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. 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. 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.

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