Developing a Modular Fabrication System

PETER GENOVESE IV, DAVID M. COFFMAN, ANDREW BUNOZA, LESLIE C. MAIER, RUSSELL L. BINACO, SHERMAN HARTMAN, ALEXANDER D. STEEL, DELANEY M. SHEPPARD

Engineering as a whole has seen a revolution in the last decade as the “Maker Movement” has had a resurgence in individuals and small businesses creating and designing new and original products. At the heart of this movement was the advent of consumer-grade 3D printers. The drastic drop in price of these systems coupled with their ever increasing accuracy and precision has enabled the average person to become their own production facility; creating prototypes and even final products with little to no experience. With over a quarter of a million desktop 3D printers being sold, the industry was worth over $5.1 billion in 2015. Alongside 3D printers, laser engravers and CNC milling machines have also seen a similar trend of increasing accessibility to the average consumer. These three devices are some of the most powerful fabrication tools currently available. After carefully studying these 3 machines it has been concluded that they are all have two major similarities. Firstly, these devices all rely on a rigid and precise movement system along three cardinal axes to move some manner of tool head. Secondly, they are all controlled via a computer system to allow for repeatability and accuracy typically beyond that of human control. With this understanding in mind, a system that encompassed all three devices was conceived. This modular fabrication system would consist of a robust frame and quick-swap tool head that would allow the user to rapidly and easily transition between these various devices. Additionally, the system would be modular in such a way as to allow to the user to configure the physical dimensions of the machine to best fit their needs. Since 2017, we have made great strides towards building a machine which can do this. A rigid fame was constructed from 8020 extrusions, a common structural component that is easy to use and modify. To this was attached two motion systems. One moves a build plate in the vertical (Z) direction using ball screws for precise yet forceful movement. The other motion system controls the movement of the head in the XY direction, using a configuration of belts and pulleys known as CoreXY, which allows a more even distribution of loads to the drive motors than a traditional single-motor, single-axis system. A quick-swapping head mechanism is mounted to the CoreXY motion system to allow the user to swap end effectors. 3D printer and laser engraver heads have been fabricated. Finally, the electronic control system has been integrated with the frame, and we can currently jog all three axes of motion electronically. We are on track to perform actual 3D prints and laser engraving by the end of 2019.