11. Open Source Hardware - From Fibers to Fabric

This week, our team collaboratively worked on "Open Source Hardware". We divided responsibilities based on individual expertise and ensured effective communication throughout the process.

1. for Design please check the Erika Mirzoyan

2. for Machine Assembly please check the Christina Avagyan

3. for BOM & Programming please chek the Anoush Arshakyan

Research & Ideation

Research and Document Existing Fabrication Methods

Overview of Fabrication Techniques

The first step involved understanding the spectrum of existing fabrication methods, particularly in the intersection of textiles and hardware. The goal was to identify machines and methods that align with creating innovative fabric-based designs while being adaptable and open-source.

Study of Fabrication Methods in Textile Design

I explored the processes used in both traditional and modern textile manufacturing to understand how different materials are treated. This included:

• Weaving and Knitting Machines: These machines represent traditional approaches, but modern iterations include programmable looms and knitting devices, such as Jacquard looms and computerized knitting machines.

• Laser Cutting and Engraving: These methods are increasingly popular for intricate textile designs and functional cuts, as they provide high precision. Machines like the Epilog Laser Cutter are widely used in design studios for textiles.
  
  

• Digital Fabrication in Fashion: Techniques such as 3D printing and CNC machining were reviewed, focusing on how they can integrate with textiles for unique outcomes. For instance, hybrid CNC cutters can engrave, cut, and shape fabrics with digital precision.

3D Printing in Fashion

3D printing, also known as additive manufacturing, offers designers unprecedented control over creating intricate and customizable designs.

1. Techniques and Processes

   • Direct Fabric Integration:
     3D printing can directly integrate with textiles, allowing designs to be printed onto fabric surfaces. This technique enables flexible, wearable outcomes, such as fashion pieces with embedded rigid patterns or decorative elements. Machines like the Stratasys J850 can print both rigid and flexible materials in a single cycle, allowing for a cohesive fusion between textiles and structural designs.

   • Material Compatibility:

     • TPU (Thermoplastic Polyurethane): Known for its flexibility and strength, TPU is widely used for wearable 3D-printed fashion accessories like belts, bracelets, and shoes.

     • PLA (Polylactic Acid): A biodegradable option for environmentally friendly fashion pieces.

     • Bio-Materials: Materials like alginate and gelatin are used for responsive textiles that adapt to environmental conditions, ideal for creating garments that change shape, texture, or even color based on stimuli.

2. Applications in Fashion

   • Custom Garments: Designers like Iris van Herpen use 3D printing to create avant-garde fashion pieces, merging fabric with intricate lattice-like designs.

   • Wearable Technology: Sensors and electronics can be integrated into 3D-printed elements, opening avenues for interactive garments.

   • Rapid Prototyping: Fashion houses utilize 3D printers to create prototypes of accessories or garments, reducing time-to-market and minimizing material waste.

3. Key Benefits

   • Precise customization, allowing designers to craft bespoke designs.

   • Material efficiency through additive manufacturing, significantly reducing waste compared to traditional cutting techniques.

   • Scalability for producing limited-edition pieces or prototypes.

Here’s 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
Electrospinning	Physical/Chemical	Producing ultrafine fibers by charging a polymer solution and collecting the fibers.	Polymers (PVA, PLA, Nylon).	Biomedical scaffolds, nanofiber filters.
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 décor, 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

Key Notes:

1. Spinning produces yarn from fibers, which can then be woven or knitted into fabric.

2. Knitting and Weaving are traditional methods to create fabrics but have different structural techniques.

3. Nonwoven fabrics are made by bonding fibers directly, without spinning, weaving, or knitting, using various techniques like chemical bonding, mechanical bonding, and heat bonding.

4. 3D printing is an emerging method for creating custom, intricate textile designs, often with bio-materials or biodegradable polymers.

5. Laminating and Coating are used for making fabrics suitable for specific uses like weatherproofing or adding texture.

6. Laser cutting has become a common method for precise cutting of fabrics, particularly in fashion and custom designs.

These systems are fundamental in creating textiles for a range of industries including fashion, medical, automotive, and more. Each method offers unique benefits depending on the desired fabric properties, applications, and production volume.

References & Inspiration

When discussing the inspiration for building a 3D printer for biomaterials, you can explore several aspects:

1. Nature as a Blueprint: Biomaterials often mimic natural structures like the cellular framework of plants or the self-assembling behavior of organic tissues. Discuss how studying biological systems can guide machine design to handle fragile or unique biomaterial properties.
   

2. Scientific Advancements: The work of pioneers like Neri Oxman, who explores computational design with biological and synthetic materials, provides a vision of integrating biology with fabrication.

Ideation for a 3D Printer for Biodegradable Materials

Given that our lab could not access a dedicated biomaterial printer, we recognized the need to create one. Fortunately, we already had a semi-finished machine that was initially designed for painting tasks.

With Rudolf's expertise and our team's support, we decided to repurpose and optimize this existing equipment to function as a 3D bioprinter. We conducted an in-depth ideation session to explore all possible modifications and adjustments necessary to adapt the machine for bioprinting purposes.

The brainstorming session led to a comprehensive plan for converting the machine, addressing both hardware and software requirements. This collaborative effort allowed us to move forward with a customized, cost-effective solution that would meet our specific needs for printing with biomaterials

The following is the output of this meeting and the brainstorming with Rudolf and the team:

Concept and Goal:

The goal is to design a 3D printer tailored for biocompatible and biodegradable materials, such as alginate, gelatin, or other bio-based polymers. These materials are ideal for producing eco-friendly textiles, wearable art, or functional objects that prioritize sustainability.

Design Foundation: The Importance of Movement

Core Movement Mechanism:
Most 3D printers rely on precise movement in three axes —X (horizontal), Y (depth), and Z (vertical)— to accurately deposit material layer by layer. The success of this machine depends on achieving this precise movement, which will be at the heart of our design.

1. X and Y Axis Movement:

   • The X and Y axes control horizontal and depth positioning, enabling the print head to traverse the print bed.

   • We will implement this movement using a linear rail system combined with stepper motors to ensure precision.

   • The print head will be mounted on a crossbar, which is guided by belts attached to the motors. This mechanism ensures fast and smooth movement across the plane.

2. Z Axis Movement:

   • The Z axis controls the vertical positioning of the print head or the build plate. Instead of relying on belts, we will implement geared movement for enhanced control and stability.

   • A gear and lead screw system will be used, driven by a stepper motor, to allow incremental lifting or lowering of the platform. This approach offers higher resolution and precision, essential for working with delicate biomaterials.

Properties of the Printer

1. Bio-Material Compatibility:

   • The machine will handle materials with high viscosity, such as hydrogels, alginate, or gelatin.

   • Nozzle systems will allow controlled extrusion, with an option for cooling/heating based on material needs.

2. Adjustable Movement Precision:

   • Movement on the X and Y axes will be controlled with belts for speed.

   • The Z-axis movement, achieved through a gear system, ensures fine resolution for layer deposition.

3. Environmentally Friendly Focus:

   • The use of biodegradable materials minimizes waste, and the printer’s modular design will allow for upgrades and repairs, extending its lifespan.

Process

Materials for the 3D Printer & Frame

1. Body Frame: Aluminum Extrusion

   • Material: Aluminum extrusion profiles were selected for the main structure due to their key properties:

     • Lightweight: Makes the frame easy to transport and maneuver.
     • Durability: Withstands operational stresses, providing stability during the printing process.
     • Ease of Assembly: Aluminum extrusion allows for modular construction using standard connectors and brackets, making it simple to disassemble or expand in the future.

   • Assembly Process:

     • The aluminum extrusions were cut to the required lengths using a metal saw.
     • L-brackets and T-slot connectors were used to secure the pieces into a rigid rectangular frame.
     • Care was taken to ensure all joints were tightly fastened, and the structure was square and level to avoid misalignments during operation.

1. 3D Printed Extruder: The extruder and some supporting parts, such as gear housings and motor brackets, were fabricated using PLA filament.
   

Fabrication Process:

1. Design:

   • The extruder was modeled in CAD software, incorporating a syringe holder to accommodate the bio-material reservoir.

   • Supporting gears for the Z-axis and motor mounts were also designed for precision and fit.

1. 3D Printing:
   • The parts were printed using PLA filament on an FDM printer with settings optimized for structural strength (e.g., 20–40% infill and 0.2 mm layer height).

1. Post-Processing:

   • Support Removal: Support structures generated during printing were carefully removed using precision tools like cutters or pliers.

   • Surface Smoothing: Sandpaper (fine grit) was used to eliminate rough edges for a seamless fit during assembly.

   • Cleaning: All parts were cleaned using a soft brush to remove debris and ensure a clean surface for assembly.

Integration:

• The PLA extruder securely houses the syringe used for bio-material extrusion, ensuring stability during operation.
• PLA brackets were installed to hold stepper motors and provide movement in the X and Y axes.