Engineering Commons^™

General Design Procedure For Free And Open-Source Hardware For Scientific Equipment, Shane W. Oberloier, Joshua M. Pearce

Department of Materials Science and Engineering Publications

Distributed digital manufacturing of free and open-source scientific hardware (FOSH) used for scientific experiments has been shown to in general reduce the costs of scientific hardware by 90–99%. In part due to these cost savings, the manufacturing of scientific equipment is beginning to move away from a central paradigm of purchasing proprietary equipment to one in which scientists themselves download open-source designs, fabricate components with digital manufacturing technology, and then assemble the equipment themselves. This trend introduces a need for new formal design procedures that designers can follow when targeting this scientific audience. This study provides five steps in the …

Design Of Post-Consumer Modification Of Standard Solar Modules To Form Large-Area Building-Integrated Photovoltaic Roof Slates, Joshua M. Pearce, Jay Meldrum, Nolan Osborne

Department of Materials Science and Engineering Publications

Building-integrated photovoltaic (BIPV) systems have improved aesthetics but generally cost far more than conventional PV systems because of small manufacturing scale. Thus, in the short and medium term, there is a need for a BIPV mounting system that utilizes conventional modules. Such a design is provided here with a novel modification of conventional photovoltaic (PV) modules to allow them to act as BIPV roofing slates. The open-source designs for the mechanical components necessary to provide the post-consumer conversion for a conventional PV module are provided, and prototypes are fabricated and installed on a mock roof system along with control modules …

Distributed Manufacturing Of Flexible Products: Technical Feasibility And Economic Viability, Aubrey Woern, Joshua M. Pearce

Department of Materials Science and Engineering Publications

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 …

Ambiance-Dependent Agglomeration And Surface-Enhanced Raman Spectroscopy Response Of Self-Assembled Silver Nanoparticles For Plasmonic Photovoltaic Devices, Jephias Gwamuri, Ragavendran Venkatesan, Mehdi Sadatgol, Jeyanthinath Mayandi, Durdo O. Guney, Joshua M. Pearce

Department of Materials Science and Engineering Publications

The agglomeration/dewetting process of thin silver films provides a scalable method of obtaining self-assembled nanoparticles (SANPs) for plasmonics-based thin-film solar photovoltaic (PV) devices. We show the effect of annealing ambiance on silver SANP average size, particle/cluster finite shape, substrate area coverage/particle distribution, and how these physical parameters influence optical properties and surface-enhanced Raman scattering (SERS) responses of SANPs. Statistical analysis performed indicates that generally Ag SANPs processed in the presence of a gas (argon and nitrogen) ambiance tend to have smaller average size particles compared to those processed under vacuum. Optical properties are observed to be highly dependent on particle …

Open Source 3-D Printed Nutating Mixer, Dhwani K. Trivedi, Joshua M. Pearce

Department of Materials Science and Engineering Publications

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 …

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 …

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

Department of Materials Science and Engineering Publications

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 …

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 …

Three Hundred And Sixty Degree Real-Time Monitoring Of 3-D Printing Using Computer Analysis Of Two Camera Views, Siranee Nuchitprasitchai, Michael C. Roggemann, Joshua M. Pearce

Department of Materials Science and Engineering Publications

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 …

Free And Open Source 3-D Model Customizer For Websites To Democratize Design With Openscad, Yuenyong Nilsiam, Joshua M. Pearce

Department of Materials Science and Engineering Publications

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

Department of Materials Science and Engineering Publications

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 Multi-Head 3d Printer For Polymer-Metal Composite Component Manufacturing, J. Laureto, Joshua M. Pearce

Department of Materials Science and Engineering Publications

As low-cost desktop 3D printing is now dominated by free and open source self-replicating rapid prototype (RepRap) derivatives, there is an intense interest in extending the scope of potential applications to manufacturing. This study describes a manufacturing technology that enables a constrained set of polymer-metal composite components. This paper provides (1) free and open source hardware and (2) software for printing systems that achieves metal wire embedment into a polymer matrix 3D-printed part via a novel weaving and wrapping method using (3) OpenSCAD and parametric coding for customized g-code commands. Composite parts are evaluated from the technical viability of manufacturing …

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 …