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

The DREAM Printer Department of Mechanical & Aerospace Engineering Jessica Javian Jeremy Valencia Morgan Petusevsky Justin Matthew Nicolas Aronstein Everhart Sousa EML 4501 Summer 2020, Group 4

Department of Mechanical & Aerospace Engineering Team’s Hedgehog Concept Motivating Factor -Thinking outside the box while maintaining high functionality Most innovative printer Differentiating design Design Drivers Factor -Highest profit per Innovation working hour -Proprietary Design -Lowest cost per handling time

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

Department of Mechanical & Aerospace Engineering Preliminary Subsystem Concepts Cell Delivery • Micro-Toothpaste • Artificial Vessel • Wizard

Department of Mechanical & Aerospace Engineering Preliminary Subsystem Concepts Actuation • Pneumatic Sliders • Sofu robotic Arm

Department of Mechanical & Aerospace Engineering 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. Full assembly to turret mount 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

Department of Mechanical & Aerospace Engineering 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. Thermal Actuator 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 of motors to the 100 mm 3 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. Bellow sub-assembly 21- uses 2 thermal actuators which are < 5 actuator limit.

Department of Mechanical & Aerospace Engineering 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 of 10. Syringe tube sub-assembly 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

Department of Mechanical & Aerospace Engineering 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

Department of Mechanical & Aerospace Engineering 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

Department of Mechanical & Aerospace Engineering Paraffin Wax Conduction Analysis

Department of Mechanical & Aerospace Engineering Design Highlight 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 Isometric XY dovetail rendering

Department of Mechanical & Aerospace Engineering XY locomotion demonstration

Department of Mechanical & Aerospace Engineering Simplified Cost Table - All components besides OTS parts including pumps, the syringe, and the wiring will be 3D printed. - DMLS printing breakdown: 3D Printer Cost to Make - @ $0.60/g and total material weight of OTS $668.30 120g, DMLS costs $72.00. - 3D printing breakdown: 3D Printing $100.53 - @ $0.36/g and total material weight of Assembly Cost $56.70 32.7, traditional 3D printing costs $11.77. Total $837.34 - 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.

Department of Mechanical & Aerospace Engineering Full Assembly

Department of Mechanical & Aerospace Engineering Bioprinter within (100mm) 3 cube Isometric view with baseball for size comparison Top View of Bioprinter with bounding box

Department of Mechanical & Aerospace Engineering 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 ● opportunity 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.

Department of Mechanical & Aerospace Engineering Thanks for listening! Any Questions?