Open Source Microfactory Boot Camp

Narrative

3D printing and open source micromanufacturing, in its infancy, has great potential for distributing production. We start with a 3D printer, learn how to build one, and set up an online printing service for producing parts. In order to expand our enterprise - and enable the printing of large objects at low cost - we diversify into producing 3D printing filament from scrap plastic. We grind down scrap plastic, extrude it into 3D printing filament with our filament maker, and then wind it onto spools with the filament winder. Produced at a cost of only 10 cents per lb - we have inexpensive 3D printing filament that is almost free. So we can run an online 3D printing service successfully. But can we then develop high value products that are competitive with standard consumer goods? That is our goal. So we collaborate on the Open Source Everything Store, where we design a whole catalogue of products that compete with Amazon and Walmart - but are designed and produced locally. Household consumer goods total a $20T global market - so the pie is large and there is plenty of room for collaboration. It turns out that with 3D printing, a CNC Circuit Mill, and a small laser cutter/engraver - and a bunch of readily available, off-the-shelf parts - we can produce a whole range of useful products, and thus begin to effect manufacturing. We are excited, and want to spread the word. So we run public workshops teaching people to build these machines, and to design products that can be made with these machines - using a completely open source toolchain. We take this to our local libraries, schools, events - and involve thousands of people in collaborative product design. We teach them massive parallel swarm-based development techniques - and every child and grandmother begin designing their own products. The depth of local manufacturing increases - and people begin making more of the parts that would normally be purchased - such as motors and power supplies. We change the face of manufacturing...

That is the narrative we'd like to see happen, and the 1 week OSE Boot Camp is an introduction to how to do this in practice. We not only show you how to build the tools - but how to leverage massive collaborative design processes - so that we democratize product development and make it a bit more responsible. Perhaps the greatest single impact is environmental - as people learn to build their products - they also know how to fix them - as they are open source and made from widely available resources that are part of a circular economy.

Schedule

Day 1 - Intro + 3D Printer

Morning -

• 1 hr - Theory - introductions and OSE introduction
• 1 hr - Practice - FreeCAD - designing parts from sketches
• 1 hr - Theory - How to Design a 3D Printer
• 1 hr - Practice - Building a 3D Printer

afternoon -

• 4-6 hours - Building a 3D printer from scratch

Day 2 - 3D Print Cluster + Filament Maker

Morning

• 1 hr - Theory - How to Set up a Print Cluster Server with Octoprint
• 1 hr - Practice - Connecting a cluster and doing a mass print job
• 1 hr - Theory - Filament Maker. How to design Heating Systems for the 3D printing ecosystem - power supplies, heated beds, extruder heaters, heated build chambers, filament makers. Insulation, cooling, mechanics, power calculations for scalability.
• 1 hr - Practice - Cranking out filament from scrap plastic (not commercial pellets)

Afternoon

• 1 hr - Theory - How to build and use a filament width sensor
• 1 hr - Practice - Printing with Home Made Filament
• 1 hr - Theory - Ordering parts for the 3D Printer and CNC Circuit Mill
• 1 hr - Practice - Setting up an Online 3D Printing Service.

Day 3 - Ciruit Mill + Electronics

Morning

• 1 hr - Practice - KiCAD - from basics to using part libraries and design
• 1 hr - Theory and Practice - CNC Circuit Mill Design Guide + design with FreeCAD Part Library
• 1 hr - Thoery and Practice - milling with a CNC circuit mill: producing Gcode files, bed leveling, soldering

Afternoon

• 1 hr - Theory and Practice - Stepper Drivers - wiring up a larger Stepper Driver System with RAMPS
• 1 hr - PID Controllers, Relays, and MOSFETs

Day 4 - Filament Maker

• 1 hr - Theory - How to Design a Filament Maker
• 1 hr - Practice - Making filament

Logistics

• The OSE Boot Camp is limited to 12 participants (not including the OSE Fellows program)
• Arrival - evening before, with a welcome introduction at 8 PM.
• Food - food is included in the program
• Lodging - we have 12 spots available on site in shared-room accommodations, otherwise you can get a hotel in Cameron, MO