D3D Thesis Project Plan

Critical Path

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Team Charter

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Background

Self-reproduction

The RepRap Project has acheived exponential growth in numbers of machines by mechanisms of self replication and evolution.

That is without centralized production or authorative instructions.

This machines are called \i{RepRap Machines} and are most often Fused Filament Fabrication (FFF) 3D printers, similar to the designs developed within the RepRap project.

Especially one family of printer designs has spread virally, namely the Prusa designs.

Including all three reference versions of the Prusa designs as well as all derivatives, more than 100000 (insert new number here on Jan 15) Prusa printers have been built, which is (some percentage) of the global consumer 3D printer market.

This makes the RepRap Prusa the first open source hardware (OSHW) designs to channel (some significant share) of a billion dollar market(ref) towards the spread out, small scale makers, scientists, hackers and dealers costituting of the OSHW community all over the world.

Part of the Prusa Mendel's succes comes from being the first printer to be realistically build-able

 during a weekend workshop when it was released back in 2009(ref).

It's printed parts took 10 h to print,

 compared to the 20 h of its main contester at the time of release, the Sells Mendel(ref).

The interest enabled Josef Prusa pre-sell printed parts and thereby fund travels around Europe

 to host 3D printer workshops.

By hosting workshops, he spread both the printer design and detailed knowledge on how to use

 and replicate it.

Detailed build instructions were also put online, the number of contributors increased

 and the design established a reputation as easily customizable.

All this made the Prusa Mendel design (and later Prusa i2 and Prusa i3)

 spread at a higher rate than other RepRap design.

If we do extraordinary well we hope to see a period of self-sustaining workshop reproduction and gradual improvement through evolutionary/free market selection mechanisms.

Purpose

This project aims to design a 3D printer workshop with self-reproducing properties. Focus will be on shaping workshop plan trying to identify and include the right tools and incentives for reproduction. The workshop plan is the inheritance material in this story, and we will modify and evaluate it through four workshop/evaluation iterations. On each iteration, data will be collected and analyzed to improve our understanding of how to facilitate workshop self-reproduction. Similarly to how the RepRap project focused solely on making its 3D printer design capable of self-reproduction, this project focuses only on the self-reproduction of the workshop. Any technical features and explicit functional requirements should be seen as perceived consequences of the self-reproduction goal that might change as our understanding of workshop self-reproduction changes.

TODO: Copy relevant stuff from https://www.overleaf.com/read/vmpdtnzsgdgg over here...

TODO: Write Story from Background, Goal etc here, Google-Doc here and D3D Fusion Project Team Charter here. Focus on the tips I've got:

• Broader opening that explains main characters and concepts that builds the story
• Clearer links to earlier work

Related Projects

The super-project, D3D Fusion focuses on people and Distributive Enterprise. This thesis project focuses on the workshop, including the D3D Printer.

self-replicating 3D printer (not necessarily a fantastic 3D printer),

this thesis will focus on creating workshop with self-propagating features.

This means tailoring a 3D printer design, creating an initial workshop plan and packaging it as a clone-able and easily modifiable kit. The core idea is to make an enterprise that spreads exponentially by mechanisms of self replication and evolution.

The evolution part is important: successful entrepreneurs share their versions of the workshop kit and will be replicated more often than the less successful attempts. This means we only need to reach the threshold of self-propagation before the kit starts to "improve itself". That is why we should focus on achieving the first propagation rather than perfecting a single part of the D3D Workshop Kit.

Backlog of Tasks

• Evaluate RAMBO fitness for purpose (can it handle enough current). Otherwise use RAMPS with drv8825.
• Set correct V_ref and steps per mm (drivers/firmware)

• CAD l_module, including interfaces
• Order parts for l_module prototyping
• Design tests for l_module prototype
• Build l_module prototype
• Test l_module prototype, possibly iterate design
• Estimate costs for l_module design in $ and prep-time
• Record build time l_module (when built by non-developer)

• CAD frame, including corner brackets
• Order parts for frame prototype
• Design tests for frame prototype
• Build frame prototype
• Test frame, possibly iterate design
• Estimate costs for frame design in $ and prep-time
• Record build time frame (when built by non-developer)

• CAD the tool mount part, including bed probe
• Order parts for tool-mount prototype
• Design tests for tool-mount prototype
• Build tool-mount prototype
• Test tool-mount, (test reliability of bed probe)
• Estimate costs for tool-mount design in $ and prep-time
• Record build time tool-mount (when built by non-developer)

• Order hot end for extruder prototype

• CAD the tool extruder
• Order parts for extruder prototype
• Design tests for extruder prototype
• Build extruder prototype
• Test extruder, possibly iterate design
• Estimate costs for extruder design in $ and prep-time
• Record build time extruder (when built by non-developer)

• Milestone: Build times for l_module, frame, tool mount and extruder recorded
• Milestone: All modules have module-tests created
• Milestone: All modules pass module-tests
• Milestone: First complete D3D Printer prototype built

• Order Prusa Steel kits
• All instructors test out documentation and kit by building kit themselves

• Define "workshop reprodicability"
• Define what data to collect during WS and how

• Define which workstations should exist in WS (before WS1)
• For each workstation plan what hardware is needed
• Design testing procedures for each workstation
• Write instructions for each individual workstation
• Print out two sets of documentation for every workstation
• Plan and draw WS local layout and flows (workstations' relative placement and parts/participants-flow between them)
• Put chairs and tables in place in WS local
• Build complete example-printer and all example-modules for WS workstations (before WS1)
• Place example-modules, tools, instructions, test-rigs, nuts and bolts on workstations (before WS1)
• Create WS1 time schedule
• Simulate complete workshop (time: between USA arrival and first workshop)

• Compile data-collection routine, build-steps, schedule, workshop local layout and hardware flows and welcome letter into one document: "WS1 Plans". This will evolve into project main delivery
• Milestone: First version of Workshop Plans released
• Send out WS1 Plans to participants

• Host WS1 according to WS1 Plans
• Depending on type of data-collection: ask participants to fill out form.
• Milestone: First WS completed

• Collect instructor experiences through WS retrospective/evaluation meeting
• From WS1 data determine bottlenecks for reproducability (cover at least build-process, participant satisfaction and instructor satisfaction).
• Compile "WS1 Experiences and Key Metrics", thesis quality, presented on wiki (Were Prusa Steel design suitable for paralell WS production?)

• Do design improvements for D3D Printer for workshop (prepare design for WS2 action)
• Order for WS2:
  • steel
  • PLA filament
  • stepper motors (and lead screws + coupler if not already lead screw shaft on motor)
  • electronics
  • endstops
  • BuildTak or similar
  • linear bearings
  • smooth rods
  • hot ends (with thermistor, resistor, maybe PTFE tubing)
  • hobbed bolts
  • nuts and screws
  • power supplies
  • Force Sensistive Resistors
• Compile BOM for WS2 with sources and prices
• Print parts for WS2
• Cut steel parts for WS2

• Adjust WS local layout to match D3D Printer build (instead of Prusa Steel)
• Compile "WS2 Plans"
• Send out WS2 Plans to participants

• Host WS2 according to WS2 Plans

• Depending on type of data-collection: ask participants to fill out form.
• Collect instructor experiences through WS retrospective/evaluation meeting.
• From WS2 data determine bottlenecks for reproducability (cover at least build-process, participant satisfaction and instructor satisfaction).
• Compile "WS2 Experiences and Key Metrics", thesis quality, presented on wiki

• Improve WS Plans
• Decide whether to use Prusa Steel or D3D Printer for remaining 2 workshops.

• Prepare WS3
• Host WS3
• Compile "WS3 Experiences and Key Metrics", thesis quality, presented on wiki

• Improve WS Plans

• Prepare WS4
• Host WS4
• Torbjørn returns to Sweden
• Compile "WS4 Experiences and Key Metrics", thesis quality, presented on wiki
• Milestone: Four workshops hosted

• Finish thesis
• Present