Zack PolizziMaxwell Tucker

North Carolina School of Science and Mathematics

DESIGN AND CONSTRUCTION OF A MULTI-MATERIAL 3D PRINTER

Introduction | Design and Construction | Business Plan

3D PRINTERS

• Allow for rapid creation

of 3-dimensional objects

• Applications in rapid

prototyping, design

testing, flexible

production, and a

variety of other uses

http://www.wired.com/design/2013/07/is-this-cast-the-future-of-healing-broken-bones/

http://biginscience.com/big-in-science-articles/2012/8/26/could-3d-printing-help-an-ailing-economy.html

http://protinus.wordpress.com/tag/bathsheba-grossman/

Introduction | Design and Construction | Business Plan

PROBLEMS WITH CURRENT DESIGNS

• Current consumer printers offer limited material selection

• Relatively slow print speeds

• Extrusion printing struggles with complex unsupported structures

http://solidsmack.com/cad-design-news/evd-unsensored-bre-pettis-interview-and-makerbot-store-tour/attachment/makerbot-replicator-2/

Introduction | Design and Construction | Business Plan

ORIGINAL ENGINEERING GOALS

Build a working 3D printer which is capable of printing in multiple different materials

• Create a design that is flexible and extensible

• Have the ability to print directly from 3D CAD drawings

• Aiming to print in various metals, plastics, ceramics, sugar,

glass, and many other materials

Introduction | Design and Construction | Business Plan

DESIGN EVOLUTION

• Originally an idea for a Research in

Physics project

• Original design was for a solar-

powered 3D printer

• Built a prototype over Mini-Term

• Presented research in Singapore

• Currently working on upgrades and

hope to bring product to market

through Entrepreneurship class

Photo Credit: Luke Fernandez

Introduction | Design and Construction | Business Plan

DESIGN THEORY

Selective Laser Sintering

1. Lay down a base material layer

2. Melt a cross-section of the 3D object into the base

material

3. Add a thin layer of additional material

4. Melt the next cross-section into the new material layer

5. Repeat until printing is finished, building 2D layers

vertically upon each other until the 3D object is complete

http://upload.wikimedia.org/wikipedia/commons/3/33/Selective_laser_melting_system_schematic.jpg

Introduction | Design and Construction | Business Plan

CONSTRUCTION: XY TABLE

Photo Credit: Luke Fernandez

Introduction | Design and Construction | Business Plan

CONSTRUCTION: ELECTRONICS AND PRINT HEAD

Photo Credit: Zack Polizzi

Photo Credit: Luke Fernandez

Photo Credit: Luke Fernandez

Introduction | Design and Construction | Business Plan

CURRENT WORK

Planned Upgrades

• Laser Powered

• Greater Material Capability

• Higher Resolution

• Faster Print Speeds

• Fully Automatic Printing

Photo Credit: Zack Polizzi

Introduction | Design and Construction | Business Plan

LASER UPGRADES

Photo Credit: Zack Polizzi

Introduction | Design and Construction | Business Plan

LASER DIODE POWER SUPPLY

40A Buck Regulator Schematic

Introduction | Design and Construction | Business Plan

Introduction | Design and Construction | Business Plan

Completed Power Supply

Introduction | Design and Construction | Business Plan

COMPETITIVE MATRIX

16

Printer Our Printer Makerbot Reprap Shapeways EOSINT 280

Print Speed 5cm3/min 1cm3/min .5 cm3/min 6-20 days 10cm3/min

Product Cost $5,000 $3,000 $700+ $20-$1,000/print $680,000

Material Capabilities

Many powdered materials

ABS/PLA plastic

ABS/PLA Plastic

Plastics, 3 metals,

ceramic, sandstone

Plastics, metals,

ceramics

QUESTIONS?

THANKS TO LUKE FERNANDEZ, STUART WELLS, DR. LOBUGLIO, DR. HALPIN, DR. BENNETT, DR. SHECK

NCSSM RESEARCH