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P10551 - Nano-ink Deposition System Detailed Level Design Review

P10551 - Nano-ink Deposition System Detailed Level Design Review. FAB AMERICA. Eric Hettler - ME William Gallagher - ISE Christopher Mieney - ME Gregory Ryan - ME Joseph Cole - EE. Design Review Agenda. Project Overview Needs/Specifications Current System Selected Concept

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P10551 - Nano-ink Deposition System Detailed Level Design Review

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  1. P10551 - Nano-ink Deposition SystemDetailed Level Design Review FAB AMERICA Eric Hettler - ME William Gallagher - ISE Christopher Mieney - ME Gregory Ryan - ME Joseph Cole - EE

  2. Design Review Agenda • Project Overview • Needs/Specifications • Current System • Selected Concept • Material Delivery System • Drawings • BOM • Feasibility • Control Electronics • Drawings • BOM • Feasibility • Curing • Drawings • BOM • Feasibility • Risk Assessment • Test Plan

  3. Project Overview http://fabathome.org Fab@Home open-source architecture Print photo-curable resin Color printing used as a vehicle to demonstrate multi-material print capability

  4. Systems Overview

  5. Concept Screening/Selection • Motion Control • Stepper Motor • Servo Motors • Pulleys • Rack and Pinion • Pneumatics • Color Mixing • 3 pre mixed reservoirs that mix in manifold • Inject individual inks into stream of resin • Mix inks and inject into stream of resin • Print like an inkjet (halftoning) • Put down resin and print with inkjet on top • Material Delivery • Micro Valve (solenoid) • Ball Point Approach • Micro Rocker Valve (solenoid) • Inkjet (Thermal) • Inkjet (Piezoelectric) • Disposable Syringe • Curing • Ambient Light (fluorescent) • Mini Halogen Bulbs • LEDs • Laser • Fiber Optics

  6. Material Delivery - Manifold

  7. Material Delivery - Manifold

  8. Lee Valves Proposed Design: Micro Valves Proposed Design: material delivery nozzles Tube ID: .0075” Photos From The Lee Company

  9. Material Delivery - BOM

  10. Material Delivery - Feasibility • Ran preliminary valve test (.0075” ID nozzle) • Valve can deliver consistent small droplets of high viscosity liquid • Valve cannot “jet out” high viscosity liquid • Flow rates seem reasonable • Put resin through syringe (.00825” ID nozzle) • Could not produce “jet”

  11. Valve Controls http://fabathome.org Constant 24 volts for the spike Constant 3.5 volts for the hold 5 volt is pulsed The rising edge initiates the spike and hold

  12. Control Electronics

  13. Control Electronics - BOM

  14. Curing System

  15. Curing System

  16. Curing System Feasibility Irradiance at the Bulb Surface: Irradiance at the Work Part: Total Cure Time: • Assumptions: • The center line of the bulb is considered to be the source of light for purposes of measuring radii • The layer thickness is taken to be 0.01 inches thick • The entire UV output of the bulb (1 watt) is produced at the required wavelength of 355 nm • Note: • Cure time may be further reduced through the addition of a reflector

  17. Curing System BOM

  18. Test Plan • Serve To Verify System Design and Quantify Variability • Subsystems • Curing • Valves • Motion Control • Color Delivery • Integration effects • Size • Layer • Shrinkage/Deformation

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