Product Designer
TOOL CHANGING 3D PRINTER
In Spring 2020, I completed my BS in Industrial Design at DAAP, and this project was my undergraduate thesis. It's a culmination of all of the skills and experience I've gained through five semesters of co-op, which includes a year of experience in the 3D printing industry. This project received an IDSA Student Merit Award during the 2020 DAAPworks.
The Tool Changing 3D Printer utilizes open-source tech and development to create a multi-material printing solution for the home or office. My passion for 3D printing inspired me to tackle the challenge of creating an MVP around the new technology and motion system architecture.
This 3D printer is for makers, designers, and engineers who want the capability to create objects and parts that were previously unattainable. It provides a true multi-material FDM 3D printing solution, achieved by using multiple kinematically coupled extruder assemblies in a process similar to a tool changing CNC machine.
"IT'S THE NEXT STEP IN FDM PRINTING"
Multi-tool FDM printing comes with more complex systems and features than a standard FDM 3D printer, requiring new solutions and innovations to create a machine that is ready for both professional and hobbyist users.
DESIGNED FOR MANUFACTURE
Borrowing from the ideas of other printers on the market, the design of the printer enclosure puts practicality first. Informed by user feedback, the enclosure is simple, robust, and serviceable.
EXPANDABILITY
The construction and format of the printer enclosure allows for expandability as the technology of tool-changing 3D printing develops. The architecture allows for upgradability and new features, as well as providing a robust and versatile base for future development.
USER-CENTERED DESIGN
Thoughtfully applied automated processes allow for a better user experience. Mesh bed leveling not only provides for a more accurate print surface, but also creates cost savings. Automatic software compensation accommodates for any inaccuracies in parts and assembly, allowing for manufacture and maintenance without sacrificing performance.
SPECIALIZED MOTIONS SYSTEM
The "Core-XY" movement provides for relatively simple motion system conducive with tool changing. The nature of the movement in the X and Y axes provides for a very simple tool mounting interface, and also accommodates standard extruder assemblies.
FILAMENT STORAGE
Filament is stored in the warm, dry enclosure, utilizing radiant heat from the printing process to keep the filament conditioned while in use. This eliminates the need for a separate maintainer unit during printing. By utilizing the empty space in the enclosure, the overall size of the unit is decreased.
HOT-SWAPPABLE TOOLS
By using a proprietary BUS connector to transmit data and power to the extruder, tool heads can be interchanged quickly and easily with just a single connector.
MODULAR TOOLS
For the purposes of the project, I focused on the development of an extruder and nozzle assembly for 3D printing as the primary tool. However, with a robust coupling and mounting system, there is opportunity for expanding into rapid prototyping tools beyond 3D printing (laser engraver, syringe, spindle, plotter, etc.)
OPEN-SOURCE COMPONENTS
The 3D print head assembly is designed around the popular and practically universal E3D V6 Hotend. Capable of printing at high temperature, this nozzle checks all the boxes.
Extrusion is handled by the BondTech BMG Extruder, making the tool direct-drive, and capable of printing flexible materials.
HIGH-TEMP PRINTING
High Temperature materials such as PEAK, PEKK, and composites require a heat resistant enclosure. The print head enclosure is designed in such a way that, when cast or machined from aluminum, the mounting plate provides base that will remain rigid and repeatable at temperatures in excess of 450C.
