Materials Science and Engineering Commons^™

Could 79 People Solarize The U.S. Electric Grid?, Joshua M. Pearce, Emily Prehoda

Department of Materials Science and Engineering Publications

Although wealth inequality has many established negatives, this study investigates a potential positive, unprecedented wealth concentration makes it possible for solutions to large and seemingly intractable problems to be deployed by convincing a relatively small number of individuals to invest. In order to probe this potential outcome of inequality, this study quantifies the number of people necessary to radically reduce the greenhouse gas emissions responsible for global climate destabilization from the U.S. electric grid, which is one of the largest sources of emissions. Specifically, this study determined that 1544 GW of solar photovoltaic (PV) technology must be deployed to eliminate …

Economic Potential For Distributed Manufacturing Of Adaptive Aids For Arthritis Patients N The U.S., Nicole Gallup, Jennifer Bow, Joshua M. Pearce

Department of Materials Science and Engineering Publications

By 2040, more than a quarter of the U.S. population will have diagnosed arthritic conditions. Adults with arthritis and other rheumatic conditions earn less than average yet have medical care expenditures that are over 12% of average household income. Adaptive aids can help arthritis patients continue to maintain independence and quality of life; however, their high costs limit accessibility for older people and the poor. One method used for consumer price reduction is distributed manufacturing with 3-D printers. In order to assess if such a method would be financially beneficial, this study evaluates the techno-economic viability of distributed manufacturing of …

Micronutrient Availability In Alternative Foods During Agricultural Catastrophes, David C. Denkenberger, Joshua M. Pearce

Department of Materials Science and Engineering Publications

Several catastrophes could block the sun, including asteroid/comet impact, super volcanic eruption, and nuclear war with the burning of cities (nuclear winter). Previous work has analyzed alternate food supplies (e.g., mushrooms growing on dead trees, bacteria growing on natural gas). This was shown to be technically capable of feeding everyone with macronutrients (protein, carbohydrates, and lipids) and minerals, although economics and politics remain uncertain. The present work analyzes vitamin availability in such alternative food scenarios. The vitamin content of various alternate foods is compared to the US recommended daily allowance (RDA) as well as the average requirement defined by the …

Open Source Low-Cost Power Monitoring System, Shane W. Oberloier, Joshua M. Pearce

Department of Materials Science and Engineering Publications

This study presents an entirely open-source, low-cost power monitoring system capable of many types of measurements including both loads and supplies such as solar photovoltaic systems. In addition, the system can be fabricated using only open source software and hardware. The design revolves around the Digital Universal Energy Logger (DUEL) Node, which is responsible for reading and properly scaling the voltage and current of a particular load, and then serializing it via an on-board ATTiny85 chip. The configuration of the DUEL node allows for custom sensitivity ranges, and can handle up to 50 A and 300 V. Up to 127 …

Approaches To Open Source 3-D Printable Probe Positioners And Micromanipulators For Probe Stations, Iiro Hietanen, Ismo T. S. Heikkinen, Hele Savin, Joshua M. Pearce

Department of Materials Science and Engineering Publications

Three types of highly-customizable open source probe positioning systems are evaluated: (a) mostly 3-D printed, (b) partially printed using OpenBeam kinematic constraints, and (c) a 3-level stack of low-cost commercial single axis micropositioners and some printed parts. All systems use digital distributed manufacturing to enable bespoke features, which can be fabricated with RepRap-class 3-D printer and easily accessible components. They are all flexible in material choice for custom components. The micropositioners can be set up for left-right use and flat or recessed configurations using either mechanical or magnetic mounting. All systems use a manual probe holder that can be customized …

Belt-Driven Open Source Circuit Mill Using Low-Cost 3-D Printer Components, Shane W. Oberloier, Joshua M. Pearce

Department of Materials Science and Engineering Publications

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 …

Economic Advantages Of Dry-Etched Black Silicon In Passivated Emitter Rear Cell (Perc) Photovoltaic Manufacturing, Chiara Modanese, Hannu S. Laine, Toni P. Pasanen, Hele Savin, Joshua M. Pearce

Department of Materials Science and Engineering Publications

Industrial Czochralski silicon (Cz-Si) photovoltaic (PV) efficiencies have routinely reached >20% with the passivated emitter rear cell (PERC) design. Nanostructuring silicon (black-Si) by dry-etching decreases surface reflectance, allows diamond saw wafering, enhances metal gettering, and may prevent power conversion efficiency degradation under light exposure. Black-Si allows a potential for >20% PERC cells using cheaper multicrystalline silicon (mc-Si) materials, although dry-etching is widely considered too expensive for industrial application. This study analyzes this economic potential by comparing costs of standard texturized Cz-Si and black mc-Si PERC cells. Manufacturing sequences are divided into steps, and costs per unit power are individually calculated …

Fused Particle Fabrication 3-D Printing: Recycled Materials’ Optimization And Mechanical Properties, Aubrey Woern, Dennis Byard, Robert B. Oakley, Matthew J. Fiedler, Samantha Snabes, Joshua M. Pearce

Department of Materials Science and Engineering Publications

Fused particle fabrication (FPF) (or fused granular fabrication (FGF)) has potential for increasing recycled polymers in 3-D printing. Here, the open source Gigabot X is used to develop a new method to optimize FPF/FGF for recycled materials. Virgin polylactic acid (PLA) pellets and prints were analyzed and were then compared to four recycled polymers including the two most popular printing materials (PLA and acrylonitrile butadiene styrene (ABS)) as well as the two most common waste plastics (polyethylene terephthalate (PET) and polypropylene (PP)). The size characteristics of the various materials were quantified using digital image processing. Then, power and nozzle velocity …

A National Pragmatic Safety Limit For Nuclear Weapon Quantities, Joshua M. Pearce, David C. Denkenberger

Department of Materials Science and Engineering Publications

This study determines the nuclear pragmatic limit where the direct physical negative consequences of nuclear weapons use are counter to national interests, by assuming all unknowns are conservatively optimistic. The only effect considered is nuclear winter (“nuclear autumn” in the low weapons limits) and the resultant effects on the aggressor nation. First, the ability of low nuclear weapon limits is probed for maintaining deterrence in the worst-case scenario of attacking the most-populous nation. Second, the ability of aggressor nations to feed themselves is assessed without trade and industry resultant from a nuclear attack causing “nuclear autumn” (10% global agricultural shortfall). …

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

Department of Materials Science and Engineering Publications

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 …

Design Optimization Of Polymer Heat Exchanger For Automated Household-Scale Solar Water Pasteurizer, David C. Denkenberger, Joshua M. Pearce

Department of Materials Science and Engineering Publications

A promising approach to reducing the >870,000 deaths/year globally from unsafe water is flow-through solar water pasteurization systems (SWPs). Unfortunately, demonstrated systems have high capital costs, which limits access for the poor. The most expensive component of such systems is the heat exchanger (HX). Thus, this study focuses on cost optimization of HX designs for flow-through SWPs using high-effectiveness polymer microchannel HXs. The theoretical foundation for the cost optimization of a polymer microchannel HX is provided, and outputs are plotted in order to provide guidelines for designers to perform HX optimizations. These plots are used in two case studies: (1) …

Applications Of Open Source Gmaw-Based Metal 3-D Printing, Yuenyong Nilsiam, Paul G. Sanders, Joshua M. Pearce

Department of Materials Science and Engineering Publications

The metal 3-D printing market is currently dominated by high-end applications, which make it inaccessible for small and medium enterprises, fab labs, and individual makers who are interested in the ability to prototype and additively manufacture final products in metal. Recent progress led to low-cost open-source metal 3-D printers using a gas metal arc welding (GMAW)-based print head. This reduced the cost of metal 3-D printers into the range of desktop prosumer polymer 3-D printers. Consequent research established good material properties of metal 3-D printed parts with readily-available weld filler wire, reusable substrates, thermal and stress properties, toolpath planning, bead-width …

Development Of A Resilient 3-D Printer For Humanitarian Crisis Response, Benjamin L. Savonen, Tobias Mahan, Maxwell W. Curtis, Jared W. Schreier, John K. Greshonen, Joshua M. Pearce

Department of Materials Science and Engineering Publications

Rapid manufacturing using 3-D printing is a potential solution to some of the most pressing issues for humanitarian logistics. In this paper, findings are reported from a study that involved development of a new type of 3-D printer. In particular, a novel 3-D printer that is designed specifically for reliable rapid manufacturing at the sites of humanitarian crises. First, required capabilities are developed with design elements of a humanitarian 3-D printer, which include, (1) fused filament fabrication, (2) open source self-replicating rapid prototyper design, (3) modular, (4) separate frame, (5) protected electronics, (6) on-board computing, (7) flexible power supply, and …

Open Source 3d Printers: An Appropriate Technology For Building Low Cost Optics Labs For The Developing Communities, Jephias Gwamuri, Joshua M. Pearce

Department of Materials Science and Engineering Publications

The recent introduction of RepRap (self-replicating rapid prototyper) 3-D printers and the resultant open source technological improvements have resulted in affordable 3-D printing, enabling low-cost distributed manufacturing for individuals. This development and others such as the rise of open source-appropriate technology (OSAT) and solar powered 3-D printing are moving 3-D printing from an industry based technology to one that could be used in the developing world for sustainable development. In this paper, we explore some specific technological improvements and how distributed manufacturing with open-source 3-D printing can be used to provide open-source 3-D printable optics components for developing world communities …

General Design Procedures For Airport-Based Solar Photovoltaic Systems, Anurag Anurag, Jiemin Zhang, Jephias Gwamuri, Joshua M. Pearce

Department of Materials Science and Engineering Publications

A source of large surface areas for solar photovoltaic (PV) farms that has been largely overlooked in the 13,000 United States of America (U.S.) airports. This paper hopes to enable PV deployments in most airports by providing an approach to overcome the three primary challenges identified by the Federal Aviation Administration (FAA): (1) reflectivity and glare; (2) radar interference; and (3) physical penetration of airspace. First, these challenges and precautions that must be adhered to for safe PV projects deployment at airports are reviewed and summarized. Since one of the core concerns for PV and airport symbiosis is solar panel …

Fabricating Ordered 2-D Nano-Structured Arrays Using Nanosphere Lithography, Chenlong Zhang, Sandra Cvetanovic, Joshua M. Pearce

Department of Materials Science and Engineering Publications

Recent advances in the use of plasmonic metamaterials to improve absorption of light in thin-film solar photovoltaic devices has created a demand for a scalable method of patterning large areas with metal nanostructures deposited in an ordered array. This article describes two methods of fabricating ordered 2D nanosphere colloidal films: spin coating and interface coating. The two methods are compared and parameter optimization discussed. The study reveals that:

• For smaller nanosphere sizes, spin coating is more favorable, while for larger nanospheres, the angled interface coating provides more coverage and uniformity.

• A surfactant-free approach for interface coating is developed …

3-D Printing Open-Source Click-Muac Bands For Identification Of Malnutrition, Ross Michaels, Joshua M. Pearce

Department of Materials Science and Engineering Publications

No abstract provided.

Emerging Business Models For Open Source Hardware, Joshua M. Pearce

Department of Materials Science and Engineering Publications

The rise of Free and Open Source models for software development has catalyzed the growth of Free and Open Source hardware (also known as “Libre Hardware”). Libre Hardware is gaining significant traction in the scientific hardware community, where there is evidence that open development creates both technically superior and far less expensive scientific equipment than proprietary models. In this article, the evidence is reviewed and a collection of examples of business models is developed to service scientists who have the option to manufacture their own equipment using Open Source designs. Profitable Libre Hardware business models are reviewed, which includes kit, …

Emergence Of Home Manufacturing In The Developed World: Return On Investment For Open-Source 3-D Printers., Emily E. Petersen, Joshua M. Pearce

Department of Materials Science and Engineering Publications

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 Automated Mapping Four-Point Probe, Handy Chandra, Spencer W. Allen, Shane W. Oberloier, Nupur Bihari, Jephias Gwamuri, Joshua M. Pearce

Department of Materials Science and Engineering Publications

Scientists have begun using self-replicating rapid prototyper (RepRap) 3-D printers to manufacture open source digital designs of scientific equipment. This approach is refined here to develop a novel instrument capable of performing automated large-area four-point probe measurements. The designs for conversion of a RepRap 3-D printer to a 2-D open source four-point probe (OS4PP) measurement device are detailed for the mechanical and electrical systems. Free and open source software and firmware are developed to operate the tool. The OS4PP was validated against a wide range of discrete resistors and indium tin oxide (ITO) samples of different thicknesses both pre- and …

Open Source Database And Website To Provide Free And Open Access To Inactive U.S. Patents In The Public Domain, Yuenyong Nilsiam, Joshua M. Pearce

Department of Materials Science and Engineering Publications

Although theoretically the patent system is meant to bolster innovation, the current United States Patent and Trademark Office (USPTO) is cumbersome and involves a significant time investment to locate inactive patents less than 20 years old. This article reports on the development of an open source database to find these public domain ideas. First, a search strategy is explained. Then the operation and use of free and open source software are detailed to meet the needs of open hardware innovators. Finally, a case study is presented to demonstrate the utility of the approach with 3-D printing. The results showed how …

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

Department of Materials Science and Engineering Publications

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 …

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

Department of Materials Science and Engineering Publications

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.

Influence Of Oxygen Concentration On The Performance Of Ultra-Thin Rf Magnetron Sputter Deposited Indium Tin Oxide Films As A Top Electrode For Photovoltaic Devices, Jephias Gwamuri, Murugesan Marikkannan, J. Mayandi, Patrick Bowen, Joshua M. Pearce

Department of Materials Science and Engineering Publications

The opportunity for substantial efficiency enhancements of thin film hydrogenated amorphous silicon (a-Si:H) solar photovoltaic (PV) cells using plasmonic absorbers requires ultra-thin transparent conducting oxide top electrodes with low resistivity and high transmittances in the visible range of the electromagnetic spectrum. Fabricating ultra-thin indium tin oxide (ITO) films (sub-50 nm) using conventional methods has presented a number of challenges; however, a novel method involving chemical shaving of thicker (greater than 80 nm) RF sputter deposited high-quality ITO films has been demonstrated. This study investigates the effect of oxygen concentration on the etch rates of RF sputter deposited ITO films to …

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

Department of Materials Science and Engineering Publications

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 …

Controlling Optical Absorption In Metamaterial Absorbers For Plasmonic Solar Cells, Wyatt Adams, Ankit Vora, Jephias Gwamuri, Joshua M. Pearce, Durdo O. Guney

Department of Materials Science and Engineering Publications

Metals in the plasmonic metamaterial absorbers for photovoltaics constitute undesired resistive heating. However, tailoring the geometric skin depth of metals can minimize resistive losses while maximizing the optical absorbance in the active semiconductors of the photovoltaic device. Considering experimental permittivity data for InxGa1-xN, absorbance in the semiconductor layers of the photovoltaic device can reach above 90%. The results here also provides guidance to compare the performance of different semiconductor materials. This skin depth engineering approach can also be applied to other optoelectronic devices, where optimizing the device performance demands minimizing resistive losses and power consumption, such as photodetectors, laser diodes, …

Open-Source Photometric System For Enzymatic Nitrate Quantification, Ben T. Wittbrodt, D. A. Squires, J. Walbeck, E. Campbell, W. H. Campbell, Joshua M. Pearce

Department of Materials Science and Engineering Publications

Nitrate, the most oxidized form of nitrogen, is regulated to protect people and animals from harmful levels as there is a large over abundance due to anthropogenic factors. Widespread field testing for nitrate could begin to address the nitrate pollution problem, however, the Cadmium Reduction Method, the leading certified method to detect and quantify nitrate, demands the use of a toxic heavy metal. An alternative, the recently proposed Environmental Protection Agency Nitrate Reductase Nitrate-Nitrogen Analysis Method, eliminates this problem but requires an expensive proprietary spectrophotometer. The development of an inexpensive portable, handheld photometer will greatly expedite field nitrate analysis to …

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

Department of Materials Science and Engineering Publications

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 …

Open-Source Syringe Pump Library, Bas Wijnen, Emily J. Hunt, Gerald C. Anzalone, Joshua M. Pearce

Department of Materials Science and Engineering Publications

This article explores a new open-source method for developing and manufacturing high-quality scientific equipment suitable for use in virtually any laboratory. A syringe pump was designed using freely available open-source computer aided design (CAD) software and manufactured using an open-source RepRap 3-D printer and readily available parts. The design, bill of materials and assembly instructions are globally available to anyone wishing to use them. Details are provided covering the use of the CAD software and the RepRap 3-D printer. The use of an open-source Rasberry Pi computer as a wireless control device is also illustrated. Performance of the syringe pump …

Mechanical Properties Of Components Fabricated With Open-Source 3-D Printers Under Realistic Environmental Conditions, B. M. Tymrak, M Kreiger, Joshua M. Pearce

Department of Materials Science and Engineering Publications

he recent development of the RepRap, an open-source self-replicating rapid prototyper, has made 3-D polymer-based printers readily available to the public at low costs ( < $500). The resultant uptake of 3-D printing technology enables for the first time mass-scale distributed digital manufacturing. RepRap variants currently fabricate objects primarily from acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA), which have melting temperatures low enough to use in melt extrusion outside of a dedicated facility, while high enough for prints to retain their shape at average use temperatures. In order for RepRap printed parts to be useful for engineering applications the mechanical properties of printed parts must be known. This study quantifies the basic tensile strength and elastic modulus of printed components using realistic environmental conditions for standard users of a selection of open-source 3-D printers. The results find average tensile strengths of 28.5 MPa for ABS and 56.6 MPa for PLA with average elastic moduli of 1807 MPa for ABS and 3368 MPa for PLA. It is clear from these results that parts printed from tuned, low-cost, open-source RepRap 3-D printers can be considered as mechanically functional in tensile applications as those from commercial vendors.