zack polizzi maxwell tucker north carolina school of science and mathematics d esign and c...
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Zack PolizziMaxwell Tucker
North Carolina School of Science and Mathematics
DESIGN AND CONSTRUCTION OF A MULTI-MATERIAL 3D PRINTER
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Introduction | Design and Construction | Business Plan
3D PRINTERS
• Allow for rapid creation
of 3-dimensional objects
• Applications in rapid
prototyping, design
testing, flexible
production, and a
variety of other uses
http://www.wired.com/design/2013/07/is-this-cast-the-future-of-healing-broken-bones/
http://biginscience.com/big-in-science-articles/2012/8/26/could-3d-printing-help-an-ailing-economy.html
http://protinus.wordpress.com/tag/bathsheba-grossman/
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Introduction | Design and Construction | Business Plan
PROBLEMS WITH CURRENT DESIGNS
• Current consumer printers offer limited material selection
• Relatively slow print speeds
• Extrusion printing struggles with complex unsupported structures
http://solidsmack.com/cad-design-news/evd-unsensored-bre-pettis-interview-and-makerbot-store-tour/attachment/makerbot-replicator-2/
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Introduction | Design and Construction | Business Plan
ORIGINAL ENGINEERING GOALS
Build a working 3D printer which is capable of printing in multiple different materials
• Create a design that is flexible and extensible
• Have the ability to print directly from 3D CAD drawings
• Aiming to print in various metals, plastics, ceramics, sugar,
glass, and many other materials
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Introduction | Design and Construction | Business Plan
DESIGN EVOLUTION
• Originally an idea for a Research in
Physics project
• Original design was for a solar-
powered 3D printer
• Built a prototype over Mini-Term
• Presented research in Singapore
• Currently working on upgrades and
hope to bring product to market
through Entrepreneurship class
Photo Credit: Luke Fernandez
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Introduction | Design and Construction | Business Plan
DESIGN THEORY
Selective Laser Sintering
1. Lay down a base material layer
2. Melt a cross-section of the 3D object into the base
material
3. Add a thin layer of additional material
4. Melt the next cross-section into the new material layer
5. Repeat until printing is finished, building 2D layers
vertically upon each other until the 3D object is complete
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http://upload.wikimedia.org/wikipedia/commons/3/33/Selective_laser_melting_system_schematic.jpg
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Introduction | Design and Construction | Business Plan
CONSTRUCTION: XY TABLE
Photo Credit: Luke Fernandez
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Introduction | Design and Construction | Business Plan
CONSTRUCTION: ELECTRONICS AND PRINT HEAD
Photo Credit: Zack Polizzi
Photo Credit: Luke Fernandez
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Photo Credit: Luke Fernandez
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Introduction | Design and Construction | Business Plan
CURRENT WORK
Planned Upgrades
• Laser Powered
• Greater Material Capability
• Higher Resolution
• Faster Print Speeds
• Fully Automatic Printing
Photo Credit: Zack Polizzi
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Introduction | Design and Construction | Business Plan
LASER UPGRADES
Photo Credit: Zack Polizzi
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Introduction | Design and Construction | Business Plan
LASER DIODE POWER SUPPLY
40A Buck Regulator Schematic
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Introduction | Design and Construction | Business Plan
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Introduction | Design and Construction | Business Plan
Completed Power Supply
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Introduction | Design and Construction | Business Plan
COMPETITIVE MATRIX
16
Printer Our Printer Makerbot Reprap Shapeways EOSINT 280
Print Speed 5cm3/min 1cm3/min .5 cm3/min 6-20 days 10cm3/min
Product Cost $5,000 $3,000 $700+ $20-$1,000/print $680,000
Material Capabilities
Many powdered materials
ABS/PLA plastic
ABS/PLA Plastic
Plastics, 3 metals,
ceramic, sandstone
Plastics, metals,
ceramics
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QUESTIONS?
THANKS TO LUKE FERNANDEZ, STUART WELLS, DR. LOBUGLIO, DR. HALPIN, DR. BENNETT, DR. SHECK
NCSSM RESEARCH