High Temperature Pellet Based 3D Printer Head (P15551)

MSD I - Problem Definition Review 09/11/2014

Team Introduction & Roles

Team Members Majors Roles

Ray Ali Industrial & Systems Engineer

Lead Engineer

Alyssa Palmieri Mechanical Engineer Project Manager

James Allen Mechanical Engineer Design Engineer

Kylan Ames Mechanical Engineer EDGE Manager/Team Facilitator

Project Background Brief History of 3D Printing:

1984: Charles Hull invents stereolithography (SLA)

1980-1990’s: Selective Laser Sintering (SLS) and Fused Deposition Modeling (FDM) are developed and commercialized

2005: RepRap is founded; 3D printer that is self-replicating

2009: FDM patent expires, causing an explosion in the DIY 3D printer market

2014: Selective Laser Sintering patent expires, could cause new boom in 3D printing

Problem Statement ●  Current state:

o  3D printer heads use plastic filament, which has variable diameter and is quite expensive

o  If the diameter varies too much, the feed mechanism fails o  Operation at temperatures up to 280°C

●  Desired state: o  3D printer head that uses ordinary plastic injection molding pellets as

its feedstock o  Operation at temperatures up to 380°C

●  Constraints: o  Cost < $500, preferably $200 o  Must be compatible with a majority of hobby grade 3D printers

Project Deliverables ●  CAD models of final design(s). ●  Schematics for electronics ●  Bill of Materials with sources of

components, quantities and cost ●  Clearly illustrated manual that provides

instructions on how to build printhead ●  Test results demonstrating nozzle is

capable of extruding ULTEM high temperature plastic

●  Test results demonstrating extruder can run continuously for 10 hours without clogging or failure

Use Scenarios Activate device & allow to achieve

desired operating temp

Load pelletized material into the

pellet hopper

Execute print program

Cool & clean print head

Require additional pellets/ change material/color?

Y

es

No

Prioritized List of Needs Customer Importance Description of Needs

9 Utilize unmodified plastic injection molding pellets as feedstock material

9 Documentation in the form of a operation manual required

9 Cost is to not exceed $500

7 Must be capable of operating up to 380℃

7 Must be able to print continuously for 10hrs without failure

7 Print head overall size and mass must be similar to most 3D print head assemblies

7 Print head must work with standard hobby grade 3D printers

7 Parts readily available for hobbyists to re-create the printer head

1 Interchangeable nozzles to allow for different diameters and easy cleaning

Engineering Requirements

House of Quality

House of Quality: Benchmarking

General Project Plan

Descriptive Project Plan

Questions?