STEAM Camp Module Specifications

D3D Universal

1. D3D Universal is the multi-toolhead version of D3D Simple
2. See D3D Simple for prior art on the 3-dimensional motion axis.
3. Scope of complete printer is Universal Controller, no heat on bed, Simple Extruder, and spool holder. All is mounted to a wooden board.
4. Modify current design for a specific size: 6"x6"x6" as a small and robust device
5. Needs

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Universal Tool Head Connections

Mechanical Attachment of Toolhead

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Electrical

1. Wiring is quick plug, MTA-100, 8 pin, 2 of them
2. Wiring bundle is 22 Ga, 8=stranded connector [1]

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Pen Plotter + Mill requirement:

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Wiring to Universal Controller:

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CNC Plotter

A device based on the Universal Axis capable of drawing pictures and circuit masks on copper-clad boards. The platter is part of a 3-in-1 CNC Tool which uses a CNC motion system in 3 dimensions, coupled with quick-connect toolheads. The Plotter is one of these tool heads. This uses a RAMPS-based Universal Controller and Universal Axis to move a drawing tool. The universal axes are oriented in a configuration embodied by D3D Simple. The specifications include 10 micron step size of motion, and plotting resolution limited by the width of the pen or marker tool. The nature of this development is to produce a quick-connect plotting toolhead for D3D Simple, including the software that can be run on the Universal Controller. The technology in (1) concept diagram, (2) CAD in open source file format and ideally in FreeCAD and KiCad, (3), any required wiring diagrams, (4) software, (5) Build Instructions, (6) CAM files for production, (7) BOM, (8) Exploded Part Diagram, and (9) Build Instructions.

Modular Breakdown and Requirements

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CNC Plotter Etching

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Arduino Uno

This involves circuit etching and populating an Arduino Uno board. We start from an Atmel 328 chip with DIP 28 form facor, and build a board around it: a USB port for communication and power. We connect the board to the [[Universal Controller LCD screen to show the magic of making our own controller.

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Universal Controller Light Dimmer and Welder Power Supply

We start with the Universal Controller and demonstrate basic power electronics control ciruits. We domonstrate a simple light dimmer that takes an incandescent light bulb and controls its brighness. To do this, we rectify AC to 120DC, and then use a PWM circuit to control brightness by varying the voltage.

That's only the beginning - because if we have a 2.4 kW -capable light dimmer - we can get into welding! If we rectify to DC, then PWM allows us to get any voltage between 15 and 25 volts - which is just perfect for a small welder of 100A DC. We also show how simply connecting 2 of these circuits in parallel allows us to scale power, based on using a single PWM output from the Universal Controller to trigger multiple transistors - for a 200A DC welder application

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Electric Motor

Motor Power Supply Requirement

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Electric Motor Controller Logic

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Software Toolchains

For uniformity of toolchains, we will use OSE Linux with all software preloaded. We use the Universal Controller running Marlin firmware. The software toolchain must be designed for using the Universal Controller with modified firmware to run different machines:

1. 3D printer
2. Plotter
3. CNC Mill

We can also consider using a single firmware for all these functions, but that may be too complicated for now.

3D Printer

1. Going from FreeCAD to STL export to Cura to g-code export for SD card.

Plotter

1. Going from Inkscape to gcode for drawing pictures
2. Going from KiCad to FlatCam to gcode for drawing circuit masks for copper-clad boards.

CNC Mill

1. 3 mm milling bit for light aluminum milling with coolant using a small aquarium pump
2. Using a 1 mm milling bit for circuit paths and through-holes without switching tools and with coolant
3. Etching is done using Cuprous Sulfate and a mask drawn by the circuit plotter. The requirement includes agitation by placing the etchant bath on the D3D Universal bed to be agitated back and forth. Custom firmware is required here, or we may collapse all the firmware into one version of Marlin

Cordless Welder

The cordless welder uses a number of 6s 18650 battery packs. The 18650 cells are combined using a clamping system as opposed to soldering or spot welding. Instead, modular holders with flexible elements, press fit, and bolts or set screws are used to hold batteries in place. The batteries can be removed without having to solder and unsolder. The pack geometry and modular holders are 3D printed. The battery is designed with interconnects so that the battery can be stacked either in series or parallel.

To obtain a cordless welder, a 200A aluminum bus bar (1/2" bar stock) is used to connect 24v batteries in parallel.

Universal Controller is used to control the current via the control knob.

Modular Breakdown:

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Universal Controller

The Universal Controller is a LCD-screen equipped controller based on the Arduino Mega that is capable of controlling 3D printers, CNC machines, welders, filament makers, automated machines, or any other applications where a microcontroller runs different actuators, sensors, or power elements. It is a platform consisting of the Mega, RAMPS, LCD screen, power supply, power outlet, and power handling SSR, and can be connected to external external stepper drivers, solenoid valves, or other power elements. Equipped with an Arduino Mega, it can be used to control just about enything that requires a 100 kHz or lower control signal.

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