Andre FaroniRory Timar Josh Stroud

ME 102B Final Presentation:

Building a 3D Metal Printer

4/29

Overview

Design Process

What + WhyOvervie

wWrapup Q+A

Goal: explore printing metal parts

with weldingResult: Lots of trial and

error

Here’s what we learned…

Why a 3D Metal Printer?

Design Process

What + WhyOvervie

wWrapup Q+A

?

First Prototype Doesn’t Work

What + WhyOvervie

wWrapup Q+A

Design Process

Focus on learning about + prototyping TIG welding

circuitry

Tackle the

riskiest part first!

Iterating on Power Circuit

Car Ignition

Coil

Factory HV Caps

DIY Transformer to Spec

Flyback Transform

er

DIY Capacitor

Salvaged Transform

er

High Voltage Arc Ignition

What + WhyOvervie

wWrapup Q+A

Design Process

Iterating on Power CircuitHF Current

Control

`

Continuous Current Power Supply

HV Capacitor “Zap” Array

Jewelry Micro-Tig Welding

Insight!

What + WhyOvervie

wWrapup Q+A

Design Process

Beefier Microcontroller Powers Closed-Loop Control

What + WhyOvervie

wWrapup Q+A

Design Process

Arduino Uno16 MHz

ARM Cortex M-4168 MHz

HF Current Control

PI current control

Capacitor Charging

P voltage control

Misadventures in Startup Land

Free Ventures

What + WhyOvervie

wWrapup Q+A

Design Process

We want this!

Final Prototype

Overview

Wrapup Q+ADesign Process

What + Why

System Overview

What + WhyOvervie

wWrapup Q+A

Design Process

System Operation

Overview

Wrapup Q+ADesign Process

What + Why

1 2 3

System Operation

Design Process

Overview

Wrapup Q+AWhat +

Why

1 2 3

System Operation

Design Process

Overview

Wrapup Q+AWhat +

Why

2 31

Microcontroller Control

Design Process

Overview

Wrapup Q+AWhat +

Why

Experimental Data

Design Process

Overview

Wrapup Q+AWhat +

Why

Lessons Learned

• Know when to model, know when to build

• Invention = SMART trial and error.

Design Process

What + WhyOvervie

wQ+A

Wrapup

WrapupGoal: a 3D metal printer for the masses

Insight: Combine TIG welding practice with existing 3D printer tech

Final Result: an experimental platform to test + tune our welding process

Design Process

What + WhyOvervie

wWrapu

pQ+A

Biggest Lesson: Even when the work you set for yourself wasn’t finished, you’ve come too far to

say it’s worth coming back

Timeline in Janurary

Design Process

What + WhyOvervie

wWrapup Q+A

Image sources

Tig welder: http://cfnewsads.thomasnet.com/images/large/025/25335.jpg

Microtig welder: http://www.millerwelds.com/education/articles/images/Fig.-7-Micro-TIG1lr.jpg

Arduino: http://arduino.cc/en/pub/skins/arduinoWide_SSO/slider_home/h_01.jpg

ARM: http://d3dpuk1s8nsuve.cloudfront.net/wp-content/uploads/2012/05/STM32-F0-microcontroller-series.jpg

Thomas edison: http://2.bp.blogspot.com/--wbqi2ucw14/UhoodohiWiI/AAAAAAABxOk/KxVcgjYLeiY/s320/Entrepreneur%E2%80%99s+Curse.jpg

Misadventures in Startup Land

Free Ventures

What + WhyOvervie

wWrapup Q+A

Design Process

We want this!