Digital Commons Network^™

Surface Plasmon Induced Enhancement In Selective Laser Melting Processes, Dentcho A. Genov, Raj K. Vinnakota

Dentcho Genov

Patent Enforcement In Cyberterritories, Daniel Harris Brean

Daniel Harris Brean

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 …

Impact Of Diy Home Manufacturing With 3d Printing On The Toy And Game Market, Emily Peterson, Joshua M. Pearce

Joshua M. Pearce

The 2020 toy and game market is projected to be US$135 billion. To determine if 3D printing could affect these markets if consumers offset purchases by 3D printing free designs, this study investigates the 100 most popular downloaded designs at MyMiniFactory in a month. Savings are quantified for using a Lulzbot Mini 3D printer and three filament types: commercial filament, pellet-extruded filament, and post-consumer waste converted to filament with a recyclebot. Case studies probed the quality of: (1) six common complex toys; (2) Lego blocks; and (3) the customizability of open source board games. All filaments analyzed saved the user …

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

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 …

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

Paul Sanders

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 …

Open Source Laser Polymer Welding System: Design And Characterization Of Linear Low-Density Polyethylene Multilayer Welds, John Laureto, Serguei V. Dessiatoun, Michael M. Ohadi, Joshua M. Pearce

Joshua M. Pearce

The use of lasers to weld polymer sheets provides a means of highly-adaptive and custom additive manufacturing for a wide array of industrial, medical, and end user/consumer applications. This paper provides an open source design for a laser polymer welding system, which can be fabricated with low-cost fused filament fabrication and off-the-shelf mechanical and electrical parts. The system is controlled with free and open source software and firmware. The operation of the machine is validated and the performance of the system is quantified for the mechanical properties (peak load) and weld width of linear low density polyethylene (LLDPE) lap welds …

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 …

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 …

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 …