September 2020 STEAM Camp

Overview

1. 3 weekends. 4-8 hours each day, 6 days total.
2. 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.
3. Participation: each day is $25, select the days you want.
4. Kit cost - $800. $600 for printer, $25 for OSE Linux, $50 BOM cost for electric motor kit, $40 BOM cost for Arduino
   1. D3D Universal 3D Printer - build from scratch. $600 alone.
   2. 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
   3. 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.

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.

1. Build a complete 3D printer from scratch - including a heated bed, extruder, and controller.
2. Learn to upload firmware, calibrate the first print - and begin printing.
3. Build a 3D Printer Extruder from Scratch. Learn how an extruder works, and how you can redesign it yourself.
4. Design Lesson on Making industrial-grade extruders with 80W heaters for 20 lb/extrusion rates

Hours:

1. Hour 1: 11 AM to Noon: 30 minute OSE Intro - Collaborative Design, This is a real exercise in collaborative design.
2. 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
3. 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.
4. Hour 4: Universal Axes build - Includes 15 minutes on Universal Axis design - and how to scale these to any size frame.
5. Hour 5-7: finish extruder, axes, heat bed.
6. Hour 8: Build review: we discuss build and any trouble spots to make improvements.
7. After hours and before next day's 11 AM start: participants finish any unfinished parts.

Day 2:

1. Hour 1-2: 11 AM to 1PM: Controller build. 15 minute lesson on the Universal Controller.
2. Hour 3-5: Startup procedure. 1. Check direction of motors, including extruder. First prints.
3. Hour 6: Using FreeCAD to Create Designs for 3D printing.
4. Hour 7: Your first simple design - sliced and 3D printed.

Weekend 2

Day 1, 4 hours:

1. Learn Arduino, coding, and build your own Arduino-like microcontroller from scratch. With Mitch Altman.

Day 2, 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.

1. 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.
2. Hour 3-4: Soldering, making and breaking connections, and populating circuit board with components.
3. 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.

Sat-Sun Sep 19-20, 2020 - 3D Printing and Collaboration

1. 3D Printer Build - D3D Universal v20.07
2. 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

1. Arduino and Programming - building a basic Arduino from scratch. With Mitch Altman
2. KiCad - basic lesson in designing electronics. Building the Basic Arduino in KiCad and soldering it from scratch on stripboard. [1]

Sat-Sun Oct 3-4, 2020 - FreeCAD and 3D Printing an Electric Motor

1. FreeCAD design - Gaining basic proficiency in designing anythign you dream of. Working with Dirk's Electric Motor and printing it.
2. 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

1. Plotting with the D3D CNC Plotter - point pictures, line pictures, OSE greeting cards, neat images
2. Vinyl cutting with the D3D Universal - cutting out numbering and lettering and logos in vinyl.