STEAM Camp 9 Day Curriculum

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Day 1 - OSE Intro and Collaborative Development of Technology That Matters

Note: need to open ends of Motor and Carriage Piece to simplify belt threading.

OSE Intro, Collaboration, FreeCAD, and Universal Axis.

  • 9 AM OSE Introduction: Collaborative Design for a Transparent and Inclusive Economy of Abundance
    • Review of OSE Workshops FB page for introductions
  • 10 How to Start an Open Source Project to change the world with Collaborative Literacy and Open Source Product Development.
    • Incentive Challenges and Extreme Manufacturing.
    • Open source project infrastructure: work log, wiki, FreeCAD, Google Presentations, Gitlab. Roadmap, critical path, repos, taxonomy, versioning, version history.
    • Open Source Boot Camp Universal Axis Tools: 3D printer, circuit plotter, cnc mill.
    • OSE Dev Kit - Universal Axis Tools + OSE Linux, FreeCAD, Cura, Arduino IDE, OBS Studio, Kdelive, KiCAD. FB.
    • Open Source Everything Store - the Open Source Amazon
  • 11 FreeCAD. Learning the basic FreeCAD workflow for design in 45 minutes + Test. Embedding 3D WebGL and part library into the Wiki
  • 12 Universal Axis, Universal Controller, and Marlin CNC Control
    • Understanding functions of parts
    • Scaling, Modifying, Connecting the Unviersal Axis. Ex D3D Simple 3D Printer, Plotter, Mill.
    • Cura to Marlin - Understanding the software workflow and its modification
  • 1-2 - Lunch
  • 2-6 PM - 3D Printer Build

Day 2 - Making Circuits and Electronic Devices

  • 9 AM - Reflections and Learnings from yesterday. Background 3D printing of Circuit Plotter Parts.
  • 10 - Modular Electronics: Intro to Designing like a Pro with Advanced Modules
    • Brains (controllers) - Arduino and its performance specs to understand its capacities, sensors available, output devices, wireless devices, key relevant shields
    • Power Electronics - Intro to handling power with power elements. Hands on with an Arduino AC Light Dimmer with only a single opto-isolated MOSFET using the Universal Controller
    • Sensors and displays - Hands-on Temperature logger with RAMPS LCD by reprogramming the Universal Controller
    • Wiring, Connector Types, and Communications - Wire Ampacity, MTA-100, Ferrules, IDC, D-Sub, Jelly Crimp, Phoenix, Dupont, Ethernet, Wireless RAMPS
  • 11 - Designing in KiCad: an Arduino Uno
    • KiCad 101. Circuit making process with KiCad and part libraries. Designing an Arduino around the Atmel 328 chip.
    • Generating toolpath files for plotting
    • Importing electronics from KiCad into FreeCAD.
    • Using FlatCam, post-processing, and importing into Lulzbot Cura
  • Noon - Building a Circuit Plotter - basic and ecological circuit making at your fingertips
    • How to design a modular, quick-connect XY plotter tool head for the Universal Axis
    • How to etch circuits in an environmentally friendly way
    • Pen holder build
    • Building the quick mount
    • Modifying Marlin Software for a plotter application
  • 1 PM - Lunch
  • 2 - Plotting and Etching an Arduino Uno: circuit plotting for practical results
  • 4 - Soldering the Arduino Together
    • Soldering components
    • Programming the arduino with Arduino IDE. Sketch and upload.
    • Test run with Reprapdiscount Full Graphic Smart Controller - Hello World: Open Source Rocks!

Day 3

  • 9 AM - Reflections and Learnings from yesterday.
  • 10 - Designing Brushless Electric Motors - going brushless for life
    • Axial flux vs radial flux motors
    • Design of a simple coreless Radial Flux motor. FreeCAD Motor Designer.
    • Design of a brushless motor controller
  • 11 - Electric Motor Build: Building a 50W stackable axial flux pancake motor
    • Coil winding using a winding jig
    • Magnet attachment to cnc cut disks
    • Motor assembly with 3D printed parts
  • 1 PM - Lunch
  • 2 - Motor Controller Build - using ready circuit boards for a simple control circuit
    • Soldering components and wiring up the system
  • 3 - Making a CNC mill from the Electric Motor
    • Mounting the motor and attaching a 2 mm milling bit
    • Making a Quick-attach mount for the Universal Axis.
    • Wiring the motor
  • 5 - Using Marlin for CNC Milling with auto bed leveling
    • Mounting a work piece
    • Sample CNC Milling of aluminum

Day 4

  • 9 AM - Reflections and Learnings from yesterday.
  • 10 - Battery Packs for Just About Everything - using ubiquitous 18650 cells
    • How to design battery packs. Scalable, parametric battery holder in FreeCAD with interconnects.
    • How to design battery chargers for 18650 cells
  • 11 - Building a 24V battery pack - from a prepared and 3D printed kit
    • Building Battery Holder
    • Interconnecting batteries
    • Adding a state of charge indicator light
  • 1 PM - Lunch
  • 2 - Arduino-controlled Battery Charger - we learn how to charge batteries - with a scalable smart charger controlled by the Universal Controller. We do a sample prototype build.
    • Hardware build
    • Software and its logic
  • 3:30 - An Arduino-Controlled Cordless Welder - Did you know that Cordless Welders exist? We will stack battery packs to make a cordless welder
    • Circuit Build of power stage - understanding how to switch large amounts of current with an Arduino brain
    • Connection to Universal Controller - to provide current control, selectable through the LCD screen
    • Programming the Arduino controller - controller logic
    • How to program the Reprapdiscount Smart Controller LCD screen
    • Doing a sample weld

Day 5-9: Project Days

There are 3 options - which area all also unique gift items:

  1. Aerial Drone - Use your smart phone (or Raspberry Pi Tablet if you have already built one) to fly your drone, using your own battery packs, ESC, and 3D printed parts. In successive camps, we will use our own 3D printed axial flux electric motors to make advanced technology down to earth.
  2. Raspberry Pi Tablet - make a fully functional computer tablet from a touch screen, a Raspberry Pi, and a 3D printed case printed with your own printer, and a circuit board for the camera and charger. You will also make your own battery pack from the popular 18650 lithium ion cells.
  3. Cordlesss Drill / Vaccuum Robot - Refine the battery pack, make a charger, refine the electric motor, add a geardown and chuck, and there is the world's first open source, practical cordless drill.

Links

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