Research

19 pages, 7986 KiB

Open AccessArticle

Belt-Driven Open Source Circuit Mill Using Low-Cost 3-D Printer Components

by Shane Oberloier and Joshua M. Pearce

Inventions 2018, 3(3), 64; https://0-doi-org.brum.beds.ac.uk/10.3390/inventions3030064 - 05 Sep 2018

Cited by 12 | Viewed by 10633

Barriers to inventing electronic devices involve challenges of iterating electronic designs due to long lead times for professional circuit board milling or high costs of commercial milling machines. To overcome these barriers, this study provides open source (OS) designs for a low-cost circuit [...] Read more.

Barriers to inventing electronic devices involve challenges of iterating electronic designs due to long lead times for professional circuit board milling or high costs of commercial milling machines. To overcome these barriers, this study provides open source (OS) designs for a low-cost circuit milling machine. First, design modifications for mechanical and electrical subsystems of the OS Distributed 3-D (D3D) Robotics prototyping system are provided. Next, Copper Carve, an OS custom graphical user interface, is developed to enable circuit board milling by implementing backlash and substrate distortion compensation. The performance of the OS D3D circuit mill is then quantified and validated for: positional accuracy, cut quality, feature accuracy, and distortion compensation. Finally, the return on investment is calculated for inventors using it. The results show by properly compensating for motion inaccuracies with Copper Carve, the machine achieves a motion resolution of 10 microns, which is more than adequate for most circuit designs. The mill is at least five times less expensive than all commercial alternatives and the material costs of the D3D mill are repaid from fabricating 20–43 boards. The results show that the OS circuit mill is of high-enough quality to enable rapid invention and distributed manufacturing of complex products containing custom electronics. Full article

(This article belongs to the Special Issue Innovations in 3-D Printing)

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16 pages, 34410 KiB

Open AccessArticle

Low-Level Control of 3D Printers from the Cloud: A Step toward 3D Printer Control as a Service

by Chinedum E. Okwudire, Sharankumar Huggi, Sagar Supe, Chengyang Huang and Bowen Zeng

Inventions 2018, 3(3), 56; https://0-doi-org.brum.beds.ac.uk/10.3390/inventions3030056 - 19 Aug 2018

Cited by 24 | Viewed by 11571

Abstract

Control as a Service (CaaS) is an emerging paradigm where low-level control of a device is moved from a local controller to the Cloud, and provided to the device as an on-demand service. Among its many benefits, CaaS gives the device access to [...] Read more.

Control as a Service (CaaS) is an emerging paradigm where low-level control of a device is moved from a local controller to the Cloud, and provided to the device as an on-demand service. Among its many benefits, CaaS gives the device access to advanced control algorithms which may not be executable on a local controller due to computational limitations. As a step toward 3D printer CaaS, this paper demonstrates the control of a 3D printer by streaming low-level stepper motor commands (as opposed to high-level G-codes) directly from the Cloud to the printer. The printer is located at the University of Michigan, Ann Arbor, while its stepper motor commands are calculated using an advanced motion control algorithm running on Google Cloud computers in South Carolina and Australia. The stepper motor commands are sent over the internet using the user datagram protocol (UDP) and buffered to mitigate transmission delays; checks are included to ensure accuracy and completeness of the transmitted data. All but one part printed using the cloud-based controller in both locations were hitch free (i.e., no pauses due to excessive transmission delays). Moreover, using the cloud-based controller, the parts printed up to 54% faster than using a standard local controller, without loss of accuracy. Full article

(This article belongs to the Special Issue Innovations in 3-D Printing)

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7 pages, 851 KiB

Open AccessArticle

Biocompatibility of 3D-Printed Methacrylate for Hearing Devices

by Frank Alifui-Segbaya and Roy George

Inventions 2018, 3(3), 52; https://0-doi-org.brum.beds.ac.uk/10.3390/inventions3030052 - 27 Jul 2018

Cited by 10 | Viewed by 7603

Abstract

The capacity of 3D printing (3DP) technologies to initiate speedy polymerization of solvent-free resins accounts for their utility in the manufacturing of medical devices. Nonetheless, independent biological evaluation of 3D-printed materials is recommended due to the unique parameters of the manufacturing process, which [...] Read more.

The capacity of 3D printing (3DP) technologies to initiate speedy polymerization of solvent-free resins accounts for their utility in the manufacturing of medical devices. Nonetheless, independent biological evaluation of 3D-printed materials is recommended due to the unique parameters of the manufacturing process, which can influence their physical, chemical and biological properties. In this study, E-Shell 450 clear methacrylate indicated for 3DP of hearing devices was examined for biological safety using zebrafish bioassays adapted to Organization for Economic Cooperation and Development (OECD) fish embryo test. In addition, the proprietary material was characterized for composition using headspace gas chromatography–mass spectrometry (GC–MS). To initiate the biological test, newly fertilized zebrafish eggs were cultured on non-treated and ethanol-treated methacrylates in glass petri dishes with ultrapure water, incubated at 28.5 °C and assessed for developmental endpoints of toxicity at 24 h intervals until 96 h. Toxicological data indicate that non-treated methacrylate is extremely toxic in zebrafish bioassays, whereas ethanol-treated counterpart showed a relative lower toxicity possibly due to ethanoic–aqueous interactions as observed by GC–MS. With the current influx of 3D printing materials, users are urged to exercise caution. Operators must also take cognizance of the potential toxicity of the chemicals used in 3DP and implement safety measures to limit their exposure. Full article

(This article belongs to the Special Issue Innovations in 3-D Printing)

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10 pages, 4109 KiB

Open AccessArticle

How to Automate a Kinematic Mount Using a 3D Printed Arduino-Based System

by Luis José Salazar-Serrano, Gerard Jiménez and Juan P. Torres

Inventions 2018, 3(2), 39; https://0-doi-org.brum.beds.ac.uk/10.3390/inventions3020039 - 19 Jun 2018

Cited by 5 | Viewed by 8433

Abstract

We demonstrate a simple, flexible and cost-effective system to automatize most of the kinematic mounts available nowadays on the market. It combines 3D-printed components, an Arduino board, stepper motors and simple electronics. The developed system can control up to ten stepper motors independently [...] Read more.

We demonstrate a simple, flexible and cost-effective system to automatize most of the kinematic mounts available nowadays on the market. It combines 3D-printed components, an Arduino board, stepper motors and simple electronics. The developed system can control up to ten stepper motors independently and simultaneously using commands sent through the serial port, and it is suitable for applications where optical realignment using flat mirrors is required on a periodic basis. Full article

(This article belongs to the Special Issue Innovations in 3-D Printing)

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13 pages, 2322 KiB

Open AccessArticle

Development of New Hybrid Acrylic/Epoxy DLP-3D Printable Materials

by Simone Lantean, Ignazio Roppolo, Marco Sangermano, Candido Fabrizio Pirri and Annalisa Chiappone

Inventions 2018, 3(2), 29; https://0-doi-org.brum.beds.ac.uk/10.3390/inventions3020029 - 17 May 2018

Cited by 35 | Viewed by 7879

Abstract

Light induced three dimensional (3D) printing techniques generally use printable formulations that are based on acrylic monomers because of their fast reactivity, which is balanced with their good final properties. However, the possibility to enlarge the palette of 3D printable materials is a [...] Read more.

Light induced three dimensional (3D) printing techniques generally use printable formulations that are based on acrylic monomers because of their fast reactivity, which is balanced with their good final properties. However, the possibility to enlarge the palette of 3D printable materials is a challenging target. In this work, hybrid printable formulations that are based on acrylic and epoxy resins are presented and their printability on DLP (Digital Light Processing) machines is demonstrated. Hexanediol diacrylate (HDDA) and an epoxy resin—3,4-Epoxycylohexylmethyl-3′,4′-epoxycyxlohexane carboxylate (CE)—in different ratios are used and the influence of a bridging agent, Glycidyl methacrylate (GMA), is also investigated. The reactivity of the different active species during irradiation is evaluated and the mechanical properties, including the impact toughness, the thermo-mechanical properties, and the volumetric shrinkage, are studied on printed samples. Full article

(This article belongs to the Special Issue Innovations in 3-D Printing)

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18 pages, 6434 KiB

Open AccessArticle

Evaluation of Capacitive Markers Fabricated by 3D Printing, Laser Cutting and Prototyping

by Julian Kreimeier, Thomas Bielmeier and Timo Götzelmann

Inventions 2018, 3(1), 9; https://0-doi-org.brum.beds.ac.uk/10.3390/inventions3010009 - 26 Jan 2018

Viewed by 5928

Abstract

With Tangible User Interfaces, the computer user is able to interact in a fundamentally different and more intuitive way than with usual 2D displays. By grasping real physical objects, information can also be conveyed haptically, i.e., the user not only sees information on [...] Read more.

With Tangible User Interfaces, the computer user is able to interact in a fundamentally different and more intuitive way than with usual 2D displays. By grasping real physical objects, information can also be conveyed haptically, i.e., the user not only sees information on a 2D display, but can also grasp physical representations. To recognize such objects (“tangibles”) it is skillful to use capacitive sensing, as it happens in most touch screens. Thus, real objects can be located and identified by the touch screen display automatically. Recent work already addressed such capacitive markers, but focused on their coding scheme and automated fabrication by 3D printing. This paper goes beyond the fabrication by 3D printers and, for the first time, applies the concept of capacitive codes to laser cutting and another immediate prototyping approach using modeling clay. Beside the evaluation of additional properties, we adapt recent research results regarding the optimized detection of tangible objects on capacitive screens. As a result of our comprehensive study, the detection performance is affected by the type of capacitive signal processing (respectively the device) and the geometry of the marker. 3D printing revealed to be the most reliable technique, though laser cutting and immediate prototyping of markers showed promising results. Based on our findings, we discuss individual strengths of each capacitive marker type. Full article

(This article belongs to the Special Issue Innovations in 3-D Printing)

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14 pages, 1174 KiB

Open AccessArticle

Inexpensive Piezoelectric Elements for Nozzle Contact Detection and Build Platform Leveling in FFF 3D Printers

by Michael Simpson and Simon Khoury

Inventions 2018, 3(1), 8; https://0-doi-org.brum.beds.ac.uk/10.3390/inventions3010008 - 25 Jan 2018

Cited by 4 | Viewed by 14539

Abstract

Inexpensive piezoelectric diaphragms can be used as sensors to facilitate both nozzle height setting and build platform leveling in Fused Filament Fabrication (FFF) 3D printers. Tests simulating nozzle contact are conducted to establish the available output and an output of greater than 8 [...] Read more.

Inexpensive piezoelectric diaphragms can be used as sensors to facilitate both nozzle height setting and build platform leveling in Fused Filament Fabrication (FFF) 3D printers. Tests simulating nozzle contact are conducted to establish the available output and an output of greater than 8 Volts found at 20 °C, a value which is readily detectable by simple electronic circuits. Tests are also conducted at a temperature of 80 °C and, despite a reduction of greater than 80% in output voltage, this is still detectable. The reliability of piezoelectric diaphragms is investigated by mechanically stressing samples over 100,000 cycles at both 20 and 80 °C, and little loss of output over the test duration is found. The development of a nozzle contact sensor using a single piezoelectric diaphragm is described. Full article

(This article belongs to the Special Issue Innovations in 3-D Printing)

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13007 KiB

Open AccessArticle

Contact-Free Support Structures for Part Overhangs in Powder-Bed Metal Additive Manufacturing

by Kenneth Cooper, Phillip Steele, Bo Cheng and Kevin Chou

Inventions 2018, 3(1), 2; https://0-doi-org.brum.beds.ac.uk/10.3390/inventions3010002 - 28 Dec 2017

Cited by 60 | Viewed by 11093

Abstract

This study investigates the feasibility of a novel concept, contact-free support structures, for part overhangs in powder-bed metal additive manufacturing. The intent is to develop alternative support designs that require no or little post-processing, and yet, maintain effectiveness in minimizing overhang distortions. The [...] Read more.

This study investigates the feasibility of a novel concept, contact-free support structures, for part overhangs in powder-bed metal additive manufacturing. The intent is to develop alternative support designs that require no or little post-processing, and yet, maintain effectiveness in minimizing overhang distortions. The idea is to build, simultaneously during part fabrications, a heat sink (called “heat support”), underneath an overhang to alter adverse thermal behaviors. Thermomechanical modeling and simulations using finite element analysis were applied to numerically research the heat support effect on overhang distortions. Experimentally, a powder-bed electron beam additive manufacturing system was utilized to fabricate heat support designs and examine their functions. The results prove the concept and demonstrate the effectiveness of contact-free heat supports. Moreover, the method was tested with different heat support parameters and applied to various overhang geometries. It is concluded that the heat support proposed has the potential to be implemented in industrial applications. Full article

(This article belongs to the Special Issue Innovations in 3-D Printing)

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9951 KiB

Open AccessArticle

The Use of 3D Printing in the Fabrication of Nasal Stents

by David Mills, Karthik Tappa, Uday Jammalamadaka, Jeffery Weisman and Jennifer Woerner

Inventions 2018, 3(1), 1; https://0-doi-org.brum.beds.ac.uk/10.3390/inventions3010001 - 23 Dec 2017

Cited by 12 | Viewed by 8234

Abstract

Nasoalveolar molding of the cleft lip, nose, and alveolar palate has been a successful strategy for the restoration of oronasal function and appearance, but it has some drawbacks. The temporary implant that is inserted before surgical reconstruction is a large appliance requiring numerous [...] Read more.

Nasoalveolar molding of the cleft lip, nose, and alveolar palate has been a successful strategy for the restoration of oronasal function and appearance, but it has some drawbacks. The temporary implant that is inserted before surgical reconstruction is a large appliance requiring numerous adjustments, it can irritate delicate soft tissues, and interfere with the infant’s ability to nurse or feed. In the early post-operative period and for months after cleft lip repair, patients wear standardized silicone stents that come in multiple sizes, but require significant sculpting to fit the unique cleft deformity. Three-dimensional (3D) printing offers the potential of highly personalized and patient-specific treatment. We developed a method that produces a customized 3D printed stent that matches the contours and unique features of each patient and permits modification and adjustments in size and shape as the patient ages. With 3D scanning technology, the device can be designed at the first visit to create an appliance that can be worn sequentially with minimal trauma, does not impede feeding, and a prosthesis that will improve compliance. The device will be worn intraorally to help shape the alveolus, lip, and nose before surgical repair. Furthermore, the stent can be doped with drugs as each patient’s case warrants. Full article

(This article belongs to the Special Issue Innovations in 3-D Printing)

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