Open Source Microfactory Boot Camp 2019

About

This time around we are experimenting with an experimental boot camp. We focus around the 3D printer, and then around Open Source Product Development with the participants: experiments and learning prototyping techniques and applying them to real design.

Time and Place

• July 1 - July 7

Schedule

• Day 1 - Build your own 3D printer - the latest version of D3D v19.02 with the Titan Aero high performance extruder and Volcano nozzle that can handle faster print rates with 0.25 mm up to 1.2 mm nozzles. V19.02 is easier to build and align, removing the need for welding if you don't have a welder or don't want to mess with JB-Weld epoxy. Choose from 6", 8", and 12" print bed versions. Cost is $799, $899, and $1299 if you want to take the 3D printer home with you.
• Day 2 - Learn to use your 3D Printer and to design objects using open source CAD. This will be the foundation for doing useful design in the remaining days of the Boot Camp. We will teach you how to use FreeCAD to do simple and complex design so you can create and modify 3D printing files using a completely open source toolchain. We will teach you a basic, but powerful workflow that can be learned in 1 hour of hands-on practice - so that you can add effective CAD design to your skill set as one of the core outcomes of the Boot Camp. To test the accuracy of your printer, we will 3D print calipers that have up to 50 micron accuracy. We will teach you how to switch to different nozzles for printing - depending on if you want high detail or fast prints. We will teach you how to design printable objects, and how to prepare them for successful printing.
• Day 3 - Large 3D Printer. Today we will build 2 large printers - one that has a 1 meter bed, and another that is a 6' tall 3D printer. To do this, we will use the 1" size Universal Axis in the larger printer. We will print with large printing nozzles of 80W - which can print up to 20lb of plastic per day. This means that 3D printing of large objects such as furniture or building materials such as plastic lumber now becomes feasible. If there is the interest and energy, we can use our D3D CNC Circuit Mill to mill an extruder from scratch - see Open Source Rubber Optimized Extruder.
• Day 3 - 3D Printed Motors - Options 1. invite David to present on 3D Printed Stepper Motor. 2, Do linear motors for the steam engine models, driven by arduino. Do other 3d printed motors. Build a Halbach array motor -

• Day 5 - It's time to turn our 3D prints to metal. We will experiment with lost plastic casting using PolyCast. We will encapsulate 3D prints using plaster of paris and greensand - and make metal objects from Zinc Aluminum alloys. We will brew our own zinc aluminum alloy from zinc, aluminum, and a little bit of copper using a small furnace.
• Circuits for controlling motors

• Day 6-7- We will explore open source product development by collaborating on an array of projeccts. We have options to work on the design of a 3D printed, cordless drill, a CNC Router, and a Heavy Duty CNC machine. We can build larger and different versions of CNC machines using the Universal Axis system with geardown. We have to decide as a group on 2-3 projects that we would like to tackle, so that we allocate multiple 3D printers for real-time, on-demand prototyping without long wait periods for parts. We will use our 3D printers and our capacity to make metal parts. FOr th We will design and build various geardowns, battery packs, and simple 3D printed circuits (component holder structures for soldered components), and hack together a functional cordless drill. Here we let the creativity of the group take over - for applying CAD design rapid prototyping in plastic and metal, and other techniques. We will provide crash course tutorials on cordless drill design, electric motor design, battery pack design, and controls, building of 3D printed planetary gears, and other topics relevant to making a cordless drill.

• Day 3 - Build a Filaments Maker - OSE is about industrial productivity on a small scale - meaning that we want to print useful, lerger-scale objects in addition to small 3D prints. For OSE, that means printing plastic lumber, rubber tires for vehicles, glazing panels for greenhouses, chairs and furniture, and much more. For that - 3D printing fiament costs become prohibitive, as commercial 3D printing filament costs are $10/lb - which makes printing of any sizeable objects cost-prohibitive. This is where the open source filament maker comes in, where we can produce 3D printing filament from waste plastic. We will build 1-4 filament makers (depending on how many people register for the course) from easy to source, off-the-shelf parts - and start making our own filament on Day 3. Thus, if we use scrap plastic - our filament cost drops 100x from $10lb, to about $0.10 per lb. 3D printing costs another 10 cents/lb in electricity. But don't take our word for it - we will take data using an improved and insulated version of our 3D printer - with super fast printing nozzles - to reduce printing costs to well bolow the above figures. We will break up into 2 groups, with one group working on the Filament Maker, and another on the plastic shredder - using the newly built 3D printers to produce parts on demand as a swarming print cluster.

Possible Extended Session

• Extra Credit - Optional Day 8-9 - Design and Build of a Rubber Optimized Extruder. Using lost plastic casting and milling with OSE's D3D CNC circuit mill - we will then build our new design. This will allow us to print large rubber objects with high feed rate.

Experiments

• 3D printed geardowns
• 3D Printer linear bearings with metal balls
• 3D printed electric motor
• heating elements for heat beds, filament makers, and an Electric Kiln for Metal Melting
• MIG Casting into greensand for small, precise metal parts such as couplers.
• Building a 1 meter print bed 3D printer. Stationary bed with 4 Z axes raising the XY gantry
• Building a 1" universal axis with router
• Building a 2" universal axis - applying the lessons from geardown design. Making our own bushings from ZA alloy for the 2" universal axis
• Results - Lower cost Simple 3D Printer

Other Possibilities

• Build a filament maker for producing 3D printing filament from scrap plastic. We will teach you how to design a practical filament maker so that you can take every-day plastics from the waste stream and turn them into useful 3D printing filament. After a design session - you will learn how to actually build a working filament maker. We will build a filament maker similar to the Precious Plastic design - but redesigned for a simpler build that can be done easily as a group in One Day. As such, we will break into 2 groups and build 2 filament makers. After going through this process, you will know a filament maker inside out. We are also offering kits for the filament maker so you can Build Yourself, after this workshop.
• Making filament and composing filament formulas - We will use the newly-built filament maker to produce 3D printing plastic from scrap PLA, ABS, PET, and PVC - and mix these with each other as well as sand, sawdust, and other materials to produce composite filaments. The process starts with grinding, for which we need to use grinders.
• Playing with Geardowns and Building a Plastic Shredder - Give me a lever long enough... and I shall move the world. - Archimedes. We will 3D print planetary gears and apply them to building a heavy duty shredder.
• Building an open source, 3D Printed Cordless Drill - we will 3D print electric motors, use the CNC Circuit Mill to mill circuits and aluminum, and experiment with Desktop Metal Casting to make metal parts from low melting Zinc Aluminum allows that melt in a pot right on your stovetop at only 420C. We will also make simple circuits using 3D printed circuit making techniques. Combined with the planetary geardown and a battery pack based on common 18650 cells - we will spend 2 days designing and building a functional cordless drill starting from waste plastic, aluminum, and post-1982 pennies.

Cost

• $99 - live remote participation. Join us on our new 1 Gbit fiber connection - participate remotely, and ask us questions during the presentation sessions. We will record 2 presentations each day, and leave the video link live throughout the rest of the builds. We can now broadcast to the world - no more agony of a 4 Mbit internet line!
• $699 for the week immersion, but you don't take a 3D printer home with you
• $1399 full week experience, plus take a 8" bed printer home with you
• $899 3D printer kit only. Includes access to the live remote presentation.

Extras:

• Want to take a kit for the Plastic Extruder?
• Want to take a kit for the Plastic Shredder home with you?
• Want to take a kit for the CNC Circuit Mill home with you?
• Need to print larger, more functional items? Participate in the Boot Camp - and take a 3D printer with a 12" heated bed home with you - $1599.

• Need to go industrial? We are offering the first ever public production run of the D3D Mega - with a 3' by 3' print bed, and Super Volcano nozzle - that can print up to 20 lbs of plastic per day! Now you can start printing furniture and construction materials. First time special offer of $_______ (including heated bed) - this is our largest printer option, with heated bed, depending on options. We are offering this build after the Boot Camp - as 3 extra days of build. Now this can get expensive fast if you are buying commercial filament - so that is where you want to start thinking about making your own 3D printing filament to print products with feedstocks from the waste stream.

Registration

• $99
• $699
• $1399
• Donate for extras

Links

• Summer School