CAD and 3D Design of Ink-Testing ToolsDavid So

August 21st, 2015

My Projects

Much more than just Mechanical Engineering

Fluid Centrifuge

Fluid Centrifuge

• Goal: Design a new fluid centrifuge to accommodate different sized test units

• Process:

– Evaluated current design of the Fluid centrifuge

– Created new system that fits the different sized test units

• Benefits:

– Allows new print bars to experience high amounts of acceleration in order to simulate and speed up the pull of gravity

– Will fit multiple sizes of test units

Progression of Designs

Original Design

First DesignAdded Extra For Strength

Extra Plate Not Needed

FinalRemoved Extra

Metal

Encap EFI (Electrical Fluid Immersion) Tray

What are Encaps?

• Encaps = Encapsulents

EncapsulantWire Bonds

Substrate

Silicon Print Engine

Substrate

Fluid attack

10-30 volts

Temperature (70C) Mechanical wiping

Encapsulant exposed to multiple stressors. It must protect the circuit from shorting/corroding.

Encap EII (Electrical Fluid Immersion) Tray

• Goal: Redesign a more user friendly system to test for fluid shorts

• Process:

– Received preliminary 3D model of what client wanted

– Talked with client to further understand requests and intended functionality

– Modified system to further aid and improve usability

• Benefits:

– New system allows for isolated modular access and removal of individual print bars

– Fluid reservoirs reduces the frequency of refills

Old Tray

New Tray

Fluid Humidity Level Monitor

Fluid Humidity Level Monitor

• Goal: Design a system to inject air bubbles into fluid in order to measure moisture loss due to fluid circulation

• Process:

– Received project scope and purpose

– Discussed with mentor about possible ways of accomplishing air injection into the fluid

– 3D modeled system and individual parts for 3D printing

• Benefits:

– Allows for measurement of humidity loss while fluid is circulating

– Interchangeable head system allows for different sizes of bubbles to be injected into the fluid

Fluid Humidity Level Monitor

Separa

tor

FLUI

D

AIR Bubble

r

Humid

.

Sense

.

Humid

.

Sense

.

Fluid Humidity Level Monitor

St. Helens Micro Pump

InkJet Micro Pump

• Goal: Use InkJet to create a micro pump

• Process:

– Used an Arduino to fire a InkJet pen

– 3D modeled head of InkJet print head

– Developed module to attach ribbon cable to InkJet print head

• Benefits:

– InkJet pen functions as a micro pump to allow slow and controlled pumping of fluid

Building the System

InkJet Print Head for Micro Pumping

Shooting Ink

Code Used

// Inputs and Outputs

const int buttonPin1 = 1;

//const int buttonPin5 = 5;

const int ledPin3 = 3;

const int ledPin4 = 4;

const int ledPin5 = 5;

const int ledPin6 = 6;

const int ledPin8= 8;

//const long interval = 1000; //

interval at which to blink (milliseconds)

int button1State = 0;

int oninterval = 1; // Length for

time on

int offinterval = 1000; // Length for

time off

int numloop = 5000; // Number

of times blinked

int sensorValue = 0; // Dimmer code

int outputValue = 0; // Dimmer code

const int ledPin = 2;

void setup() {

pinMode(ledPin, OUTPUT);

pinMode(ledPin3, OUTPUT);

pinMode(ledPin4, OUTPUT);

pinMode(ledPin5, OUTPUT);

pinMode(ledPin6, OUTPUT);

pinMode(ledPin8, OUTPUT);

pinMode(buttonPin1, INPUT);

// Serial.begin(115200);

//pinMode(buttonPin5, INPUT);

}

/*When button is pressed, cartridge will

fire numloop number of times.

Length is specified by oninterval and

offinterval */

void loop()

{

button1State = digitalRead(buttonPin1);

if (button1State == LOW)

{

digitalWrite(ledPin, HIGH);

for (int i =0; i < numloop; i ++)

{

digitalWrite(ledPin3, HIGH);

//delay (oninterval);

delayMicroseconds (oninterval);

digitalWrite(ledPin3, LOW);

digitalWrite(ledPin4, HIGH);

//delay (oninterval);

delayMicroseconds (oninterval);

digitalWrite(ledPin4, LOW);

digitalWrite(ledPin5, HIGH);

//delay (oninterval);

delayMicroseconds (oninterval);

digitalWrite(ledPin5, LOW);

digitalWrite(ledPin6, HIGH);

//delay (oninterval);

delayMicroseconds (oninterval);

digitalWrite(ledPin6, LOW);

digitalWrite(ledPin8, HIGH);

//delay (oninterval);

delayMicroseconds (oninterval);

digitalWrite(ledPin8, LOW);

delayMicroseconds (offinterval);

//delay (offinterval);

//Serial.print(1);

//Serial.print(\n);

}

}

digitalWrite(ledPin, LOW);

}