11. Open Source Hardware - From Fibers to Fabric¶
π Research & Ideation¶
𧡠Exploring Fabrication Methods π§ Overview of Techniques¶
We studied existing methods in textiles and hardware to find open-source, innovative solutions. The goal was to identify machines and methods that align with creating innovative fabric-based designs while being adaptable and open-source.
βοΈ Key Techniques Explored¶
- Weaving & Knitting π§Ά: Traditional meets tech with programmable looms and knitting machines.
- Laser Cutting & Engraving π₯: Perfect for intricate designs, precise and functional.
- 3D Printing π€: Merges fabrics and structures for custom, sustainable designs.
π¨οΈ 3D Printing in Fashion¶
Techniques
- Fabric Integration π¨: Print patterns directly on textiles for flexible designs.
- Materials π±: TPU (flexible), PLA (eco-friendly), Bio-materials (adaptive to nature).
Applications
- Custom garments π
- Wearable tech ποΈ
- Rapid prototyping β‘
Benefits π
- Zero waste β»οΈ
- Precise customization βοΈ
- Scalable production π
Hereβs a detailed table summarizing the textile fabrication systems, including their types, processes, materials, and typical applications:
| Fabrication Method | Type | Process | Materials Used | Applications |
|---|---|---|---|---|
| Spinning | Mechanical, Chemical | Fibers are drawn out from a fiber source, twisted, and formed into yarn. | Cotton, wool, synthetic fibers, silk | Textile manufacturing, clothing, upholstery |
| Knitting | Mechanical | Yarn is looped into a series of interconnected loops to form fabric. | Wool, cotton, synthetic fibers | Garments, activewear, home textiles |
| Weaving | Mechanical | Two sets of yarn (warp and weft) are interlaced to form a fabric. | Cotton, silk, polyester, nylon, wool | Upholstery, garments, technical textiles |
| Tufting | Mechanical | Yarn is inserted into a fabric or backing to create raised patterns. | Cotton, silk, polyester, nylon, woolWool, nylon, polyester, cotton. | Carpets, rugs, upholstery, textile patterns. |
| Bonding | Chemical/Thermal | Fusing materials together using heat, adhesives, or ultrasonic methods. | Polyester, polypropylene, nylon, polyurethane. | Medical textiles, nonwoven fabrics, protective clothing, wipes. |
| Nonwoven Fabric | Chemical, Mechanical, Thermal | Fibers are bonded together by chemical, mechanical, or thermal methods. | Polyester, polypropylene, natural fibers | Medical textiles, filters, wipes, insulation |
| Felting | Mechanical, Chemical | Fibers are entangled and bonded under pressure, heat, and moisture. | Wool, synthetic fibers | Mats, carpets, insulation, filters |
| Braiding | Mechanical | Yarns are interlaced to form a tube or a flat structure. | Polyester, nylon, cotton | Ropes, cords, narrow textiles |
| Crocheting | Mechanical | Similar to knitting, but with a hooked needle to form interlocking loops. | Yarn, cotton, synthetic fibers | Garments, accessories, home textiles |
| 3D Printing | Additive Manufacturing | Layers of material are deposited to form complex shapes | PLA, nylon, TPU, bio-materials | Customized textiles, medical, architectural designs |
| Extrusion | Mechanical | Polymers are melted and forced through a mold to form fibers or filaments. | Nylon, polyester, polypropylene, biodegradable polymers | Fiber production, nonwovens, 3D printing |
| Meltblowing | Thermal | Polymer melts are extruded through fine nozzles into a high-speed airflow. | Polypropylene, other thermoplastics | Filtration fabrics, medical textiles |
| Spinning and Weaving (Textile Loom) | Mechanical | Fibers are spun into yarn, then interlaced into fabric on a loom. | Cotton, wool, polyester, nylon | Garment textiles, upholstery, home fabrics |
| Laminating | Chemical, Mechanical | Layers of fabric are bonded together using heat, pressure, or adhesives. | Polyester, polyurethane, natural fibers | Outdoor fabrics, medical textiles, technical fabrics |
| Coating | Chemical | A layer of material is applied to fabric for waterproofing or other effects. | PVC, silicone, polyurethane, rubber | Outdoor gear, automotive textiles, medical textiles |
| Laser Cutting | Thermal, Mechanical | High-powered laser cuts fabric precisely without physical contact. | Cotton, polyester, acrylic, nonwoven materials | Customized fashion, home dΓ©cor, technical fabrics |
| Printing (Screen, Digital) | Chemical/Mechanical | Ink or dye is applied to fabric to create patterns or images. | Cotton, polyester, silk, nylon | Fashion textiles, home furnishings, promotional fabrics |
π‘ Ideation: Building a 3D Bioprinter¶
Our lab repurposed an existing machine to print biodegradable materials. With teamwork and creativity, we designed a solution tailored for eco-friendly printing. πΏ
βοΈ Design Goals¶
- Use alginate, gelatin, and bio-polymers for sustainable designs.
- Focus on precise X, Y, Z movement for accuracy and smooth prints.
π Core Mechanism¶
- X/Y Movement β‘οΈβ¬οΈ: Linear rails + stepper motors for smooth motion.
- Z Movement βοΈ: Gear and lead screw system for precision with fragile materials.
π Inspiration¶
We drew ideas from nature π³ and innovators like Neri Oxman, exploring how biological systems influence design.
For more details about our research and references, check out Fatemeh Mollaie's documentation. π
"ΥΥ₯Υ½ΦΥΈΥΊ Mesrop": Innovating CNC Pen Plotters with Upcycled Sustainability¶
During Fab Academy 2023 at Fab Lab Armenia, Anoush and her team created "ΥΥ₯Υ½ΦΥΈΥΊ Mesrop," a CNC pen plotter inspired by Mesrop Mashtots, inventor of the Armenian alphabet. The machine uses a CoreXY mechanism, known for precision and speed. They upcycled components from a Canon printer and used the CR30 3D printer for unique parts, blending sustainability and innovation.
For Fabricademyβs Open Source Hardware Week, we improved the design for textiles and flexible materials, showcasing the potential of upcycled resources and collaborative problem-solving.
For more information about Mesrop, follow Anoush's link: Anoush Arshakyan's documentation. π
π Simple Paste Extruder¶
A Simple Paste Extruder is a device designed to extrude materials like clay, food pastes, or other thick substances in a controlled manner. It works similarly to a regular 3D printer extruder, but instead of filament, it uses viscous materials. The paste is pushed through a nozzle, allowing for precise layer-by-layer deposition, making it ideal for applications such as ceramics, edible creations, and even soft materials. Simple paste extruders are often used in creative and experimental fields, offering flexibility in material usage and design.
To develop our extruder, we began researching examples of paste extruders to design a versatile system tailored to our needs.
We worked on building a Simple Paste Extruder, a minimalist extruder designed for 3D printing with paste materials. While we initially found a design on Thingiverse, it was incompatible with our motor. To address this, we created a custom model in Fusion 360, guided by Mkhitar.
π οΈ Workflow¶
π Step 1: Reference the Existing Design¶
- β Download: Obtained the existing extruder model from Thingiverse.
- β Import: Imported the model into Fusion 360 using the Insert > Mesh tool.
- β
Measure: Used the Measure tool to analyze dimensions and proportions.
This helped us adapt the design to fit our specific motor.
βοΈ Step 2: Sketching the New Design¶
Opened the Sketch tool in Fusion 360.
Created basic 2D outlines:
- Designed the frame and key components using rectangular and circular shapes.
- Added constraints and dimensions for precise proportions.
Saved the sketch for extrusion.
π Step 3: Extrusion¶
-
Used the Extrude tool to turn the 2D sketch into a 3D model:
-
Designed a sturdy frame to hold all components (motor, gears, and paste container).
- Added cutouts and slots for functional parts.
βοΈ Step 4: Motor Holder Customization¶
Measured the motor dimensions using Calipers for accuracy.
In Fusion 360:
- Sketched the motor holder outline onto the frame.
- Used Extrude to create a snug-fitting holder.
Positioned the holder to ensure stability and alignment with the motor.
π Step 5: Gear Integration¶
Used the Create > Helical Gear tool in Fusion 360 to design gears:
- π‘ Number of Teeth: Adjusted for optimal gear size.
- π‘ Module: Controlled the gear's dimensions.
- π‘ Pressure Angle: Ensured smooth motion transfer.
Positioned and aligned gears in the assembly for reliable movement.
π οΈ Tested virtually in Fusion 360 to confirm compatibility.
π§ Step 6: Frame Assembly¶
Assembled all components virtually in Fusion 360:
- Placed the motor holder, gears, and frame together.
- Checked for interference and made adjustments.
Ensured all parts fit and function correctly.
π Step 7: Adding Holders for Stability¶
To improve the structural stability of the extruder, we decided to add holders to the frame:
Sketched support brackets onto the sides of the frame.
Used the Extrude tool to create the holders:
- Designed them to securely lock all components in place during operation.
- Positioned them strategically around the paste container and motor.
Virtually tested the stability in Fusion 360, ensuring the holders didn't interfere with other components.
This addition ensures the extruder parts remain steady during operation, minimizing vibration and enhancing reliability. π
π¨ Final Model Description¶
- Frame: Rectangular structure with a circular base to hold the paste container.
- Gears: Positioned at the top to control the extrusion mechanism.
- Motor Holder: A secure mount for the motor, located at the back of the frame.
- Design: Compact, minimalistic, and tailored to the motor's dimensions.
π Next Steps¶
- π€ 3D Printing: Print each component using a 3D printer.
- π© Assembly: Put all parts together, ensuring proper alignment and stability.
- βοΈ Testing: Test the extruder's performance with various paste materials.
π With these steps, we created a customized, efficient, and functional paste extruder tailored to our project needs. Feel free to reach out if you have any questions or ideas! π
πΈ Assembled Paste Extruder¶
Below are the results of our Simple Paste Extruder project, showing both the 3D-printed frame and the fully assembled extruder.
3D-Printed Frame¶
This is the 3D-printed frame that serves as the base of our extruder. Key design features include:
- Cutouts and mounts for securing the motor and syringe.
- Additional holders to improve stability during operation.
- Pre-drilled screw holes for easy assembly. The frameβs minimalistic and lightweight design ensures functionality while maintaining durability.
Fully Assembled Extruder¶
The assembled extruder includes all the components working together:
- A motor securely mounted at the top, connected to the gear system.
- A syringe positioned in the circular cutout at the bottom for paste extrusion.
- The gears and syringe are aligned for precise and smooth extrusion.
- The open-frame design provides:
- Easy access for adjustments or repairs.
- A compact structure for better portability.
π§ Key Improvements¶
- We added extra holders to the frame for better security and reduced movement of parts.
- Using precise 3D-printed parts allowed for accurate assembly and alignment.
π Next Steps¶
- Test extrusion performance with various paste materials to assess functionality.
- Make adjustments if necessary to improve consistency and precision.
Below you can see a video demonstrating how the paste extruder works in action, initially tested without any liquid to ensure the mechanism operates smoothly. π₯β¨
Integration of the Extruder into the Machine π οΈ¶
After finalizing the design of our paste extruder, we successfully integrated it into our machine. The process involved mounting the extruder frame securely to the machine's structure using bolts and adjustable supports, ensuring stability during operation.
In the left image, you can see the extruder firmly attached to the machine, with the syringe aligned vertically to facilitate smooth extrusion. The threaded rod at the top is connected to a motor, allowing precise control of the syringe plunger.
We utilized a perforated plate to enable flexibility in positioning the extruder. This modular approach allows for easy adjustments and ensures compatibility with the machine's framework.
Machine Assembly Overview¶
In this section, we describe the assembly process of our paste extruder machine, focusing on the key components that make it functional and efficient. The design incorporates a combination of aluminum extrusions, custom 3D-printed parts, and precision motors to create a robust system capable of controlled material extrusion. We will walk you through the frame construction, movement system, and the unique features that contribute to the machine's operation.
Machine Assembly Description¶
Frame Construction¶
The frame is built using aluminum extrusions for a sturdy base, with corner joints secured by brackets and screws.
3D-Printed Components¶
All non-aluminum parts, including motor mounts, belt tensioners, and the syringe holder, are custom-designed and 3D-printed for precision and functionality.
Motors and Movement System¶
Four stepper motors control the X and Y axes with precision, using custom 3D-printed mounts and belt tensioners.
Toolhead and Z-Axis Mechanism¶
The toolhead holds the syringe and features a vertically mounted DC motor for precise Z-axis movement, controlled by 3D-printed parts.
Pulley System¶
The stepper motors drive pulleys connected to timing belts and idler pulleys, ensuring accurate movement and tension.
For more information about the machine assembly description, you can go to Christina Avagyan's documentation.
CONNECTING GRBL TO ARDUINO AND CNC SHIELD¶
We began with GRBL, an open-source firmware for CNC machines. GRBL converts G-code into movement commands for stepper motors. We used an Arduino Uno paired with a CNC shield to connect the components.
The first step was installing GRBL by importing it into the Arduino IDE. After flashing the firmware onto the Arduino using the grblUpload.ino file, the Arduino became the control brain of our machine.
The CNC shield mounted on the Arduino managed the stepper motors. We activated CoreXY functionality in the GRBL configuration file to support precise X and Y movements using two motors.
CALIBRATING AND OPERATING WITH UGS¶
We used Universal G-Code Sender (UGS) to communicate with the machine. UGS helped us check GRBL settings and adjust steps per millimeter for precise movement.
To verify communication with the Arduino, we used the command $$ in UGS. If the machine moved inaccurately, we recalculated the steps per millimeter.
We also set up the homing sequence to ensure the machine starts from a consistent position.
MOTION CONTROL AND EXTRUSION SYSTEM¶
For motion, TMC2208 stepper drivers controlled the X and Y axes. We used a DC motor and an IRFZ44N MOSFET for the extrusion system. The DC motor was controlled via PWM to regulate extrusion speed, ensuring it was synchronized with the machine's movements.
LightBurn software was used to manage precise movements and G-code, although it's typically designed for laser cutting.
REFINING THE MACHINE¶
After integrating the hardware and software, we performed tests to fine-tune the machine. The main adjustments focused on achieving a balance between speed and accuracy, ensuring reliable operation for both rapid and detailed tasks.
For more information about GRBL and Arduino, follow Anoush's link: Anoush Arshakyan's documentation. π
You can see our video below β it's magic how our extruder brought the design to life!