Experimental Investigations of Fused Filament Fabrication for Applications to Affordable Scientific Hardware

This research aims to make science more accessible through the use of open source 3-D printers. A new control system for CNC machines in general and 3-D printers specifically, is developed and presented that enables web-based control of 3-D tools from any Internet connected device. The system can be set up and controlled entirely from a web interface. A tool was designed to help apply science to the developing world. The developing world remains plagued by lack of access to safe drinking water. A methodology is provided for the design, development, and technical validation of a low-cost open-source water testing platform. A case study is presented where the platform is developed to provide both colorimetry and nephelometry. This approach resulted in equipment that costs between 7.5 and 15 times less than current commercially available tools. A syringe pump was designed and manufactured using an open-source hardware and software. The design, bill of materials and assembly instructions are available. The cost of the entire system, including the controller and web-based control interface, is on the order of 5% or less of a commercial syringe pump having similar performance. The design should suit the needs of almost any research activity requiring a syringe pump. A low-cost, open source 3-D microscope stage is presented. A RepRap 3-D printer was converted into an optical microscope equipped with a customized holder for a USB microscope. The machine is able to operate with USB or conventional microscopes. The repeatibility is below 2-D microscope stages, but it is adequate for the majority of scientific applications. The stage costs less than 3% to 9% of the closest proprietary commercial stages. A deformation model for PLA was expanded to use a physics based temperature gradient. This generalized the model to 3-D printing in a room temperature environment. Tests confirm that this is a valid model for predicting warpage of thin vertical walls of PLA. Additionally, the effect of annealing was examined. It was found that at a temperature of 50°C, no shrinkage or crystallization takes place, but at 90°C the plastic rapidly crystallizes to around 20% crystallinity

Free and Open-Source Automated 3-D Microscope

International audienceOpen-source technology not only has facilitated the expansion of the greater research community, but by lowering costs it has encouraged innovation and customizable design. The field of automated microscopy has continued to be a challenge in accessibility due the expense and inflexible, non-interchangeable stages. This paper presents a low-cost, open source microscope 3-D stage. A RepRap 3-D printer was converted to an optical microscope equipped with a customized, 3-D printed holder for a USB microscope. Precision measurements were determined to have an average error of 10 μm at the maximum speed and 27 μm at the minimum recorded speed. Accuracy tests yielded an error of 0.15%. The machine is a true 3-D stage and thus able to operate with USB microscopes or conventional desktop microscopes. It is larger than all commercial alternatives, and is thus capable of high depth images over unprecedented areas and complex geometries. The repeatibility is below 2-D microscope stages, but testing shows that it is adequate for the majority of scientific applications. The open source microscope stage costs less than 3% to 9% of the closest proprietary commercial stages. This extreme affordability vastly improves accessibility for 3-D microscopy throughout the world

Free and Open-source Control Software for 3-D Motion and Processing

International audienceRepRap 3-D printers and their derivatives using conventional firmware are limited by: 1) requiring technical knowledge, 2) poor resilience with unreliable hardware, and 3) poor integration in complicated systems. In this paper, a new control system called Franklin, for CNC machines in general and 3-D printers specifically, is presented that enables web-based three dimensional control of additive, subtractive and analytical tools from any Internet connected device. Franklin can be set up and controlled entirely from a web interface; it uses a custom protocol which allows it to continue printing when the connection is temporarily lost, and allows communication with scripts

Integrated voltage—current monitoring and control of gas metal arc weld magnetic ball-jointed open source 3-D printer

To provide process optimization of metal fabricating self-replicating rapid prototyper (RepRap) 3-D printers requires a low-cost sensor and data logger system to measure current (I) and voltage (V) of the gas metal arc welders (GMAW). This paper builds on previous open-source hardware development to provide a real-time measurement of welder I-V where the measuring circuit is connected to two analog inputs of the Arduino that is used to control the 3-D printer itself. Franklin firmware accessed through a web interface that is used to control the printer allows storing the measured values and downloading those stored readings to the user’s computer. To test this custom current and voltage monitoring device this study reports on its use on an upgraded all metal RepRap during the printing of aluminum alloy (ER1100, ER4043, ER4943, ER4047, and ER5356). The voltage and current data were analyzed on a per alloy basis and also layer-by-layer in order to evaluate the device’s efficacy as a monitoring device for 3-D printing and the results of the integrated design are discussed

Free and open-source control software for 3-D motion and processing

RepRap 3-D printers and their derivatives using conventional firmware are limited by: 1) requiring technical knowledge, 2) poor resilience with unreliable hardware, and 3) poor integration in complicated systems. In this paper, a new control system called Franklin, for CNC machines in general and 3-D printers specifically, is presented that enables web-based three dimensional control of additive, subtractive and analytical tools from any Internet connected device. Franklin can be set up and controlled entirely from a web interface; it uses a custom protocol which allows it to continue printing when the connection is temporarily lost, and allows communication with scripts

Substrate Release Mechanisms for Gas Metal Arc 3-D Aluminum Metal Printing. 3D Printing &Additive Manufacturing

International audienceLimited material options, prohibitively expensive equipment, and high production costs currently limit the ability of small and medium enterprises to use 3-D printing to prototype and manufacture metallic goods. A low-cost open-source 3-D metal printer that utilizes gas metal arc welding technology has been developed that could make metal printing accessible to the average consumer. Unfortunately, this technology would demand access to expensive cutting tools for part removal from the substrate. This paper investigates several substrate treatments to provide a low-cost method to easily remove 3-D printed 1100 aluminum parts from a reusable substrate. Coatings of aluminum oxide and boron nitride on 1100 aluminum and A36 low carbon steel substrates were tested. Lap shear tests were performed to assess the interlayer adhesion between the printed metal part and the print substrate. No warping of the substrate was observed during printing. It was determined that boron nitride coated low carbon steel provided the lowest adhesion strength. Printing aluminum on uncoated low carbon steel also allowed easy removal of the aluminum part with the benefit of no additional coating steps or costs

Mobilising investors for Blue Growth

The European Union's Blue Growth Strategy is a long term strategy to support sustainable growth in the marine and maritime sectors, aiming to contribute to innovation and economic growth (European Commission, 2012). The EU sees the financial sector as a key partner to bring about transition to sustainable consumption and production. However, knowledge about investment behavior, experience with working with these investors, and ways to engage investors in the Blue Growth sectors is lacking. This paper examines this knowledge gap. It characterizes investors and identifies investor behavior, investors' motives, and conditions and criteria relevant for investors to invest in Blue Growth sectors. The presented results are derived from a literature study on investors and investment behavior, an electronic survey and in-depth interviews. Stereotypical images of private equity bankers or wealthy individuals do not do justice to the diversity of investors involved in the Blue Growth sectors. These sectors are still in development and various risks reduce the willingness to invest. Risk mitigation should be seen as a shared responsibility of entrepreneurs, investors and governments. Government support must go further than financial support for research and development or technological demonstration projects. Proven technologies get stuck in the Valley of Death as investors alone are not willing to take the risk associated with upscaling of promising technologies. Tied in a reciprocal relationship, governments need to attract private investors—their capital, knowledge, and networks—to further grow of the Blue Growth sectors while investors need stable, predictable, and effective government support schemes to mitigate their financial risks