, a standalone individual system (instead of on an industrial shelf) – though more expensive – may allow for more precise automation and a better overall product.

This study has been a humbling experience for the amount of work that goes into the development of a project like this, considering the short time frame and the concurrent development of the research paper, presentation, and portfolio within this semester-long internship-based research class. This project has allowed me to better develop my skills with designing and conceptualizing several 3D printed and composite parts, as well as improving my professional skills when interacting with coworkers and employers. I have learned new design practices and systems, like the Fusion360 drafting workspace, and working with larger mechanical assemblies like the X-axis carriage I developed in this project. I am incredibly thankful for my mentor and the opportunity to be able to develop a project like this for him and his small business, and I hope that the work I've put in (and will continue to put in) will amount to a successful, affordable (maybe I can get one for myself!) end product that jumpstarts the industry/market for a better experience in 3D printing as a whole.

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