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Reprapable Recyclebot: Open Source 3-D Printable Extruder For Converting Plastic To 3-D Printing Filament, Aubrey Woern, Joseph Mccaslin, Adam Pringle, Joshua M. Pearce
Reprapable Recyclebot: Open Source 3-D Printable Extruder For Converting Plastic To 3-D Printing Filament, Aubrey Woern, Joseph Mccaslin, Adam Pringle, Joshua M. Pearce
Joshua M. Pearce
In order to assist researchers explore the full potential of distributed recycling of post-consumer polymer waste, this article describes a recyclebot, which is a waste plastic extruder capable of making commercial quality 3-D printing filament. The device design takes advantage of both the open source hardware methodology and the paradigm developed by the open source self-replicating rapid prototyper (RepRap) 3-D printer community. Specifically, this paper describes the design, fabrication and operation of a RepRapable Recyclebot, which refers to the Recyclebot’s ability to provide the filament needed to largely replicate the parts for the Recyclebot on any type of RepRap 3-D …
Three Hundred And Sixty Degree Real-Time Monitoring Of 3-D Printing Using Computer Analysis Of Two Camera Views, Siranee Nuchitprasitchai, Michael C. Roggeman, Joshua M. Pearce
Three Hundred And Sixty Degree Real-Time Monitoring Of 3-D Printing Using Computer Analysis Of Two Camera Views, Siranee Nuchitprasitchai, Michael C. Roggeman, Joshua M. Pearce
Joshua M. Pearce
Prosumer (producing consumer)-based desktop additive manufacturing has been enabled by the recent radical reduction in 3-D printer capital costs created by the open-source release of the self-replicating rapid prototype (RepRap). To continue this success, there have been some efforts to improve reliability, which are either too expensive or lacked automation. A promising method to improve reliability is to use computer vision, although the success rates are still too low for widespread use. To overcome these challenges an open source low-cost reliable real-time optimal monitoring platform for 3-D printing from double cameras is presented here. This error detection system is implemented …
Distributed Manufacturing Of Flexible Products: Technical Feasibility And Economic Viability, Aubrey Woern, Joshua M. Pearce
Distributed Manufacturing Of Flexible Products: Technical Feasibility And Economic Viability, Aubrey Woern, Joshua M. Pearce
Joshua M. Pearce
Distributed manufacturing even at the household level is now well established with the combined use of open source designs and self-replicating rapid prototyper (RepRap) 3-D printers. Previous work has shown substantial economic consumer benefits for producing their own polymer products. Now flexible filaments are available at roughly 3-times the cost of more conventional 3-D printing materials. To provide some insight into the potential for flexible filament to be both technically feasible and economically viable for distributed digital manufacturing at the consumer level this study investigates 20 common flexible household products. The 3-D printed products were quantified by print time, electrical …
Free And Open Source 3-D Model Customizer For Websites To Democratize Design With Openscad, Yuenyong Nilsiam, Joshua M. Pearce
Free And Open Source 3-D Model Customizer For Websites To Democratize Design With Openscad, Yuenyong Nilsiam, Joshua M. Pearce
Joshua M. Pearce
3-D printing has entered the consumer market because of recent radical price declines. Consumers can save substantial money by offsetting purchases with DIY pre-designed 3-D printed products. However, even more value can be obtained with distributed manufacturing using mass customization. Unfortunately, the average consumer is not technically sophisticated enough to easily design their own products. One solution to this is the use of an overlay on OpenSCAD parametric code, although current solutions force users to relinquish all rights to their own designs. There is thus a substantial need in the open source design community for a libre 3-D model customizer, …
Energy Payback Time Of A Solar Photovoltaic Powered Waste Plastic Recyclebot System, Shan Zhong, Pratiksha Rakhe, Joshua M. Pearce
Energy Payback Time Of A Solar Photovoltaic Powered Waste Plastic Recyclebot System, Shan Zhong, Pratiksha Rakhe, Joshua M. Pearce
Joshua M. Pearce
The growth of both plastic consumption and prosumer 3-D printing are driving an interest in producing 3-D printer filaments from waste plastic. This study quantifies the embodied energy of a vertical DC solar photovoltaic (PV) powered recyclebot based on life cycle energy analysis and compares it to horizontal AC recyclebots, conventional recycling, and the production of a virgin 3-D printer filament. The energy payback time (EPBT) is calculated using the embodied energy of the materials making up the recyclebot itself and is found to be about five days for the extrusion of a poly lactic acid (PLA) filament or 2.5 …
Open Source 3-D Printed Nutating Mixer, Dhwani K. Trivedi, Joshua M. Pearce
Open Source 3-D Printed Nutating Mixer, Dhwani K. Trivedi, Joshua M. Pearce
Joshua M. Pearce
As the open source development of additive manufacturing has led to low-cost desktop three-dimensional (3-D) printing, a number of scientists throughout the world have begun to share digital designs of free and open source scientific hardware. Open source scientific hardware enables custom experimentation, laboratory control, rapid upgrading, transparent maintenance, and lower costs in general. To aid in this trend, this study describes the development, design, assembly, and operation of a 3-D printable open source desktop nutating mixer, which provides a fixed 20° platform tilt angle for a gentle three-dimensional (gyrating) agitation of chemical or biological samples (e.g., DNA or blood …
Free And Open-Source Control Software For 3-D Motion And Processing, Bas Wijnen, G. C. Anzalone, Amberlee S. Haselhuhn, Paul G. Sanders, Joshua M. Pearce
Free And Open-Source Control Software For 3-D Motion And Processing, Bas Wijnen, G. C. Anzalone, Amberlee S. Haselhuhn, Paul G. Sanders, Joshua M. Pearce
Joshua M. Pearce
RepRap 3-D printers and their derivatives using conventional firmware are limited by: 1) requiring technical knowledge, 2) poor resilience with unreliable hardware, and 3) poor integration in complicated systems. In this paper, a new control system called Franklin, for CNC machines in general and 3-D printers specifically, is presented that enables web-based three dimensional control of additive, subtractive and analytical tools from any Internet connected device. Franklin can be set up and controlled entirely from a web interface; it uses a custom protocol which allows it to continue printing when the connection is temporarily lost, and allows communication with scripts.
Integrated Voltage—Current Monitoring And Control Of Gas Metal Arc Weld Magnetic Ball-Jointed Open Source 3-D Printer, Yuenyong Nilsiam, Amberlee S. Haselhuhn, Bas Wijnen, Paul G. Sanders, Joshua M. Pearce
Integrated Voltage—Current Monitoring And Control Of Gas Metal Arc Weld Magnetic Ball-Jointed Open Source 3-D Printer, Yuenyong Nilsiam, Amberlee S. Haselhuhn, Bas Wijnen, Paul G. Sanders, Joshua M. Pearce
Joshua M. Pearce
To provide process optimization of metal fabricating self-replicating rapid prototyper (RepRap) 3-D printers requires a low-cost sensor and data logger system to measure current (I) and voltage (V) of the gas metal arc welders (GMAW). This paper builds on previous open-source hardware development to provide a real-time measurement of welder I-V where the measuring circuit is connected to two analog inputs of the Arduino that is used to control the 3-D printer itself. Franklin firmware accessed through a web interface that is used to control the printer allows storing the measured values and downloading those stored readings to the user’s …
Low-Cost Open-Source Voltage And Current Monitor For Gas Metal Arc Weld 3d Printing, Anthony Pinar, Bas Wijnen, Gerald C. Anzalone, Timothy C. Havens, Paul G. Sanders, Joshua M. Pearce
Low-Cost Open-Source Voltage And Current Monitor For Gas Metal Arc Weld 3d Printing, Anthony Pinar, Bas Wijnen, Gerald C. Anzalone, Timothy C. Havens, Paul G. Sanders, Joshua M. Pearce
Joshua M. Pearce
Arduino open-source microcontrollers are well known in sensor applications for scientific equipment and for controlling RepRap 3D printers. Recently low-cost open-source gas metal arc weld (GMAW) RepRap 3D printers have been developed. The entry-level welders used have minimal controls and therefore lack any real-time measurement of welder voltage or current. The preliminary work on process optimization of GMAW 3D printers requires a low-cost sensor and data logger system to measure welder current and voltage. This paper reports on the development of a low-cost open-source power measurement sensor system based on Arduino architecture. The sensor system was designed, built, and tested …
Emergence Of Home Manufacturing In The Developed World: Return On Investment For Open-Source 3-D Printers., Emily E. Petersen, Joshua M. Pearce
Emergence Of Home Manufacturing In The Developed World: Return On Investment For Open-Source 3-D Printers., Emily E. Petersen, Joshua M. Pearce
Joshua M. Pearce
Through reduced 3-D printer cost, increased usability, and greater material selection, additive manufacturing has transitioned from business manufacturing to the average prosumer. This study serves as a representative model for the potential future of 3-D printing in the average American household by employing a printer operator who was relatively unfamiliar with 3-D printing and the 3-D design files of common items normally purchased by the average consumer. Twenty-six items were printed in thermoplastic and a cost analysis was performed through comparison to comparable, commercially available products at a low and high price range. When compared to the low-cost items, investment …
Open-Source 3-D Printing Technologies For Education: Bringing Additive Manufacturing To The Classroom, Chelsea Schelly, Gerald C. Anzalone, Bas Wijnen, Joshua M. Pearce
Open-Source 3-D Printing Technologies For Education: Bringing Additive Manufacturing To The Classroom, Chelsea Schelly, Gerald C. Anzalone, Bas Wijnen, Joshua M. Pearce
Joshua M. Pearce
Objective 3-D printing technologies have the potential to improve both Science, Technology, Engineering, and Mathematics (STEM) education and Career and Technical Education (CTE), as well as integrating these two educational emphases and providing opportunities for cross-curriculum engagement. The objective of this study is to investigate the potential of open-source (OS) technologies in an educational setting, given the combination of economic constraints affecting all educational environments and the ability of OS design to profoundly decrease the cost of technological tools and technological innovation. Methods This paper reports on a 3-day workshop augmented with online instructional and visual tools designed for middle …
Evaluation Of Potential Fair Trade Standards For An Ethical 3-D Printing Filament, Savanna R. Feeley, Bas Wijnen, Joshua M. Pearce
Evaluation Of Potential Fair Trade Standards For An Ethical 3-D Printing Filament, Savanna R. Feeley, Bas Wijnen, Joshua M. Pearce
Joshua M. Pearce
Following the rapid rise of distributed additive manufacturing with 3-D printing has come the technical development of filament extruders and recyclebots, which can turn both virgin polymer pellets and post-consumer shredded plastic into 3-D filament. Similar to the solutions proposed for other forms of ethical manufacturing, it is possible to consider a form of ethical 3-D printer filament distribution being developed. There is a market opportunity for producing this ethical 3-D printer filament, which is addressed in this paper by developing an “ethical product standard” for 3-D filament based upon a combination of existing fair-trade standards and technical and life …
Polymer Recycling Codes For Distributed Manufacturing With 3-D Printers, Emily J. Hunt, Chenlong Zhang, Nicholas C. Anzalone, Joshua M. Pearce
Polymer Recycling Codes For Distributed Manufacturing With 3-D Printers, Emily J. Hunt, Chenlong Zhang, Nicholas C. Anzalone, Joshua M. Pearce
Joshua M. Pearce
With the aggressive cost reductions for 3-D printing made available by the open-source self-replicating rapid prototypers (RepRaps) the economic advantage of custom distributed manufacturing has become substantial. In addition, the number of free designs is growing exponentially and the development and commercialization of the recyclebot (plastic extruders that fabricate 3-D printing filament from recycled or virgin materials) have greatly improved the material selection available for prosumer 3-D printer operators. These trends indicate that more individuals will manufacturer their own polymer products, however, there is a risk that an even larger fraction of polymer waste will not be recycled because it …
Reversing The Trend Of Large Scale And Centralization In Manufacturing: The Case Of Distributed Manufacturing Of Customizable 3-D-Printable Self-Adjustable Glasses, Jephias Gwamuri, Ben T. Wittbrodt, Nick C. Anzalone, Joshua M. Pearce
Reversing The Trend Of Large Scale And Centralization In Manufacturing: The Case Of Distributed Manufacturing Of Customizable 3-D-Printable Self-Adjustable Glasses, Jephias Gwamuri, Ben T. Wittbrodt, Nick C. Anzalone, Joshua M. Pearce
Joshua M. Pearce
Although the trend in manufacturing has been towards centralization to leverage economies of scale, the recent rapid technical development of open-source 3-D printers enables low-cost distributed bespoke production. This paper explores the potential advantages of a distributed manufacturing model of high-value products by investigating the application of 3-D printing to self-refraction eyeglasses. A series of parametric 3-D printable designs is developed, fabricated and tested to overcome limitations identified with mass-manufactured self-correcting eyeglasses designed for the developing world's poor. By utilizing 3-D printable self-adjustable glasses, communities not only gain access to far more diversity in product design, as the glasses can …
Life-Cycle Economic Analysis Of Distributed Manufacturing With Open-Source 3-D Printers, Ben T. Wittbrodt, A. G. Glover, J. Laureto, G. C. Anzalone, D. Oppliger, J. L. Irwin, Joshua M. Pearce
Life-Cycle Economic Analysis Of Distributed Manufacturing With Open-Source 3-D Printers, Ben T. Wittbrodt, A. G. Glover, J. Laureto, G. C. Anzalone, D. Oppliger, J. L. Irwin, Joshua M. Pearce
Joshua M. Pearce
The recent development of open-source 3-D printers makes scaling of distributed additive-based manufacturing of high-value objects technically feasible and offers the potential for widespread proliferation of mechatronics education and participation. These self-replicating rapid prototypers (RepRaps) can manufacture approximately half of their own parts from sequential fused deposition of polymer feedstocks. RepRaps have been demonstrated for conventional prototyping and engineering, customizing scientific equipment, and appropriate technology-related manufacturing for sustainable development. However, in order for this technology to proliferate like 2-D electronic printers have, it must be economically viable for a typical household. This study reports on the life-cycle economic analysis (LCEA) …
Applications Of Open Source 3-D Printing On Small Farms, Joshua M. Pearce
Applications Of Open Source 3-D Printing On Small Farms, Joshua M. Pearce
Joshua M. Pearce
There is growing evidence that low-cost open-source 3-D printers can reduce costs by enabling distributed manufacturing of substitutes for both specialty equipment and conventional mass-manufactured products. The rate of 3-D printable designs under open licenses is growing exponentially and there arealready hundreds of designs applicable to small-scale organic farming. It has also been hypothesized that this technology could assist sustainable development in rural communities that rely on small-scale organic agriculture. To gauge the present utility of open-source 3-D printers in this organic farm context both in the developed and developing world, this paper reviews the current open-source designs available and …
In Situ Formation Of Substrate Release Mechanisms For Gas Metal Arc Weld Metal 3-D Printing, Amberlee S. Haselhuhn, Bas Wijnen, Gerald C. Anzalone, Paul G. Sanders, Joshua M. Pearce
In Situ Formation Of Substrate Release Mechanisms For Gas Metal Arc Weld Metal 3-D Printing, Amberlee S. Haselhuhn, Bas Wijnen, Gerald C. Anzalone, Paul G. Sanders, Joshua M. Pearce
Joshua M. Pearce
This study provides an in-depth investigation into low-cost and no-cost substrate release mechanisms that allow gas metal arc weld 3-D printed ER4043 aluminum and ER70S-6 steel parts to be removed from a reusable print substrate with minimal energy. Aluminum oxide, boron nitride, and titanium nitride coatings were evaluated as possible substrate release agents for aluminum printing. Additionally, the in situ formation of substrate release agents such as intermetallics and oxides were tested for both aluminum and steel printing. Testing was performed with a modified Charpy impact tester to remove 3-D printed metal parts from an 1100 aluminum or A36 low …