11. Open Source Hardware - From Fibers to Fabric¶
Research & Ideation¶
Research
Machine Assembly Description¶
Frame Construction
The frame is constructed using aluminum extrusions, providing a sturdy and modular base structure. Corner joints are secured with brackets and screws for stability.
3D-Printed Components
All non-aluminum parts, including motor mounts, belt tensioners, and the syringe holder, are designed and 3D-printed by the team. The 3D-printed components are tailored to ensure precise fits and functionality, demonstrating the customizability and adaptability of the design. The mounts and holders are printed using a durable filament to withstand the operational forces during movement and material dispensing.
Motors and Movement System
Four stepper motors are mounted at each corner of the frame, using the custom 3D-printed motor mounts. The motion system uses belts, guided and tensioned with 3D-printed tensioners, ensuring accurate and smooth operation along the X and Y axes.
Toolhead and Z-Axis Mechanism
The central toolhead features a 3D-printed syringe mount, designed to securely hold the syringe and ensure stability during material extrusion. A vertically mounted DC motor, also supported by 3D-printed parts, controls the syringe's dispensing mechanism (Z-axis movement).
The pulley system¶
Pulley and Belt Connection:
The stepper motors drive pulleys connected to timing belts.
The belts are tightly looped around these pulleys and additional idler pulleys to create a controlled motion system.
Motion Transfer:
When the motor shaft rotates, the pulley attached to it moves the belt in a linear direction.
This motion is then transmitted to the structure or part of the machine connected to the belt.
Tensioners and Guides:
The red and teal components seem to function as tensioners or idler pulleys, ensuring the belt stays aligned and maintains proper tension.
Proper alignment and tension are crucial for precise motion and to prevent the belt from slipping or coming off.
Usage in Systems
This kind of setup is typically used to move a print head, build platform, or another mechanism in X, Y, or Z directions.
Machine Assembly and Operation Process¶
Programming the Mechanism¶
The machine uses an Arduino board programmed with GRBL firmware to control the stepper motors for the X and Y axes and a DC motor for the Z-axis. GRBL serves as the controller, interpreting G-code commands for precise movement and material dispensing.
Setting the Zero Point
The home position (zero point) is calibrated to establish the starting location of the toolhead. This ensures alignment and consistent operation throughout the process.
Configuring the Axes
X and Y Axes: Stepper motors are used for horizontal movements, with belts and 3D-printed tensioners ensuring smooth and precise motion. Z Axis: A DC motor drives the vertical movement of the extruder. The motor controls the syringe’s plunger, enabling precise dispensing of the alginate material.
System Integration
The machine’s operation mirrors that of a laser cutting system. The control board (Arduino with GRBL) is connected to the motors, facilitating real-time communication and movement synchronization based on the design file.
Preparing the Extruder
A syringe, filled with alginate, acts as the extruder. The syringe is mounted on a custom 3D-printed holder and driven by the DC motor for controlled vertical extrusion.
Design Preparation in LightBurn
The design file is created and set up in LightBurn software, which generates G-code for the machine. This G-code is sent to the Arduino, guiding the machine’s movements and dispensing actions.
Painting on Fabric
The DC motor-controlled extruder dispenses the alginate material onto the fabric in precise patterns, as defined by the LightBurn design. This process enables the machine to "paint" on the fabric with high accuracy and repeatability.
