The DREAM Printer Department of Mechanical & Aerospace - - PowerPoint PPT Presentation

Department of Mechanical & Aerospace Engineering

The DREAM Printer

EML 4501 Summer 2020, Group 4

Justin Aronstein Nicolas Sousa

Jessica

Valencia Jeremy Petusevsky Javian Morgan Matthew Everhart

Department of Mechanical & Aerospace Engineering

Hedgehog Concept

Most innovative printer design Innovation

• Proprietary Design

Differentiating Factor

• Thinking outside the box while

maintaining high functionality Design Drivers

• Highest profit per

working hour

• Lowest cost per

handling time Team’s Motivating Factor

Department of Mechanical & Aerospace Engineering

Product Overview

• Bioinspired design at the juxtaposition of engineering and aestheticism
• Proprietary thermal wax actuators allow for unmatched Fluidic actuation and

controllability

• Thermal actuation maximizes positioning ability by minimizing vibration
• Proprietary pneumatic bellow and dovetails facilitate z-axis locomotion
• Hydraulic cell deposition and extraction allows for high precision flow rates
• 3D Additive Manufacturing utilized in order to maintain low cost and simplify

fabrication

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Preliminary Subsystem Concepts

Cell Delivery

• Micro-Toothpaste
• Artificial Vessel
• Wizard

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Preliminary Subsystem Concepts

Actuation

• Pneumatic Sliders
• Sofu robotic Arm

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Design Sub-system Analysis

Mount

• Nikon Turret Fixture Adapter
• Attaches to Dovetail actuator

Customer Needs Met: 1, 2, 3, 9, 18, and 19. 1- The Dovetail adapter and the cell holding frame account for 32.7 g of the total weight. 2- The top mount has a diameter of 41.60mm creating a tight fit with the microscope turret. 3- Both structures fit within the (100 mm)3 space that the printer takes up. 9- Both structures are manufactured using additive manufacturing and result in a total cost of $14.13 which is below the $4,000 cost limit. 16, 17, 19- Both structures can be sterilized using several standard lab cleaning methods. 18- It takes 36.3 seconds to assemble the turret mount and 35 seconds to assemble the cell holding frame.

Cell holding frame Full assembly to turret mount

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Design Sub-system Analysis

Actuation

• Thermal Actuator for x/y motion
• Bellow operates in the z-direction
• Approximately 33.5 psi to keep bellow stationary

Customer Needs Met: 4, 5, 6, 7, 8, 9, 10, 12, and 21. 4- Its movement across the microgel well plate is < 9μm. 5- Its linear speed is ~ 1 μm/s desired speed. 6- Z travel can reach up to 12mm which meets the Round, Flat, and V-Shaped bottom 96 Well Plate . 7- The modularity of the sub-system received a qualitative score of 10 avoiding the connection

• f motors to the 100 mm3 space.

9- It costs $12.54 which is <$4,000 cost limit. 10- Its lifecycle is expected to 43,800 hours which meets the desired 10,440 hours. 12- X and Y axes are aligned with optical axis to within 1 degree of vertical. 21- uses 2 thermal actuators which are < 5 actuator limit.

Bellow sub-assembly Thermal Actuator

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Syringe tube sub-assembly

Design Sub-system Analysis

Cell Delivery/Actuation

• Hydraulic deposition and extraction
• Hydraulic pressure moves cells into and out of the syringe through a 34 gauge needle

Customer Needs Met: 3, 8, 9, 11, 14, 16, 17, 19, and 20. 3- Weighs 5.01 g which is <200g weight limit. 8- Prints in each well 6.94mm wide, 10.3mm deep. 9- Costs $3.00 which is <$4,000 cost limit. 11- 0.5 mL/s flow rate. 14- The LLS medium cannot escape the structure in any way which gives it a qualitative score

• f 10.

16, 17, 19- The structure can be cleaned in 3 standard lab cleaning methods. 20- Cell viability ~80%

Department of Mechanical & Aerospace Engineering

Design Sub-system Analysis

Cell Holding

• Syringe like tubing
• Easily sterilized via multiple methods

Customer Needs Met: 3, 8, 14, 16, 17, 18, 19, and 20. 3- Weighs 45.93g which is <200g weight limit. 8- Prints in each well: 6.94mm wide, 10.3mm deep. 14- Extraction tip can move within the print medium. 16, 17, 19- heat/fire, UV light, and chemicals can be used for sterilizing. 20- Has ~80% cell viability afuer 24 hours.

Cell holding sub-assembly

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Design Highlight

Pneumatic Bellow Actuator

• A Pneumatically actuated bellow provides vibration free locomotion along the z-axis
• Frictionless thrust is provided by the pneumatic bellow as there are no reciprocating metal components
• An affixed z-axis dovetail facilitates monoaxial motion

Isometric View of Bellow Actuator with Z-axis Dovetail Cross sectional view of bellow actuator

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Design Highlight

Thermal actuators

• Thermal energy is converted into mechanical energy by exploiting the phase change behavior of

paraffin wax

• An copper coil coupled with a resistance temperature detector (RTD) heats a proprietary blend of

paraffin wax to its phase change temperature and change its density composition.

• Phase change driven wax expansion pushes against the diaphragm, which in turn pushes the

piston, creating actuation. The actuator is contracted with the use of springs.

Extended Thermal Actuator Exploded Thermal Actuator

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Paraffin Wax Conduction Analysis

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XY Dovetail

• Two Thermal Actuators are housed within the XY

dovetail

• Dovetail inherently enforces monoaxial locomotion for

each thermal actuator

• Avoids any rotational or axial deflections

during actuation

• Dovetail design maximizes surface area contact,

increasing shock and vibrational absorption

Design Highlight

Isometric XY dovetail rendering

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XY locomotion demonstration

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Simplified Cost Table

• All components besides OTS parts including

pumps, the syringe, and the wiring will be 3D printed.

• DMLS printing breakdown:
• @ $0.60/g and total material weight of

120g, DMLS costs $72.00.

• 3D printing breakdown:
• @ $0.36/g and total material weight of

32.7, traditional 3D printing costs $11.77.

• The assembly cost breakdown:
• 55 steps to assemble 67 parts
• 7 mins of assembly time calculated
• @ $23/hr, and overhead and bin costs of

$46 and $8.06, respectively, assembly cost results in $56.70. 3D Printer Cost to Make OTS $668.30 3D Printing $100.53 Assembly Cost $56.70 Total $837.34

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Full Assembly

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Isometric view with baseball for size comparison

Bioprinter within (100mm)3 cube

Top View of Bioprinter with bounding box

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Summary

• Novelty, Innovation, and Superior Function.

○ Core Reasons why the Dream Printer shall be selected for prototyping.

• We strayed away from the proverbial “Death by Mcmaster-Carr” to deliver something new and

different with functionality in a class of its own

• There are no stepper angles or gearing ratios holding the Dream Printer back

○ The ability to exploit the phase change parameters of paraffin wax allows actuation to achieve precision that is superior to conventional methods

• The Dream Printer can be a catalyst for innovation by giving future EML4502 students the
• pportunity to explore an uncharted territory of engineering

○ Thermal Wax Actuators have never been used in precision applications before. This represents an exciting opportunity for students to design, build, and analyze something that has never been done before.

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Thanks for listening!

Any Questions?