September 2020 STEAM Camp: Difference between revisions

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=Overview=
#redirect [[September 2020 Build Camp]]
#Remote event - with kits shipped - due to COVID
#Participation available for the world - but without kits. - kits only USA/Canada. Canada - add $70 for shipping.
#Tools are not included, need to provide some basic tools yourself
#Remote participation without kits - participate on the design lessons and classroom material, but not the builds, unless you secure parts locally.
#Filament is included only for the first day sample prints. To print the rest of the projects, you'd need to get more PLA and TPU.
#3 weekends. 4-8 hours each day, 6 days total.
#Includes OSE Linux on a USB stick - for all the software, 3D printer design workbench, frame design workbench, KiCad, FreeCAD, Arduino, Cura, and ll the software used through the program.
#Participation: each day is $25 without kits, includes OSE Linux in the USA only.
#Participation: $100 for kit for each weekend.
#Kit cost - $899. $600 for printer, $25 for OSE Linux, $60 BOM cost for electric motor + mechanics kit, $50 BOM cost for Arduino kit.
##D3D Universal 3D Printer - build from scratch
##Basic Arduino-like microcontroller - build from scratch. Parts for 2 microcontroller builds (one on a breadboard, another on stripboard) and the TV-B-Gone hacker toy as an application of the Arduino. An Arduino Uno comes with the kit. $40 alone
##3D Printed Motor Kit - magnets, winding wire, ball bearings, metal shaft, 3-phase motor controller. Ball bearings for making large and small ball bearings. $70 by itself.
#'''Summary:''' $600 kit weekend 1, $150 second week, $150 third week. Or $25 kitless.
#No money? No problem. Apply for a scholarship, and we can consider providing you with free attendance in exchange for some work. Also - if you can't afford the materials cost - you can source parts at much lower cost if you make lower cost substitutions. For example, you can use smaller or weaker magnets, get a cheap 3-phase speed controller, and so forth. Different magnets will require slight geometrical modification of the design - but that's exactly what we teach you - how to do all of that in FreeCAD.
 
=Days=
*1-2: 3d Printer Build from Scratch: learn to build a heat bed, extruder, controller, and printer - and how you can design larger versions using the [[Universal Axis]] system.
*3: Microcontroller Build From Scratch and Programming. TV-B-Gone.
*4: KiCad and Electronics Design: learn the basics, as you design your own Basic but Practical Microcontroller
*5: FreeCAD - how to design like a pro. Create designs from scratch, and learn how to modify plentiful existing part libraries. Exercises: designing belts, bearings, lineaar bearings, and pulley systems. Needs 12V battery.
*6: FreeCAD, 3D Printing, and Design. Build your own 3D Printed, 3-Phase Electric Motor Experiment from Scratch as you continue to build your FreeCAD and 3D printing skills.
 
=Detail=
=='''Weekend 1: 3D Printer Build. 2 8 hour days.'''==
#Build a complete 3D printer from scratch - including a heated bed, extruder, and controller. Push the limits of what you can make yourself - and how you can start an enterprise in your community making useful parts.
#Learn to upload firmware, calibrate the first print - and begin printing.
#Build a 3D Printer Extruder from Scratch. Learn how an extruder works, and how you can redesign it yourself.
#Design Lesson on Making industrial-grade extruders with 80W heaters for 20 lb/extrusion rates
 
 
Hours:
 
#Hour 1: 11 AM to Noon: 30 minute OSE Intro - Collaborative Design, This is a real exercise in collaborative design.
#Hour 2: Noon. Extruder Build Beginning - 15 minutes - design of an Extruder and how to design a different one. We all post pictures to a Google Photos Folder or FB, and documenters refine the documentation
#Hour 3: Heat Bed Build - Build Nichrome heater element, and make a heated bed with it. Includes 15 minutes on heater element design and nichrome wire calculations so you can redesign a heater element of any size.
#Hour 4: Universal Axes build - Includes 15 minutes on Universal Axis design - and how to scale these to any size frame.
#Hour 5-7: finish extruder, axes, heat bed.
#Hour 8: Build review: we discuss build and any trouble spots to make improvements.
#After hours and before next day's 11 AM start: participants finish any unfinished parts.
 
Day 2:
#Hour 1-2: 11 AM to 1PM: Controller build. 15 minute lesson on the Universal Controller.
#Hour 3-5: Startup procedure. 1. Check direction of motors, including extruder. First prints.
#Hour 6: Using FreeCAD to Create Designs for 3D printing.
#Hour 7: Your first simple design - sliced and 3D printed.
#Hour 8: How would you make or 3D print all the 3D printer parts yourself? How to make more parts of the 3D printer: bearings, shafts, controller, screen, relay, plug, and more. Discussion on the technology required to make each, based on what is found in the Global Village Contruction Set. Last 20 minutes: Lessons learned - how to make the program better.
 
==Weekend 2: Arduino, KiCad, Programming, and Building a working Microcontroller From Scratch==
Day 3, 4 hours:
#Learn Arduino, coding, and build your own Arduino-like microcontroller from scratch. With Mitch Altman. See details at [[Arduino for Total Newbies]].
 
Day 4, 4-5 hours:
Learn KiCad and basic electronics design as you design and build your own microcontroller. Experience the full chain from KiCad to a working microcontroller that you solder on a stripboard to make a functional device that can be programmed and used in practical projects.
 
#Hour 1-2: KiCad intro: 15 minutes. Begin designing your own microcontroller: selecting components, making connections, and checking your design. Exporting a layout that you can work from to solder your own OSEno - the minimalist OSE Arduino clone.
#Hour 3-4: Soldering, making and breaking connections, and populating circuit board with components.
#Hour 5:  KiCad review - making a change in the circuit. Testing - making LEDs blink, and turning on heavy loads with a solid state relay. Note: we will be using the existing solide state relay from the D3D Universal - so if you haven't built the kit -  you'd have to get your own solid state relay to do the experiment first hand - otherwise you can watch others do it. Also wrapup: discussion on learnings, and how to improve the program.
 
==Weekend 3: FreeCAD Design + Build Your Own 3D Printed, 3 Phase Motor==
Day 5, 4 hours lessons + 4 hours practice:
Learn more about FreeCAD design as you design and modify ball bearings, linear bearings, transmission belts, and pulleys - all that you can print with your 3D printer to make various kinds of transmission and power geardown systems. You will be provided with bearing balls - large and small - to build your projects.
#Hour 1: The Ball Bearing. FreeCAD - using spreadsheets and modifying a 3D printable ball bearings. Then 3D print your ball bearing.
#Hour 2: The Linear Bearing. Learn how to design, modify, and print a linear bearing - either will bearing balls or with plain plastic on metal.
#Hour 3: The flexible belt. Learn how to design, modify, and print rubber belts.
#Hour 4: The Pulley. Design, modify, and print pulleys for power transmission.
#Hour 8: Show-and-Tell - show the class what you have built, and how it works.
 
Day 6, 8 hours:
Now you can use your FreeCAD skills and 3D printer to design and build a 3D printed, 3-phase, electric motor. This is an experimental day where you can take our existing design - and build it to get first-hand knowledge of how to design and build an efficient, electric motor. To do this - you will have to have printed all the parts prior to this day - as it takes a day to print all the parts.
#Hour 1: The OSE 3 Phase Motor Design. How to scale it to larger sizes or add more disks to it. Power, magnetic field, and speed calculations. (45 minutes).
#Hour 2-3: Start with winding the windings. You will need a corless drill so you can grab the windings to wind them quickly.
#Hour 4: Attaching the magnets to the rotor, coils to stator, and connecting to 3-phase motor controller.
#Hour 5-7: Finishing the build. Participants work toward completion, and ask questions along the way.
#Hour 8: First run! Discussion: applications and possible applications of motor. Lessons learned, discussion, and feeback on future improvements.
 
=Sat-Sun Sep 19-20, 2020 - 3D Printing and Collaboration=
#3D Printer Build - [[D3D Universal v20.07]]
#Uploading code, printing, calibrating, slicing, finding files online. Using [[OSE Linux]], included. Principles of large-scale collaboration - [[OSE Development Protocol]] overview.
 
=Sat-Sun Sep 26-27, 2020 - Electronics=
#Arduino and Programming - building a basic Arduino from scratch. With [[Mitch Altman]]
#KiCad - basic lesson in designing electronics. Building the Basic Arduino in KiCad and soldering it from scratch on stripboard. [https://hackaday.io/project/166863-stripboard-meets-kicad/details]
 
=Sat-Sun Oct 3-4, 2020 - FreeCAD and 3D Printing an Electric Motor=
#FreeCAD design - Gaining basic proficiency in designing anythign you dream of. Working with [[Dirk's Electric Motor]] and printing it.
#Electric Motor Design. 3D printing an electic motor - before this weekend so parts are ready and we build it. FreeCAD design exercises - modifying the electric motor. FreeCAD spreadsheets for parametric design.
 
=Sat-Sun Oct 10-11, 2020 - Optional if we get this done in time=
#Plotting with the D3D CNC Plotter - point pictures, line pictures, OSE greeting cards, neat images
#Vinyl cutting with the D3D Universal - cutting out numbering and lettering and logos in vinyl.

Latest revision as of 08:33, 6 September 2020

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