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.

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 catalog 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 in a substantial way. We are excited, and want to spread the word. So we run public workshops teaching people to build these machines, and how 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 people about massive parallel swarm-based development techniques - and every child and grandmother begin designing their own products and publishing the plans on the internet for free. 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 democratize the face of manufacturing - converting consumers to producers...

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. Some may say that this is already happening - but 3D printing and distributed manufacturing has not taken much of a hold in terms of replacing consumer goods. The key is high quality, proven designs - not fringe things on 3D printing websites that in many cases cannot even be printed. The key is engaging enough cooperation - that all the possible products truly become best-in-class - while remaining fully open source. We not only show you that this new mindset is possible - but how to build the actual production tools - and how to leverage massive collaborative development processes - so that we democratize product development on the face of this earth. Perhaps the greatest single impact is environmental - as people learn to build their products - they also know how to fix them - thereby putting an end to the throw-away society - with lifetime design that can be modified, improved, or recycled back into feed-stocks. Our aim in the OSE Boot Camp is to introduce people to the first steps in seizing democratic control of production.

Schedule

Detailed Narrative

• Day 1 - Intro + 3D Printer - We start with the open source design software, how to design a 3D printer using our Universal Axis system, and then build a 3D printer from scratch in the afternoon. We use common, off-the-shelf materials and 3D printed parts, so that the builds can be replicated easily anywhere in the world. This first day of the OSE Boot Camp is open to the public for one day participation with others who want to participate in the 3D printer build.
• Day 2 - 3D Print Cluster + Filament Maker - Did you ever think about producing useful products that can be part of a circular economy? Here we teach you how you can start your own microfactory at home - which you can connect to the internet as an on-demand printing service. To reduce the cost of 3D printing filament, we will teach you how to produce your own 3D printing filament from scrap plastic. Thus, the transition to distributed, closed loop production can start right at your home.
• Day 3 - CNC Circuit Mill + Open Source Electronics Toolchains -Besides 3D printed plastic parts, many consumer goods contain circuits. We will learn how to design circuits with open source software, and how to mill them using an open source CNC Circuit Mill. We will show how to import designs from KiCad into FreeCAD. As 2 examples, we will mill an open source switch mode power supply and inverter for producing useful power. The power supply can take 120AC into an adjustable DC value - such as power supplies for the 3D printer or CNC circuit mill itself - and the inverter can take a 12 v battery and turn it into 120 AC, for example for off-grid energy systems.
• Day 4 - Laser Cutting + 3D Scanning + Rapid Prototyping - We will learn about the full laser cutter toolchain - using OSE's open source laser cutter head add-on to the Universal Axis system. And then we go deeper: building a simple CO2 discharge tube for a CO2 laser: out of PVC pipe! Then we move on to rapid prototyping and reverse engineering: using pictures of a part taken from all angles, we will reconstruct a part as a detailed 3D CAD file in FreeCAD - using an open source photogrammetry toolchain. With working knowledge of 3D printing, laser cutting, and circuit milling - we will be in a position to design and build many consumer goods. We will show an example of collaborative development by designing and building an open source cordless drill with speed control, which we are also hosting as a design challenge on HeroX. For the cordless drill, we will 3D scan an existing drill as a starting point for our design. Together with the 3D printer, CNC circuit mill, laser cutter, and processing scrap plastic into 3D printing filament - and a capacitor-based battery spot welder - we will prototype the cordless drill.
• Day 5 - The Open Source Everything Store. Imagine the open source version of Walmart or Amazon: all products are collaboratively designed and open sourced by people all over the world, and the produts designed for fabrication in the open source microfactory. Can the next generation of democratic manufacturing bring production back to communities for responsible manufacturing? We will study how large-scale prototyping events can take place in real-time, and we will

Day 1 - Intro, Big Picture + 3D Printer

Mornings: 8 AM Start

• 1 hr - Theory - introductions and OSE introduction. The world of public domain and open source.
• 1 hr - Practice - FreeCAD - designing parts from sketches
• 1 hr - Theory - How to Design a 3D Printer. Part list, build procedure.
• 1 hr - Practice - Building a 3D Printer. We work together on all the parts, then assemble them individually into the finished product.

Afternoon:

• 4 hr - Building a 3D printer from scratch
• 2 hr - calibration, printing, slicing. Cura, BlocksCAD.
• Dinner - 6-7 PM
• Dinner Lecture - The Open Source Ecology Product Ecosystem

7 PM End

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 print cluster and doing production printing
• 1 hr - Theory - Filament Maker and Extruders. How to design filament makers and extruders + power and Heating Systems for the 3D printing ecosystem. Power supplies, heated beds, Nichrome Calculator, extruder heaters, heated build chambers, filament maker heaters, extruder screw design. Insulation, cooling, mechanics, power calculations for scalability.
• 1 hr - Practice - Making 3D printing filament from scrap plastic (not commercial pellets). Grinding and extruding.
• Lunch - Conversation with E3D on Extruder Design, Large Filament, and Supersized Extruders
• Lunch - Conversation with Octoprint on 3D Print Clusters

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 on a wiki with Octoprint.

Day 3 - Ciruit Mill + Electronics

Morning:

• 1 hr - Practice - KiCAD workflow from basics to using part libraries and design.
• 1 hr - Theory and Practice - CNC Circuit Mill Design Guide + design with FreeCAD Part Library. Design of 3D PCBs with KiCAD and import into FreeCAD for modification and Gcode generation.
• 1 hr - Theory and Practice - Using a Welder Design Guide to design a spot welder circuit. Creating a KiCAD Library File for the welder.
• 1 hr - Thoery and Practice - Milling with a CNC circuit mill: producing Gcode files, bed leveling, soldering
• Lunch Lecture - How to Design an Efficient, Scalable, Arduino Inverter for Any Voltage

Afternoon:

• 1 hr - Practice - milling and soldering an arduino inverter circuit board, 500W
• 1 hr - Theory and Practice - Stepper Drivers - wiring up a larger Stepper Driver System with RAMPS
• 1 hr - Practice - PID Controllers, Relays, and MOSFETs,. rectifiers, PWM, IGBTs, and build of an inverter.

Day 4 - Small Laser Cutter, Rapid Prototyping, Crowd Development

• 1 hr - Theory + Practice - How to Design a Small Laser Cutter with FreeCAD Libraries, hands on.
• 1 hr - Practice - Laser Cutter Toolchain, from design to cutting or etching. Use cases of small laser cutting.
• 1 hr - Practice - Building an enclosure for the open source inverter using the Laser Cutter.
• 1 hr - Practice - 3D Scanning - Reverse Engineering real life objects with Photogrammetry
• Lunch Guest Lecture - How to design a Carbon Dioxide Laser Tube from Scratch

Afternoon

• 1 hr - Theory and Practice - building a 20W CO2 Laser Tube from PVC pipe. Hands-on.
• 1 hr - Theory and Practice - Printing in Different Media: concrete, mud, ceramic, laser sintering, metal (sinter- and weld-based), metal plastic filament. How to make 3D printing filament with embedded metal. Metal part printing. Open source laser sintering in metal. Metal Injection Molding. We will print with bronze-embedded PLA to produce linear motion bushings for the 3D printer. We will also take a stab at mixing finely ground plastic with bronze powder in the filament maker to produce our own metal 3D printing filament.
• 2 hr - Collaborative Development Method. Swarming on a Cordless Power Tool Construction Set tool. Collaboration ecology.

Day 5 - The Open Source Everything Store: Collaborative Design for Economic Impact

• 1 hr - Theory - Why Production Has Not Been Democratized - Yet - and the Possibilities. Public awareness of the public.
• 1 hr - Practice - Setting up an incentive design challenge online - an Add-On to the Open Source Microfactory Challenge
• 1 hr - Theory - Open Source Product Development - Modular Design and Collaboration Architecture
• 1 hr - Practice - A Design Sprint for an Open Source Cordless Tool Add-On

Afternoon

• 1 hr - Theory - Printing of large objects, composites, metals, and more.
• 1 hr - Practice - Printing greenhouse glazing and applying UV resistant coating,
• 1 hr - Theory - The Open Source Everything Store - a Global Distributive Enterprise
• 1 hr - Practice - Role allocation for the next day's build

Day 6 - The Open Source Enterprise and Organization

• 1 hr - Theory and Practice: The Open Enterprise Resource Planning: Software Infrastructure with Odoo Open ERP.
• 1 hr - Theory: Payment processing, sales website
• 1 hr - Managing a 3D printing cluster and its inventory. Design for automatic part harvesting using the OSE Robotics platform
• 1 hr - Server Admin 101. How to install Mediawiki, a print cluster, Odoo, Wordpress, and
• Lunch lecture - Conversation with Lulzbot on open enterprise.
• 1 hr - Theory and Practice. Massive Parallel Development - setting up information architecture and templates on the wiki for product development. The Development Template.
• 1 hr - The OSE Workshops business model. Leveraging Immersion Training, Crowd Collaborative Involvement with Crowd Incentive Challenges to grow a solid team.
• 1 hr - Operations and Growth. Here we discuss going beyond solo development to managing a team. This inludes R&D, production, marketing, sales, HR, logistics, and finances.
• 1 hr - Preparing for a build of a scaled up 3D printer. Rapid prototyping: frame, heat bed, multiple stepper drivers, multiple axes, and 6 mm filament.

Day 7 - Build Workshop

With all the learnings of the 6 days, it's time for a road trip to a nearby University to experience a real life workshop in practice. Our group, armed with FreeCAD design knowledge and design insights on the Universal Axis System - will both participate as a team, and guide additional participants who sign up for the workshop. This will be an experimental workshop where we show the power of the Construction Set model in building larger, more powerful machines - while collaborating as a larger team. This is possible because we are using the modular Universal Axis system - where the interfaces between the different components are clear and well-proven, and specific design principles simplify the design significantly to create a product with industry standard performance - while reducing the part count to about 1/2-1/3. We will build a 3D Printer with a 3' large bed and metal frame - in 1 day! We will demonstrate the scalability of the print bed to any size - axis sizes - and show how the simple 8 mm Universal Axis system can be leveraged to make quality machines on a larger scale, at a fraction of the cost of similar counterparts.

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