11. Open Source Hardware - From Fibers to Fabric

Research & Ideation

Research

Our team worked together on "Open Source Hardware" this week. We assigned tasks according to each person's area of expertise and made sure there was constant, efficient communication.

The first step was to comprehend the range of fabrication techniques now in use, especially where fabrics and hardware meet. The objective was to find tools and processes that are open-source, flexible, and compatible with producing creative fabric-based designs.

Ideation a Building a 3D Bioprinter

Our laboratory adapted an existing machine to print biodegradable materials. We collaborated and innovated to create an eco-friendly printing solution.

Design Goals

• To create sustainable designs, use alginate, gelatin, and bio-polymers.

• Concentrate on precise X, Y, and Z movement for accurate and smooth prints.

• Core Mechanism: Smooth X/Y movement using linear rails and stepper motors.

• Z Movement: Gear and lead screw mechanism for precise handling of fragile goods.

Inspiration

• The initial step was to investigate the range of existing production technologies, particularly at the junction of textiles and hardware. The goal was to develop tools and processes that would allow for the creation of novel fabric-based designs while being adaptable and open-source.

Image source: Chitosan composite during the robotic fabrication process

• Cellink Bio Printer

The Cellink Bio Printer is one of the leading machines in the bioprinting industry, capable of printing tissues and organs with bio-inks made from human cells. This machine serves as an inspiration for creating bioprinting systems capable of revolutionizing healthcare and research by enabling the printing of complex, multi-material structures.

https://www.cellink.com/

• Raise3D Pro2

The Raise3D Pro2 is an industrial-grade 3D printer designed for high-end manufacturing applications. Known for its dual extrusion system and precise print capabilities, it is widely used for producing functional prototypes and production parts. It serves as an inspiration for designing multi-material machines, which can be extended to bioprinting by incorporating bio-material extruders.

https://www.raise3d.com/

Key Techniques Explored¶

• Weaving & Knitting
• Traditional meets tech with programmable looms and knitting machines
• Laser Cutting & Engraving
• Perfect for intricate designs, precise and functional
• 3D Printing
• Merges fabrics and structures for custom, sustainable designs

3D Printing Techniques for Fashion

• Fabric integration allows for variable designs by printing patterns directly on textiles.
• Materials include TPU (flexible), PLA (eco-friendly), and bio-materials (naturally adaptable)

Applications

• We offer custom clothes, wearable tech, rapid prototyping, and benefits.

• We prioritize zero waste, precise personalization, and scalable production.

For more details about our research and references,check out Fatemeh Mollaie's documentation

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Mesrop Mashtots, the creator of the Armenian alphabet, served as the inspiration for the CNC pen plotter that students at Fab Lab Armenia designed during Machine Building Week in Fab Academy 2023. The machine's CoreXY mechanism, which moves along the X and Y axes with accuracy and efficiency, is one of its features. In order to emphasize sustainability and ingenuity, the project started by disassembling a Canon printing station in order to salvage parts including stepper motors, bearings, and sensors. Our machine was built using these repurposed components, which combined creativity and environmental awareness. We created necessary parts using the recently delivered CR30 3D printer, such as a long, moveable axis that was not possible to print with conventional 3D printers.

By tweaking the GRBL software and adapting an Arduino CNC shield, we were able to precisely control the pen plotter's CoreXY movements. We modified the machine for drawing activities by swapping out the Z-axis motor for a servo motor. Our abilities in mechanical design, electronics, and software setup were put to the test during the assembly, which produced a useful and adaptable CNC. In addition to improving our technical proficiency, this experience made us more aware of the value of teamwork and sustainability in digital manufacturing, which deepened our understanding of the imaginative possibilities of repurposed materials.

We made the decision to hack our machine, enhance its appearance, and add additional functionality to work with textiles and flexible materials in honor of Fabricademy's Open Source Hardware Week.The machine's mechanism, which is based on CoreXY, provides speed and accuracy, making it perfect for complex and innovative applications.

For more information about Mesrop, BOM & Programming follow Anoush Arshakyan's documentation.

Easy to use paste extruder

A Simple Paste Extruder is a device used to extrude materials such as clay, culinary pastes, and other thick substances in a controlled manner. It functions similarly to a traditional 3D printer extruder, except instead of filament, it employs viscous materials. The paste is forced via a nozzle, allowing for exact layer-by-layer deposition, making it excellent for applications such as ceramics, edible creations, and even soft materials. Simple paste extruders are commonly utilized in creative and experimental fields since they allow for greater material versatility and design.

To create our extruder, we began by examining paste extruder examples in order to design a versatile system that met our requirements.

We focused on creating a Simple Paste Extruder, a compact extruder built for 3D printing with paste materials. While we initially found a design on Thingiverse, it was not compatible with our motor. To address this, we built a custom model in Fusion 360 with Mkhitar's guidance.

Creating the New Design Sketch

opened Fusion 360's Sketch tool. made simple 2D outlines:

Rectangular and circular shapes were used in the design of the frame and important parts. Dimensions and restrictions were added for exact proportions. The sketch was saved for extrusion.

For more information about Design please check the Erika Mirzoyan

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.

System of Motion Control and Extrusion

The X and Y axes were controlled by TMC2208 stepper drivers for motion. For the extrusion system, we employed an IRFZ44N MOSFET and a DC motor. To ensure that the extrusion speed was in sync with the machine's movements, the DC motor was managed by PWM.

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Although LightBurn software is usually used for laser cutting, it was utilized to control precise movements and G-code.

How it works

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.

Conclusion

Building our CoreXY CNC/bioprinter has proven to be far more than just assembling mechanical parts; it has been a comprehensive journey filled with discovery, creativity, and invaluable hands-on learning. The process of constructing this machine allowed us to merge engineering principles with artistic problem-solving, showing us how innovative and practical solutions can emerge when we blend technology and design. By leveraging open-source tools and adapting them with our own modifications, we created a machine that not only functions efficiently but also embodies the potential of open collaboration.

Throughout the build, we paid careful attention to each detail, from the precise calibration of the CoreXY motion system, ensuring smooth and balanced movement, to the creation of a flexible extrusion mechanism driven by a DC motor and syringe. These components were designed not only for their technical specifications but also as learning milestones in understanding how complicated systems can be translated into tangible outputs. The experience was filled with moments of both success and failure, each of which contributed to our growing knowledge of CNC systems, bioprinting, and digital fabrication.

Our journey was defined by collaboration and the willingness to experiment. The challenges we faced were often met with creative solutions, and each adjustment we made brought us closer to realizing our vision. It became clear that the process of making—whether through trial and error, or through shared ideas and collective knowledge—was at the core of our success. Every step forward reinforced the power of community-driven innovation and the immense potential of open-source tools to unlock new possibilities.

This bioprinter is more than just a functional piece of equipment; it serves as a gateway to further exploration and innovation. Its design is a testament to how technology, when made accessible and adaptable, can inspire not just efficiency but creativity and new ways of thinking. It holds the promise of transforming industries such as manufacturing, science, and healthcare, where its applications could range from prototyping to bioprinting tissue for medical research. Beyond its technical aspects, the bioprinter represents the spirit of modern innovation, where boundaries are pushed, and new horizons are explored through collaboration, knowledge sharing, and creative problem-solving.

In conclusion, the project has not only contributed to our understanding of bioprinting technology and its applications but has also demonstrated the importance of perseverance, teamwork, and a passion for learning in the world of making. As we move forward, this machine will serve as a platform for future developments, innovations, and discoveries. It stands as a clear example of how, through the fusion of art, engineering, and community-driven open-source projects, we can shape the future of digital fabrication and bioprinting, creating solutions that impact not only the present but also the future of technology.