Rachel LevineME (Lead Engineer)

Sam PerryME

Amy RyanISE (Lead Programmer)

Kwadwo Opong MensahEE

P13552 Projected Image Prototyping System

Faculty Guide John Kaemmerlen Primary Customer Denis Cormier

Michael DiRomaISE (PM)

The primary objective of this project is to create a projected image 3D printer with the ability to produce a three-dimensional part.

Project Description

Customer Needs

SpecificationBuild a 3D PartBuilt with

PhotopolymerLayer ThicknessFeature Resolution

Part Size DimensionSoftware to control

all aspects

YesYes25 – 250 MicronsAble to report

process capabilitiesMax Size of 3” by 4”Fully Automated

Engineering SpecificationsTarget Value

Photopolymer: Light sensitive resin that cures when light hits it

A black and white image or “slice” is a way to selectively cure the resin

Concept Summary

Black and white image

from DLP projector

System Architecture

Physical Setup

Bath glass is covered with TeflonBath glass is secured between top and bottom

bath assemblyBath assembly is attached to the platform Bath filled with resinBuild Platform lowered Completely

Platform is lowered using the jog buttons

System Architecture

Inputs to LabViewSTL fileUnits (millimeters and inches)Slice Thickness – 50 Microns (ideal conditions)Base Speed – 1600 (ideal conditions)Cure Time – 3 seconds (ideal conditions)

System Architecture

Windows Command Line and Slicer

Information Gathered3D Object size (length, width, and height)

Functions Performed Object sliced Images background changed to black and core

changed to white Images saved to desktop

System Architecture

LabView, the projector, and the Microcontroller

Steps to move determined by layer thickness

Build Platform moves up to far enough to separate from the Teflon then down to the appropriate distance

The image will project for the set cure time then it will display a black screen.

System Architecture

Stepper Motor

Lead Screw, Linear Guide

Sandblasted Aluminum Build Platform

Jog Buttons

Resin Bath and Teflon Film

DLP Projector

Motion Controller

Motion Assembly

Macro Lens Optics

Sandblasted Aluminum Build PlatformIncreased adhesion

Teflon FilmDecreased adhesion

Lead ScrewAnti-backlash nut12.7μm (0.0005”) resolution per step

Linear GuideHigh loading support with low deflection

Motion ControllerIntegration with software

Features

System Testing Results

SuccessesMultiple complete

parts produced

System fully automated

Utilizing past teams materials (projector, case, formula, etc)

Inconsistent adhesion to build platform

Unable to use different photopolymers

Resolution of parts is low

Project Evaluation Failures

Improve Teflon FilmPermanent glass coating

Hard limit switchesDedicated softwareEncoder supportTest different photopolymer resin formulasClean up LabView Programing CodeContinue Detailed testing to determine

optimal settings

Recommendations

All risks can not be accounted forUnidentified risks, external to the project

Overlooked sources of help“Secret formula” found on past teams poster in

week 8 of the second quarter

Better testing structure earlier in the quarterManipulate one variable at a time in a

controlled manor

Lessons Learned

Any Questions?