FAB Academy 2019 Handout by qbicfablab

TUTORIAL: FAB ACADEMY 2019 HANDOUT

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

Fab Academy

TUTORIAL: WEEK 2: PROJECT MANAGEMENT

TUTORIAL:

Areej Abu Raed| Edutech Engineer 24| 01| 2019

DEVELOPING A WEBSITE Introduction to HTML and CSS: • HTML (the Hypertext Markup Language): provides the structure of the page. • CSS (Cascading Style Sheets): CSS the visual layout (Page Color, Font style and size… etc)

EXAMPLES 1- Explaining general format of HTML document. 2- Adding • Text • Link • List • Image • Buttons … etc. 3- Adding CSS https://www.w3schools.com/html/html_examples.asp https://www.w3schools.com/

BOOTSTRAP Bootstrap is a ready to use website templates https://startbootstrap.com/template-categories/all/

BRACKETS • Brackets is a modern text editor that makes it easy to design in the browser. • Live view • It works in all OS IMAGE RESIZING SOFTWARE Using different softwares like GIMP , Paint, and Photoshop to resize the images. Note: an image of a few MB is a image not well optimized for the web.

TUTORIAL:

Areej Abu Raed| Edutech Engineer 24| 01| 2019

WHAT DOES IT MEAN TO OPTIMIZE IMAGES? • Large images slow down your web pages which creates a less than optimal user experience. • Typically simpler images like PNGs should be under 100 KB or less for best performance.

Low compression (high quality) JPG – 590 KB ~ 0.59 MB

High compression (low quality) JPG – 68 KB

Medium compression (great quality) JPG – 151 KB

Git Setup: ●

Step 1:

●

Step 2:

TUTORIAL:

Areej Abu Raed| Edutech Engineer 24| 01| 2019

Git Bash: • Configure username: git config --global user.name "your username" • Configure email: git config --global user.email your email git config --global core.editor nano • Generate SSH Key ssh-keygen -t rsa -C "your email“ Enter file in which to save the key (/c/Users/Areej/.ssh/id_rsa) • Access the public key: cat ~/.ssh/id_rsa.pub • Copy the SSH key and add it to GITLab WHAT IS SSH KEY ? • SSH stands for (Secure Socket Shell), SSH keys can be used to establish a secure connection and in our situation we use it in Git operations from your local machine.

TUTORIAL:

Areej Abu Raed| Edutech Engineer 24| 01| 2019

• Got to desktop create a new folder • Go to gitbash: cd Decsktop/git/ • Go to GitLab: • Project details GIT Repository, inside your name branch, you copy this link

• git clone The Link That You Copied

TO UPLOAD YOUR FILES FOLLOW THESE COMMANDS The last thing to do is to push the files in the working directory to the repository by using: • cd your file location (Master) 1. git add -A: this will add all the files in the directory 2. git commit -m ”anything” : this command will just add a title for the updating operation 3. git push : this command will push all files added in the first command to your GITLab account

TUTORIAL: WEEK 3: COMPUTER AIDED DESIGN

PAG. 5 PAG. 6

Introduction to Computer Aided Design and the Assignment of the Week References

ONE

Introduction to Computer Aided Design and the Assignment of the Week

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

Introduction to Computer Aided Design Fab Foundation Link: http://academy.cba.mit.edu/classes/computer_design/index.html

Computer Aided Design (CAD) is a set of methods and tools to assist product designers in: ● Creating a geometrical representation of the artifacts they are designing. ● Dimensioning, Tolerancing. ● Conﬁguration Management (Changes). ● Exchanging part and assembly information between teams, organizations. ● Feeding subsequent design steps. ● Analysis (CAE) ● Manufacturing (CAM). All by means of a computer system and different softwares. There are two different modeling methods using any CAD software; these are 2D modeling and 3D modeling. For a simple comparison between 2D and 3D systems; it could be said that 2D systems create digital images, while 3D systems create digital sculptures. Similar to comparing a common paper/photo printer to a 3D printer, the main difference between 2D and 3D systems is how they interpret and reproduce data in real-world space. The following ﬂow chart represents the generic CAD process.

Assignment of the week: Model (raster, vector, 2D, 3D, render, animate, simulate, ...) a possible ﬁnal project, and post it on your class page.

To do this assignment, refer to the following tutorials provided in the following pages and Fab Foundation links:

1. 2. 3. 4. 5.

2D Modeling Tools and Tutorials 3D Modeling Tools and Tutorials UV MAPPING IN BLENDER Antimony Tabs Parametric Modeling of a Box Beam in Antimony

TWO

References

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

FAB Academy Resources: http://fabacademy.org/2019/docs/FabAcademy-Tutorials/week02_computer_aided_design/resources.html Vector vs. Raster Graphics: https://vectr.com/tutorials/what-are-vector-graphics/ 3D Modeling: ● SketchUP: ○ https://www.sketchup.com/learn/videos/826 ● Blender: ○ https://www.blender.org/support/tutorials/ ○ https://www.blenderhd.com/wp-content/uploads/2015/08/BeginnersGuideToBlender.pdf ○ https://www.evl.uic.edu/spiff/class/cs426/BlenderBasics2ndEdition.pdf ● Rhino: ○ https://web.iit.edu/sites/web/ﬁles/departments/academic-affairs/academic-resource-center/pdfs/Rhinoceros.pdf ○ http://elearning.rcub.bg.ac.rs/moodle/pluginﬁle.php/12358/block_html/content/Rhino%204.0%20Users%20Guid e.pdf

TUTORIAL: WEEK 4: COMPUTER-CONTROLLED CUTTING

PAG. 7 PAG. 8-22 PAG. 23 PAG. 24-35

Introduction to Computer Controlled Cutting and the Assignment of the Week Laser Cutting Press Fit Vinyl Cutting

ONE

Introduction to Computer Controlled Cutting and the Assignment of the Week

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

Introduction to Computer Controlled Cutting Fab Foundation Link: http://academy.cba.mit.edu/classes/computer_cutting/index.html Computer Controlled Cutting is one of the most important technologies in the digital fabrication. Cutting with a CNC machine is achieved using different methods; one of them is through laser beam and another method is through cutting knife. CNC cutting machines which cut 2D models over different materials using the laser beam are called, LASER CUTTERS. While machines that cut different materials using the cutting knife or blade are called VINYL CUTTERS. In this section of the Fab Academy, you will use the two different computer controlled cutting techniques to fabricate different 2D or 3D models. However, the CNC cutting machines are operating over 2D (X-Y coordinate) only; therefore, it can accept 2D models (ﬂated expanded version of 3D models) only.

Assignment of the week: ●

Group Assignment: ○ Characterize your laser cutter, making test part(s) that vary cutting settings and dimensions.

●

Individual Assignment: ○ Cut something on the vinyl cutter. ○ Design, lasercut, and document a parametric press-ﬁt construction kit, accounting for the laser cutter kerf, which can be assembled in multiple ways.

To do this assignment, refer to the following tutorials provided in the following pages and Fab Foundation links:

1. 2. 3. 4.

Introduction to laser cutting. Press-Fit Construction Tips Press-Fit Inkscape Vinyl Cutter

TWO

Laser Cutting

Tasnim Hussain | FAB Engineer 01| 01| 2019

Q1| Q1-1| Laser Cutting Machine LC 1390S | Cutting Machine DESIGN SOFTWARES : LaserCut (https://cnctuts.com/blog/laser-machines/download-free-lasercut-5-3-and-installation-process ) FAB FOUNDATION REFERENCES: http://fabacademy.org/2018/docs/FabAcademy-Tutorials/week3_computer_controlled_cutting/laser.html

MACHINE DESCRIPTION The G.WEIKE LC1390S is a high precision laser cutting machine that focuses a high energy laser beam onto a material resulting in a high quality and dimensionally accurate cut. The laser cutter can be used to cut, etch, engrave, drill and to cut a variety of materials. Generally laser cutting machines contain a carbon dioxide (CO2) laser that produces invisible laser radiation at a wavelength of 10600nm in the infrared spectrum. The LC1390S has a maximum cutting area of 1300 x 900 mm, uses laser power of 800 W and operates at 110-220V - 50 and 60 Hz AC supplies. The machine has a very thin focal point of 0.2mm width, this makes the machine highly precise and convenient for all kinds of precision instrument industries. Unlike other milling technologies, laser cutting is superior due to the cleanliness of material cutting which leads to material saving from being lost while milling. Furthermore, it has a very fast cutting speed of 0-24000 mm/min which greatly minimizes the time needed for cutting. http://www.gwklaser.com/pdf/LC1390.pdf The LC1390 can be used to engrave and cut List of materials shown below:

Cardboard

Uncoated Paper

Matboard

Acrylic

Plywood

Basswood

Hardwood

MDF

Masonite

Cork

Leather

Glass

Tasnim Hussain | FAB Engineer 01| 01| 2019

Materials cannot be cut with laser cutter: ● ● ● ● ● ● ●

Most metals cannot be cut with the laser cutter. The two exceptions are thin sheets of stainless or spring steel. Polycarbonate (PC, Lexan) as it produces toxic fumes. Any material containing chlorine such as PVC and vinyl. Glass and Fiberglass can only be engraved. Printed circuit board (FR4 and other material types). Carbon ﬁber. High-density polyethylene (HDPE) thicker than 1/16".

Cutting Parameters: Simple 2D designs or non vectorized drawings are not informative enough to enable the laser cutter to cut or engrave any object. In order to create a laser file, creating a vector file is needed. Vector files can be easily created using dedicated software like LaserCut or using free vector files from a website like Noun Project. The most important tip is to follow the design guidelines of the material being used as each material has specific constraints that are necessary to take into account. For instance, the kerf that the laser creates while passing over the material should be considered and the size of the object should be checked to ensure that it does not exceed the size of the cutting area of the machine. Most importantly, the laser power and speed should be adjusted carefully to suit the material type and to serve the laser design safely without risks of burns ar fire. The following table shows different power and speed ratings applied to different materials available in the lab using the LC 1390S.

Settings in the Software

Settings in the Machine

Material

Speed

Power

Speed

Power

Plywood (3mm)

25%

100%

MDF (3mm)

30%

100%

MDF (6mm)

100%

Acrylic (3mm)

20%

100%

Acrylic (5mm)

Felt Sheet (3mm) Cardboard

80%

100%

30%

100%

20%

100%

Tasnim Hussain | FAB Engineer 01| 01| 2019

LASER CUTTING Laser Cutting is a digital manufacturing technique for transforming a 2D design into a physical object. This technology can be used over a wide range of materials with very high precision and clean ﬁnish. It can cut with a minimum thickness of 0.2mm. Advantages of Laser Cutting: ● ● ● ● ●

Cutting on a wide range of materials of different thicknesses Very precise work Material saving High speed of realization Ability to cut and engrave

Laser Beam Cutting Gas Work Piece (Material) Kerf

Types of Laser Cutting: There are many types of laser cutting; however, the following are the most commonly used techniques: ● Fusion Cutting ● Oxygen-assisted Cutting ● Sublimation Cutting

CO2 Laser Cutter Operation: The laser beam is a column of very high intensity light of a single wavelength or color. For CO2 laser cutter, the wavelength is infrared light to have the beam invisible to human eye. This beam is generated from the laser resonator at about ¾ of an inch in diameter and then travel through the machine’s beam path. Then the beam may be bounced in different directions by a number of mirrors, before it is it is ﬁnally focused onto the plate. The focused laser beam goes through the bore of a nozzle right before it hits the plate. Moreover, through the nozzle bore there is a compressed gas such as Oxygen or Nitrogen. By focusing the large power beam down to a single pinpoint, the heat density at that spot is extreme. The high power density results in rapid heating, melting or vaporizing of the material. The following ﬁgure illustrates the travelling path of the beam over the machine.

Tasnim Hussain | FAB Engineer 01| 01| 2019

MACHINE SAFETY PRECAUTIONS Laser Safety Precautions: ●

Do not stare directly into the laser beam as serious and permanent damage may result to the optic nerve, cornia or lense. In case you experienced blurred vision, immediately seek medical attention.

●

Exposure to the laser beam may cause physical burns and can lead to severe damage. Proper use and care of the system is crucial for safe operation. Thus, always keep the machine door closed and observe the machine through the window while cutting.

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Stay away from the machine and keep hands clear as serious physical cuts can occur.

Material Safety: ●

Fume exhaust/ extractor system is MANDATORY when operating the laser system. Fumes and smoke from the cutting or engraving process must be extracted from the laser system and ﬁltered outside.

●

Some materials can produce toxic or corrosive fumes when being engraved or cut, thus obtain the Material Safety Data Sheet (MSDS) from the manufacturer for every material you intend to process using the laser cutter. The MSDS discloses all the safety hazards when handling or processing a particular material.

●

NEVER leave materials in the laser system after laser processing has ﬁnished. Always remover all material including scrap material from the machine as they can lead to a ﬁre hazard.

To learn more about safety hazards, check out the following link: https://ehs.washington.edu/system/ﬁles/resources/laser-cutter-safety.pdf

Tasnim Hussain | FAB Engineer 01| 01| 2019

PREPARING THE DESIGN ●

STEP 1: Getting the 2D model ready

As mentioned in the introduction, to prepare a laser cutting file, a vector file should be generated using a software like LaserCut. However, before using the software it is important to know that the a 2D model is needed. A simple 2D model can be sketched using LaserCut software. However, for highly customized design the 2D models are created using any modeling software like SolidWorks, Autodesk Inventor, AutoCAD or any other. Most importantly is to export the 2D sketch as a “DXF” file or “SVG” file. ●

STEP 2: Uploading the design to the machine

To upload the 2D model into the laser cutter, the following three are needed: 1- LaserCut 5.3 software which supports the machine controller. LaserCut 5.3: software is a Chinese developed solution to transform designs into machine code path sequence. The software comes with the machine. 2- USB Softlock to unlock the machine design software. USB Softlock is a USB device that looks similar to normal USB flash drive, it comes with the machine to enable you to use the LaserCut software, without this USB softlock the LaserCut 5.3 program cannot be operated on the computer. 3- USB Flash Drive to transfer the design to the machine. USB Flash Drive is a regular memory flash drive of 16GB max memory, since the machine does not support higher USB memory size. This flash drive is to store the machine code exported by LaserCut 5.3 to the G.WEIKE LC 1390S Laser Machine.

The ﬁrst step is to connect the “Soft Lock” USB ﬂash drive into the PC with LaserCut software to enable using the software.

Open LaserCut and then click on “File” → “Import” to obtain the 2D design - as mentioned in the introduction- that is in the format of “.dxf” or “.svg”.

Tasnim Hussain | FAB Engineer 01| 01| 2019

Then browse for the DXF ﬁle with the 2D design.

The design is uploaded into the LaserCut as one cutting layer. However, since there is text and two concentric circles, it is better to cut the parts from innermost parts to outermost parts.

The design is divided into three different cutting layers by simply coloring each part with a different color.

The layers are rearranged from innermost to outermost using the “Up” and “Down”.

Tasnim Hussain | FAB Engineer 01| 01| 2019

100 20 20

The default parameters for speed and power are adjusted to suit the material type -acrylic in this case- and the task. E.g. engraving needs slower speed and smaller power compared to cutting.

The same steps are done for the two cutting parts to adjust the cutting speed and power. Change the default parameters to the parameters shown in PAG. 2.

The ďŹ le is then downloaded and exported to obtain the laser ďŹ le.

Tasnim Hussain | FAB Engineer 01| 01| 2019

The ďŹ le is then saved into a USB ďŹ&#x201A;ash drive to be able to process it with the laser cutter.

OPERATING THE MACHINE

POWERING UP THE LASER CUTTER It is a paramount importance to power up the machine in the right way as this will help avoiding serious damages and maintaining the safety of the machine especially the laser tube. In order to safely power the machine, the four steps listed below should be followed: 1- Power up the laser tube chiller/cooler. 2- Power up the air compressor. 3- Power up the laser machine. 4- Power up the smoke ventilator (Ear protection required). *Note that the powering should be done in order from 1 to 4, wrong sequence might damage the machine. The fourth step could be done right before cutting any part.

The G.WEIKE Laser Machine consists of two panels, each panel is associated with a different section of the machine. 1- The Laser Machine Front Main Panel 2- The Laser Machine Nozzle Control Panel

Tasnim Hussain | FAB Engineer 01| 01| 2019

LASER CUTTER ANATOMY

The G.WEIKE Laser Machine consists of two panels, each panel is associated with a different section of the machine. 1- The Laser Machine Front Main Panel 2- The Laser Machine Nozzle Control Panel Detailed Description: Laser Machine Front Main Panel This panel can control the main features and functions of the machine. 1

Laser machine power switch

Machine control key panel

LCD display screen

Machine motion control for (X, Y) axis & homing button (XY-0)

USB softlock storage pocket

Emergency switch

* Note: the red (X) crossed section is unusable.

**Note: 1- The laser machine power switch is powered ON when turned in the clockwise direction and powered OFF when turned in the counterclockwise direction. 2- The machine control key panel: this panel has many buttons with the following functions

Tasnim Hussain | FAB Engineer 01| 01| 2019

Key

Functions

Display laser machine functions menu.

ENTER

Entering and conﬁrming parameter input.

ESC LASER

Escaping/Exiting from current function, parameter setting or display. Shoots laser (DANGEROUS) do not use it unless necessary for maintenance and troubleshooting purposes. Keep out from laser beam pathway.

TEST

Moves the nozzle around the artwork working area..

FILE

Displays the list of ﬁles uploaded “artworks”.

START

Start cutting the design.

STOP

Stop cutting the design.

3- The LCD display screen displays selection, ﬁle, parameters, functions etc. 4- The machine motion control buttons has two modes of functionality, these functionalities are switched by ESC & ENTER key. By default when the machine starts after homing position is achieved, it goes into LCD interaction mode. Then by pressing ESC, the keys with switch to Axis motion control, and by pressing ENTER again they keys goes back to LCD interaction -The steps in the following pages will demonstrate more-. Interact with LCD display to select and change parameters values Left (←) & Right (→) switches between displayed parameters. Up (↑) & Down (↓) change, increase or decrease parameters values. (XY-0) does nothing Controls the axis motion Left (←) & Right (→) controls the X axis. Up (↑) & Down (↓) controls the Y axis. (XY-0) moves the machine axis to homing position.

Laser Machine Nozzle Control Panel This panel is only associated with the nozzle head, controls its height and probes the material surface height from the bed. Adjusting the Z axis level should be done with special care as the nozzle head can get damaged if not properly used.

1- LCD screen 2- Nozzle motion control keys Up (↑) & Down (↓) controls the Z axis. 3- Restart is used to restart the machine.

Tasnim Hussain | FAB Engineer 01| 01| 2019

The ďŹ rst step is to power ON the laser machine.

Secondly and the most important, is to turn on the chiller to cool the machine while cutting.

Thirdly, the compressor is turned ON.

Then the ventilator is powered ON to extract smoke and fumes produced from cutting or engraving.

Tasnim Hussain | FAB Engineer 01| 01| 2019

Click “ESC” to switch from axis motion control to interaction with the LCD screen.

“FABLAB” ﬁle is selected by pressing “ENTER”.

All files with the format “.MOL” is saved in the USB flash will show. Using the right and left arrows to navigate the desired file.

The ﬁle will take few seconds to be downloaded to the machine.

Tasnim Hussain | FAB Engineer 01| 01| 2019

Then the LCD will display some basic parameters of the laser ﬁle.

Press “ESC” to exit the LCD interaction mode and to move to the axis motion control. The button (XY-0) is pressed to move the machine axis to homing position.

The material is inserted into the cutting area of the machine.

After that, “TEST” yellow button is clicked to visualize the cutting area before start cutting the design.

Tasnim Hussain | FAB Engineer 01| 01| 2019

Then the Z axis is adjusted by lowering the nozzle head to reach very close distance from the cutting surface/ material.

The nozzle should be around 2mm proximity to the surface.

After adjusting all the parameters, the door is closed for safety purposes.

Click â&#x20AC;&#x153;STARTâ&#x20AC;? to begin cutting the design.

Tasnim Hussain | FAB Engineer 01| 01| 2019

The engraving and cutting will take few minutes and it is done in order from the innermost to the outermost as speciﬁed in the design.

After ﬁnishing the laser design, the LCD will show the time consumed to do the tasks. Before switching OFF, press “ESC” button.

The pieces are left to be cooled and then they are removed from the machine bed including the scrap material.

Finally the machine is powered OFF.

THREE

Press-Fit

Tasnim Hussain | FAB Engineer 01| 01| 2019

PRESS-FIT Fab Foundation Link: http://fabacademy.org/2018/docs/FabAcademy-Tutorials/week3_computer_controlled_cutting/press_fit.html When a 3D model is being cut using laser cutter, the points of contact (joints) should be designed in a special way to allow the parts of the model to be snapped together. This is called interference fit, which is sometime referred to as press-fit or friction fit. It is the fastening between two parts which is achieved by friction to assemble the parts of a 3D model. Depending on the material and its thickness, the fitting value may vary from 10-50 µm. Following is a simple example to demonstrate the concept of the press-fit construction using a 3.8mm thick cardboard. SolidWorks software was used to draw and extrude a simple triangular modular element. The design was then exported as a DXF and was opened in Inkscape software to manage the fitting of the slots. Accounting for the kerf, the slot or the hole width was made 3.5mm (less than the thickness of the material) to provide a good fit of parts when being assembled to make a 3D model.

The triangular element is cut several times with the laser cutter.

The 3D assembled object after press-ﬁtting.

FOUR - 1

Vinyl Cutting

Tasnim Hussain | FAB Engineer 01| 01| 2019

Q1| Q1-2| Vinyl Cutter Silhouette Cameo 3 | Cutting Machine DESIGN SOFTWARES : Silhouette Studio (https://www.silhouetteamerica.com/software ) FAB FOUNDATION REFERENCES: http://fabacademy.org/2018/docs/FabAcademy-Tutorials/week3_computer_controlled_cutting/vinyl.html

MACHINE DESCRIPTION The Silhouette Cameo 3 is a fully integrated desktop cutting system. It is used to cut over 100 different materials including vinyl, paper, cardstock, fabric and other materials up to 12 inches x 12 inches (The dimensions of the cutting mat). Moreover, the Cameo 3 has a dualcarriage for multi-tool and it has a self-adjusting AutoBlade that can cut materials up to 2mm thick. Additionally, it is compatible with Print & Cut and PixScan technology. Therefore, it can be used to create printed pieces of art. The Silhouette Cameo 3 cutting machine comes with the Silhouette Studio software, power cable and USB cable, 12- Inch cutting mat, AutoBlade cutting blade and markers. For more details, check the following: https://45c5pz3jeuoy37ymbmpauzad-wpengine.netdna-ssl.com/wp-content/uploads/2017/03/cameo-3-user-manual.pdf https://www.youtube.com/watch?v=Z6kqQ40F54c

Machine Composition

Main Tools

Tasnim Hussain | FAB Engineer 01| 01| 2019

The Silhouette Cameo 3 has versatile capabilities to print and cut over different materials of different features to design different DIY pieces. For instance, it can be used to design school projects, stamps, sketches, kinds crafts, accessories, invitations, stickers, stencils, 3D projects, cards, paper crafts, home decor, etched glass and many others.

INTRODUCTION TO: Silhouette Studio Software The Silhouette Studio has a free software available in different versions for Windows and MAC OS. The software is simple and has a user friendly interface. Moreover, it is compatible with receiving designs sent from PC, tablet or mobile phone through Bluetooth (when Bluetooth is enabled). For more details regarding enabling Bluetooth connection with the Silhouette Cameo 3, visit the lik: https://www.silhouetteschoolblog.com/2016/08/silhouette-cameo-3-bluetooth-set-up.html . SAFETY PRECAUTIONS Before getting started with Cameo 3, there are some important safety instructions should be considered and followed to ensure the safety of the user, the machine and the part being cut. ●

Keep hands and objects away from moving parts when the Silhouette is plugged in and while its cutting.

●

The Silhouette blades are very sharp, keep hands clear.

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Do not disassemble or repair the Silhouette parts as this might lead to an electrical shock due to leakage.

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Pay special attention when plugging the Silhouette to the correct rated power supply.

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When the Silhouette Cameo gets overheated, unplug the AC power adapter immediately to avoid electrical shocks or ﬁre.

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Do not allow dust or metals to be near the Silhouette plug as this could cause electrical shocks or ﬁres due to current leakage.

●

The Silhouette Cameo should be placed in a clean workspace away from dust, humidity and water.

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Do not store the Silhouette Cameo in a place exposed to sunlight, humidity or dust.

Tasnim Hussain | FAB Engineer 01| 01| 2019

OPERATING THE MACHINE

After plugging the vinyl cutter to the wall outlet, use the USB cable to connect the Silhouette Cameo 3 to a laptop where the Silhouette studio is installed. Then switch on the Silhouette vinyl cutter.

When Silhouette Cameo3 Studio is opened, the above screen appears showing the 12 x 12 inches cutting mat and will be used as a canvas for your design.

To change the page dimensions (e.g. inches to mm), go to the â&#x20AC;&#x153;Page Settingsâ&#x20AC;? ribbon on the bottom right side of the screen. The settings will be useful to create longer designs or to use an extended cutting mat.

Tasnim Hussain | FAB Engineer 01| 01| 2019

The Silhouette Cameo 3 can be used to design shapes, free drawing, text, and photos. As illustrated in the following pages. The most important point to consider when the design is ﬁnished is to ensure that it is placed within the red margins to ensure that the parts are not being cut outside of the cutting area.

Designing Text: the Silhouette Studio enables adding text and designing/ featuring it as well by editing its size, weight, spacing, justiﬁcation and position of the text. Simply to add text, select “A” from the margin in the right side of the screen.

Tasnim Hussain | FAB Engineer 01| 01| 2019

The font can be edited from the “Text Style Panel” in the right hand side margin. From this panel, size, font type, color and other features can be easily modiﬁed.

Cutting Text: now after ﬁnishing with the text design, you can cut the text using the Silhouette Cameo 3 by referring to the “Trace Panel” in the right side margin.

Tasnim Hussain | FAB Engineer 01| 01| 2019

The text to be cut is selected by choosing “Select Trace Area” to enable the selection. Then choose “Outline” to create cut at the outer border of the text. Final step is to choose the “Trace Style”, “Trace” is selected for simplicity.

Adjusting the settings: before sending the design to Silhouette, the cut settings should be adjusted to ensure high quality cutting. Select “Cut Settings” from the drop down menu under the Silhouette tab. This will bring up the Cut Settings menu on the right hand side of the screen. In this menu the cutting style is selected and also the type of material which controls the sharpness of the blade that will be adjusted automatically based on the material type.

Tasnim Hussain | FAB Engineer 01| 01| 2019

Preparing the Silhouette for cutting: the ﬁrst thing to check from the design panel is to select the cutting mat with the right size.

The ﬁrst thing to consider is the design size in the Studio and to ensure that it does not cut outside the cutting area. Get the cutting mat ready to stick the material over.

The mat is then inserted under the roller bar with edges aligned with the blue marked points .

Once you have selected the appropriate settings for the cut and loaded the cutting mat, click on the “Send” to Silhouette in the top right corner of the Studio window.

The auto adjustable blade will do some calibration for few seconds to measure the thickness of the material before cutting. Then cutting starts right away.

After cutting, the machine displays a message on the screen to indicate that the cutting is ﬁnished. Release the mat by clicking on “Unload”.

Tasnim Hussain | FAB Engineer 01| 01| 2019

The mat is unloaded and the sticker is ready.

Remove the vinyl from the mat and using scissor or spatula to cut the portion with the design.

Transparent Transfer Tape

Now the hook is used to remove the extra vinyl covering the text/ designed sticker and to remove the .

After making sure that the transfer tape is completely stuck to the text, kindly peel off tape and stick the text over any desired surface using the scraper again for burnishing.

Now use a small piece of the transfer tape to cover the text and start burnishing using the scraper.

Finally the transfer tape sheet is gently removed and the sticker is ready to use!

Tasnim Hussain | FAB Engineer 01| 01| 2019

Designing a Sticker: the Silhouette Studio enables adding ready picture and then cutting it to generate a sticker. The ﬁrst step is to select the picture you like and then drag it and drop it in the Silhouette Studio.

Cutting a Sticker: to cut a sticker, follow the same steps carried to cut a text.

After ﬁnishing the design and adjusting the cutting style, the sticker is ready to cut. Again the material is sticked over the cutting mat and the mat is loaded to the Silhouette and the design is sent the same way.

After cutting, release the mat by clicking on “Unload”. Then use the hook to remove the sticker covering the text and use the transfer tape to help you place your text neatly over any desired surface.

Designing a Shape: similarly, the Silhouette Studio can be also used to design shapes by simply adding them from the left margin of the page. Also, polygons and arcs can be designed from the same panel.

Free Drawing: the Silhouette Studio allows free drawing using the “Draw Freehand” and “Draw Smooth Freehand” tools within the left margin menu. In case the drawing should be modiﬁed, you can always use the eraser tool.

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GENERAL SETUPS -

Preparing the Blades:

The AutoBlade is the main blade used for cutting. As per its name suggests, it automatically adjusts its speed and material thickness in accordance to the parameters speciďŹ ed within the Silhouette Studio software. When the AutoBlade is placed in the left tool holder of the dual carriage, it will do some calibration before cutting to adjust the blade sharpness automatically. However, the AutoBlade can be adjusted manually in case the material used is unique and unlisted in the materials list. In this case, the AutoBlade depth can be adjusted using the blade adjustment tool until the red indicator line is moved to the desired blade settings.

TIP: it is very important to select the material used with Silhouette from the studio to use the machine at the proper settings to do the job. In case the material used is not listed, either adjust the available material settings or create and save a new material and add in the speciďŹ c cut conditions. This will save time and effort to remember the perfect settings for cutting a speciďŹ c material. The crosscutting blade, is used after the design is cut on a backed material without using the cutting mat. The retached blade must be manually adjusted to recommend to the recommended blade depth in Silhouette Studio. Basically, the built in ratchet to twist the blade to the correct depth as shown below.

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After adjusting the cut settings and the blade depth, it is very important to clamp the blade over the carriage in the right way.

Pushed Down

Locked in Place

Adjusting the Rollers:

FOUR - 2

References

Tasnim Hussain | FAB Engineer 01| 01| 2019

Silhouette Cameo 3 Studio Software: https://www.youtube.com/watch?v=_edPOxHYnr4 Cutting Vinyl https://www.silhouetteschoolblog.com/2014/01/cutting-vinyl-with-silhouette-101.html Cutting Mat https://www.silhouetteamerica.com/how-to/?slug=cutting-mat Using the Print and Cut Feature https://www.youtube.com/watch?v=hO-1572JUlU Using the Silhouette Library and Store: https://www.silhouettedesignstore.com/ https://www.youtube.com/watch?v=a55oN7T2bZI https://www.silhouetteschoolblog.com/2017/01/import-downloaded-graphic-designs-silhouette-studio.html

TUTORIAL: WEEK 5: ELECTRONICS PRODUCTION

PAG. 36 PAG. 37-40 PAG. 41-42 PAG. 43-53 PAG. 54-56 PAG. 57-66

Introduction to Electronics Production and the Assignment of the Week Introduction to Basic Electronics PCB Manufacturing Making PCB Using Roland MDX-50 Milling Machine Making Flexible PCB Using Vinyl Cutter PCB Soldering Tutorial

ONE

Introduction to Electronics Production and the Assignment of the Week

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

Introduction to Electronics Production Fab Foundation Link: http://academy.cba.mit.edu/classes/electronics_production/index.html Electronics production is the ﬁrst thing to learn in Fab Academy. The main purpose of this lesson is to understand how electronics boards are produced or manufactured and then assembled to get the ﬁnal result which is an electronic device. The devices that will be constructed are as follows: 1.

FabTiny ISP Board which represents another version of an AVR ISP programmer/board that can be produced in a fab lab using a milled PCB and readily available components. The project is based on the efforts of many people. For more history of the FabTinyStar and the people who have contributed to it, please refer to Zaerc's FabTinyStar page. The following ﬁgure shows the FabTiny ISP Board after PCB milling and PCB assembly.

The FabISP is an in-system programmer for AVR microcontrollers, designed for production within a FabLab. It allows you to program the microcontrollers on other boards you make. In the following ﬁgure the implemented FabISP board is shown.

To make the two device above, the electronic circuit of each should be designed with a software like Eagle to prepare the Printed Circuit Board (PCB) layout. Then the PCB layout is to be implemented by milling the copper plates using a PCB milling machine like Roland MDX-50. After preparing the board, the electronic components should be soldered over the PCB and the board should be programmed. Programming is done through USB communication via the USBtiny and V-USB ﬁrmwares software and might be done through avrdude. Assignment of the week: -

Group Assignment: characterize the design rules for your PCB production process Individual Assignment: Make an in-circuit programmer (ISP) by milling the PCB, then optionally trying other processes.

To handle this assignment, refer to the following tutorials provided by Fab Foundation:

1. 2. 3. 4. 5. 6.

Building the FabTinyISP FabISP Production and programming Arduino as an ISP PCB Milling with Roland MDX-50 (Refer to Pages 43-51) Making ﬂexible PCBs with a Vinyl Cutter (Refer to Pages 52-54 ) Fab ISP Models compilation

TWO

Introduction to Basic Electronics

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

ELECTRICITY ●

It is a type of energy that has its origin in the attraction of two subatomic particles Proton and Electron. The electrons have high tendency to move through conductive materials such as copper. This happens due to the attraction by the positively charged particles. The positive and negative charges are usually referred to as positive and negative pole respectively. Like batteries or any other power source. This difference in charges that cause the motion of electrons is referred to as Electromotive Force (EMF) or voltage. The higher the voltage, the higher the attraction between positive and negative poles and the faster the movement of electrons.

●

Electricity is the flow of electrons around a closed path (i.a. circuit) from negative to positive poles of the battery. The flow of electrons is measured in the direction of the EMF which is acting from positive to negative. While the electrons are moving, an electric current flows in the opposite direction to their movement. In other words, the current moves from high potential/ voltage to low potential/ voltage.

The Analogy of Electric Circuit and Hydraulic Circuit

The ﬂow of current is dependant on: The strength of the battery (or source voltage/ EMF). The type of the material used (resistance). The amount of power needed by the load (e.g. light bulb).

TUTORIAL:

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ELECTRONIC CIRCUIT COMPONENTS Each circuit consists of an electric power supply, electronic components, and conductive path (i.e. wires or cables). Components usually come encapsulated in ceramic, metal, plastic or other packaging. There are different types of electronic components as follows: ●

Types:

Discreet: encapsulated one by one (resistors, transistors, capacitors)

●

Resistance: is a device that hinders to some degree the current as it passes through a closed electrical circuit, attenuating or braking the free ﬂow of electric charges or electrons. http://www.dannyg.com/examples/res2/resistor.htm

●

Capacitors: are components capable of storing energy supporting http://www.electronics2000.co.uk/calc/series-parallel-capacitor-calculator.php

●

Diode: Electronic device with two electrodes through which the current ﬂows in only one direction.

●

Zener diode: works as a regulator voltage.

electric

ﬁeld

Integrated: compounds of more complex form by several types of components. ●

Transistor - Phototransistor: is a semiconductor electronic device used to deliver an output signal in response to an input signal. It fulﬁlls functions of switch and ampliﬁer, for our purposes.

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

●

Microcontrollers: A microcontroller (abbreviated μC, UC or MCU) is a programmable integrated circuit, capable of executing commands recorded in its memory.

ATTINY44A

Atmega328

RESISTANCE Electrical Resistance is the property of an electrical element to oppose the flow of the current passing through it when a voltage is applied across the element. Mathematically, it is represented as the ratio of the voltage to current which is referred to as Ohm’s Law. The physicist Georg Ohm have observed that the resistance is directly proportional to potential difference/ voltage and inversely proportional to the flow of current. Ohm’s Law: R=V/I where, R = resistance, V = voltage across the electrical element and I = current flowing through the electrical element.

Unit of Resistance: The Electrical Resistance is measured in Ohm. CIRCUITS An electric circuit is a closed conductive path where electrons ﬂow due to the effect of electromotive force. The circuit consists of a power source (i.e. AC or DC), electronic components and conductive path (i.e. wires). Representing an Electric Circuit: 1- Schematics: using simple drawings and electronic symbols to represent the circuit. 2- Modeling the circuit using CAD platforms like Autodesk TinkerCAD or fritzing to enable visualization and simulation of circuits. For schematics representation, the electronic symbols in the following page are used along with wires and source. The following ﬁgure shows the proper way of establishing connections between electronic components in an electronic circuit. Note that the dot indicates the connection point between two or more wire. To read an electronic circuit diagram, you need to understand what schematic symbols means and how junctions are connected as shown in the following page. Unlike a block diagram or layout, a circuit diagram shows the actual connection via cables between the devices. ● ●

Note that, electric circuit is like a chain where each piece (component) is connected to the next. I.e. components’ leads are not to be CONNECTED TOGETHER. Note that, in electric circuit components connected in series will have the same current passing through and different voltage drops that sums up to the source voltage. While components connected in parallel will have the same voltage drop across all and the current supplied from the source is branched over the parallel connections.

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

Connection of the wires using manual drawing or through CAD software: Old Style

Recommended Style

Electronic Components Summary Table and Schematic Symbols:

Component Name

Image

Schematic Symbol

Description

Fixed Resistor

Resistors are used to resist or limit the ﬂow of current.

Potentiometer (Variable Resistor)

Potentiometer is nothing but a resistor of variable resistance. Thus, it allows small current to ﬂow when adjusted at the maximum resistance (100%) and allows large current to ﬂow when adjusted at the minimum resistance (0%).

Capacitor

Capacitors are charge storage elements.

LED

Diodes in general are devices that allow current to ﬂow in only one direction. Light Emitting Diode is a special case of diodes, where the current only ﬂow in one direction and with this a small voltage drop across the LED is observed as it emits light.

Battery

Battery is a DC power source used to power the circuit by providing an electromotive force that moves the electrons t generate a current.

Push Button

Switches are designed to make or break connections.

Integrated Circuit (IC)

ICs are components with different capabilities to do several functions.

Wires

They provide conductive path to allow the transmission of electricity from one point to another.

For more details: https://www.build-electronic-circuits.com/schematic-symbols/ https://www.youtube.com/watch?v=Dl1gFBNa0Ik

THREE

PCB Manufacturing

TUTORIAL:

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Printed Circuit Board Printed circuit boards (PCBs) are the boards that are used as the base in most electronics – both as a physical support piece and as the wiring area for the surface-mounted and socketed components. PCBs are most commonly made out of ﬁberglass, composite epoxy, or another composite material. While conductive material is usually copper layer. In a PCB the electronic components are mechanically supported and electrically connected using conductive tracks, pads and other features. Components are generally soldered onto the PCB to both electrically connect and mechanically fasten them to it. A PCB provides a more reliable electronic design when compared to circuits implemented on a breadboard. Green Solder Mask

PCBs require design layout to the circuit using specialized CAD software. Generally PCBs are manufactured in massive amounts which is a fast and cheap fabrication process as components are mounted and wired in one single operation. Large numbers of PCBs can be manufactured at the same time and the layout only is done once. PCB Types: 1- Single-sided is made out of a single layer of the base material or substrate (i.e. one copper layer).

2- Double-sided PCBs have a base material with a thin layer of conductive metal like copper applied to both sides of the board. The conductive link between the two sides of the board are known as vias.

3- Multi layer PCBs consist of a series of three or more double-layered PCBs.

Some other types of PCBs are rigid PCBS, ﬂexible PCBs, high-frequency PCBs and many other. Refer to the following link for further details: https://www.pcbcart.com/article/content/PCB-introduction.html

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

Types of Manufacturing Methods: 1.

Chemical Etching: To manufacture PCBs, the copper plates are normally etched using chemical solutions such as “Clear Etchant” or “Ferric Chloride”. These chemical solutions are dangerous and seriously hazardous especially in cases of skin or eye contact. Photo-resist board is used with etchant and other solutions to produce PCBs. Added to that, the disposal of the waste solutions is very dangerous and should be handled with care.

PCB Milling: Another advanced method to manufacture PCBs is using CNC milling machines which provide a safe and fast PCB manufacturing. Simply the PCB CAD ﬁles are exported and then imported into the machine’s software then the machine will generate the PCB using milling and drilling bits. The waste produced is safe and can be simply brushed up and thrown away in a normal dust bin.

PCB Printing: More advanced way to produce PCBs is by printing the layout using conductive ink. This method provides safer and faster alternative especially for prototyping. Voltera V-One is one of the PCB printing machines used in QBIC FAB LAB.

FOUR

Making PCB Using Roland MDX-50 Milling Machine

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Q1| Q1-5| Roland MDX-50 | Milling Machine DESIGN SOFTWARES : SRP Player CAM, ClickMill and Virtual Control Panel (VPanel) FAB FOUNDATION REFERENCES: http://fab.academany.org/2018/labs/fablabbrighton/media/pdf/ElectronicsProduction.pdf INTRODUCTION CNC stands for Computerized Numerical Control which is a programmable automation in which process is controlled by Numbers, Letters, and symbols. CNC Machining is a process used in the manufacturing sector that involves the use of computers to control machine tools like lathes, mills and grinders. The CAD tool works with design, or the initial creative step of any project. After that, when there is the need to manufacture it - and therefore CNC technology is demanded - another kind of software is needed: CAM is the software that creates the machine program from a digital design. Basically, CAM software produces a G-CODE that is a preparatory word, used as a communication device to prepare the MCU. The G-code indicates that a given control function such as G01, linear interpolation, is to be requested. The following block diagram illustrates the building blocks of a CNC router machine.

Input CAD 2D Design on the computer.

Interface

Output

CAM Software converts the CAD design into instructions for the machine to implement the design. These instructions are usually called a “Code”.

The code produced by the CAM software will be executed by the machine’s controller and will drive the spindle and motors to start milling/ cutting.

Roland MDX-50 MILLING MACHINE

This week assignment is a PCB that has an initial design and it is supposed to be edited. Further notes will explain better about Eagle 8.0 which is the design tool I used for PCB design. The MODELA MDX-50 is a fully automated, high-precision 3D milling machine ideal for fabricating design and working models. The MDX-50 has an Automatic Tool Changer and CAM software as standard and an optional rotary axis unit. The MODELA MDX-50 is capable of drastically reducing milling time and effort, and delivering true innovation to the design process. The MDX-50 benchtop CNC mill combines precise, automated milling and unmatched ease-of-use. An ideal solution for short-runs and prototypes, it reduces operating time and simplifies production so users of all abilities can mill on a wide range of materials. It follows the standard setup for the machine and tools we have here at Insper for FabModules and Roland MDX-40A. Input: this is an image file png that will describe the traces or cut need on the board. Select the image you need for each PCB. This exercise has this final board design for traces and this final board design for outline. Output format: Roland Mill (.rml) - this selection will set the FabMoludes to work with a milling machine. For the machine setup refer to the link and to read the user manual refer to this link.

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Automatic Tool Changer The MDX-50 features a 5-station Automatic Tool Changer with an auto-sensing function to detect tool length and ensure milling accuracy.

Status Light

For monitoring machine status in busy classrooms and studios, current job status can be checked from a distance with multi color-coded LED status lights and email notiďŹ cations.

The VPanel serves as a computer-based virtual controller with all of the functionality of a physical on-board control panel, as well as tool life management and e-mail alerts.

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Built-in Panel Screen and Functions

The built-in panel contains the frequently used functions. You can use it to perform operations while checking the machine's internal behavior.

Rate key

Axis selection keys

Select the level of precision of the hand-wheel feed. Lower scaling factors produce correspondingly slower movement, enabling you to accomplish precise positioning.

Select the axis to use as the target for hand-wheel feed and origin settings. Use the [A] key when the optional rotary axis unit is attached.

Coordinate System Selection key Press this key to change the coordinate system. The coordinate system is related to the display of the toolbar position and to the origin setting.

Origin Setting Key

Override Key

Hold down this key to set the origin to the current tool bur position of the selected axis.

Select the feeding speed override and the spindle rotating speed override.

Hand-wheel Menu Key Call up the submenu.

Spindle Key Start and stop the rotation of the spindle.

Set the hand-wheel feed for each axis and increase/decrease setting values.

Enter key ConďŹ rms operations.

Z0 Sensor Key Use this key when you use a Z0 sensor to set the Z origin.

Pause/Cancel Key Pauses and resumes cutting. When you press this key with cutting paused, you will be given the option of resuming or canceling cutting.

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PCB Manufacturing Process Steps FAB Academy Link: http://fabacademy.org/2019/docs/FabAcademy-Tutorials/week04_electronic_production/fabtinyisp_english.html

Prepare two seperate ﬁles for the PCB layout one for the traces and the other for board outline as PNG. Before saving, check that your images are the correct size for your circuit board (in mm, not dpi). Note: whatever is white will stay, black will be machined.

Go to fabmodules.org and click on “input format”. Select the format to be “image (.png)”.

Search for the image and open it.

The ﬁle will open and the board layout will appear as shown above. From “output format” select “Roland mill (.rml).

Output settings will appear on the screen. Here you need to add the machine details in terms of machine name, speed (mm/s), origin coordinates and homing.

Input all the data as shown above. Note that: ● For the machine selection, MDX-50 is not available but MDX-40 is similar to it. ● Zjog represents the Z level of the machine when it is traveling to a different location. 46

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Select the process “PCB traces (1/64)”, automatically the process details will show on the right side. The tool diameter needs to be changed from 0.4mm to 0.09mm which approximately corresponds to the diameter of the V- tool shown in the picture. However, the V- tool is usually deﬁned by angle (i.e. 45 degrees).

After that, download the RML ﬁle by selecting “Save”.

Check the Stock thickness which is the thickness of the material e.g. 1.7mm. Cut depth is the depth the tool will cut in one pass. This can be done in one go when selecting the depth to be equal or slightly bigger than the material thickness (e.g. 1.8mm cut depth can give very good cut through). Tool diameter is kept as the default 0.79mm for 1/32” tool. Then, Click “Calculate”.

Click “Calculate” to generate the RML ﬁle for the MDX-50. The circuit traces will be created with directed blue lines representing the machine milling path and red lines represent the jogs between different paths.

The same steps are repeated for the board outline with few modiﬁcations on the tool and the cutting parameters. Select Roland mill (.rml) as the output format and PCB Outline (1/32) as the cutting process.

After downloading the ﬁle, the machine should be settled up with the copper board mounted and the needed tools. First, prepare the copper plate sheet and make sure it is clean.

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Power ON the machine, note that the machine LEDs will be blue in color and the screen will show the message â&#x20AC;&#x153;Hit Enter Keyâ&#x20AC;?. This should be done to initialize the machine and make it ready.

Open the cover to place the material/ copper board, to attach the tools and to probe the z level. When opening the door, any previous operation gets automatically stopped and the LEDs will turn white and the screen shows a message to close the cover.

Copper Board Wax Block

Wooden Base

Place the Copper board over the wooden base and stick it with double sided tissue tape over a wax block. *Note that: the wooden base can be removed and the wax bock can be placed directly over the cutting bed.

Snap the tools/bits to the tool holder and place them over the automatic tool changer slots. Two tools are used, one for the traces milling which is the V-tool 45 degrees milling bit and another one for board outline cut of diameter 1/32 inches drilling bit.

Get the Z-probe ready and snap it over the special socket as shown. Also you need to make sure that the detection pin is loaded to tool slot number 6. Refer to page 24 in the manual.

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The tool is picked up.

Click on Menu many times until you get “ATC TOOL MENU” for the automatic Tool Changer. Use the hand wheel to select the tool with where the bit is attached to the tool holder. E.g. here TOOL6 which is the detection pin is selected. The spindle will move to get the selected tool then it will show on the screen that the selected tool is tool #6. .

Click Menu again multiple times until you get “USER (RML-1/NC CODE)”. For instance to change the x-coordinate, select it by hand wheel and then hit enter, after that with the hand wheel move to the positive or negative direction.

Use the hand wheel to move, the x and y to have the spindle directly facing the z-probe metallic piece. After that, click on Z0 SENSE from the panel. There will be a message displayed on the screen, to conﬁrm Z0 SENSE click ENTER.

Again use the Automatic Tool Changer to pick the milling tool (V-tool) and then to pick the cutting tool (1/32” tool) after milling.

Before start with the milling process, the X and Y origin coordinate needs to be determined and the spindle speed needs to be asjusted. Open VPanel and select the gear icon “ ”. This will allow you to access the machine setting window. Select “Origin” tap and modify the XY positions to suit the position of the material. When you reach the desired point, select “XY” to be the origin position and click on “Set”.

Increase the speed of the spindle by increasing RPM from 4500 to 5500 rpm. Then select the spindle icon to ﬁx the new speed. Finally, click OK.

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The previous steps for X and Y origin point and adjusting the spindle speed can be done using the panel keys alternatively to VPanel settings. Simply push X button to allow moving along the axis through the handwheel. When the desired point is reached, just push the ORIGIN button and hold on without removing your ﬁnger until the value change to 0.00 on the screen and VPanel accordingly. Same is done to the origin of the Y axis. The spindle speed can be changed also by selecting SPINDLE and then with the handwheel increase the value to the desired RPM speed. Refer to page 45.

Open VPanel and select “Cut” icon. This will allow you to upload your RML ﬁle for the PCB.

Upload the RML file, then it will be automatically added to the list of cut files.Finally make the file ready to cut by selecting the file and clicking “Output”.

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Now to start the milling process, click on “Cutter Management” icon as shown. You will note that the Z-level will lowered to reach the board level.

The Machine will then start the milling of the traces and LEDs will turn White. When the process is successfully ﬁnished the LEDs will turn Blue and the VPanel will indicate that the process is ﬁnished.

After milling the PCB traces, the same process is repeated for cutting the board outline. The result after milling and cutting is as shown in the ﬁgure.

One ﬁnal step is remaining, which is to assemble and solder the electronic components onto the board. Refer to the link for assembly and refer to the soldering tutorial in pages 55-64.

Notes: -

The Z-level need to be probed everytime when the board is moved or replaced. Refer to the tutorial as a reference.

Tasnim Hussain | FAB Engineer 01| 01| 2019

Suppose that the above PCB needs to be produced. The ďŹ rst thing to do is to export the monochrome format of the PNG image for the top and pads layers. This will be used for generating the RML ďŹ le for PCB milling. REMARK: All the above steps are for a PCB with SMD components only. In case you have some through hole components or you need to drill placement holes few steps needs to be done as shown below.

Only show the pads layer.

Export the layer as image.

The holes need to be completely black except for the surrounding that need to be white. Thus, you need to use Gimp software to remove the text within the holes. Final image.

Tasnim Hussain | FAB Engineer 01| 01| 2019

Use the select tool

to minimize

the size of the yellow frame to make it just right around the PCB as shown in the ďŹ gure on the right.

From Layer Settings, hide all layers and show only dimensions for the image export.

Image is exported using the same method as for the traces and pads.

Exported image of the dimension layer. This will be treated as the drill holes image in FAB Modules, where the cut depth is 1.8mm and the tool used in 1/32â&#x20AC;?.

The last image that needs to be prepared before moving to FAB Modules is for the outline. To do this follow the above steps.

FIVE

Making Flexible PCB Using Vinyl Cutter

Tasnim Hussain | FAB Engineer 01| 01| 2019

Steps to Make a Flexible PCB using the Vinyl Cutter

Fab Foundation Link: http://fabacademy.org/2018/docs/FabAcademy-Tutorials/week4_electronic_production/ﬂexible_pcb_windows_mac.html

Save the traces PNG ﬁle from here and then drag the image and drop it to the Silhouette Studio design platform as shown above. The board outline can also be downloaded and then added to the design or can be replaced with a simple rectangle at the outer edges of the board.

Open the trace panel and then select the trace area to be around the board traces as illustrated above.

Open Silhouette Cameo studio.

The board should be resized to have dimensions 45.21x22.98 mm.

Edit the tracing parameters in terms of threshold and scale to ﬁx the sharpness of the cutting. Then trace the board.

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After tracing, remove the image from the red-traced image and then delete the original image.

Prepare the copper tape, scissor and a piece of transparent PVC sheet.

Now move to “SEND” panel and select the action to be done by Tool 1 which is “CUT” in this case. Then select the proper material “Vinyl Metallic” since copper tape is being used, select “Cut” and the tool to be “AutoBlade”. You should note that the speed and force has been changed automatically.

Cut a small piece of copper tape and stick it over the PVC sheet. Then stick the PVC sheet over the cutting mat and load it to the machine.

After Loading the material click “SEND” to start cutting the design.

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After tracing, remove the image from the red-traced image and then delete the original image.

Assemble the components as shown in the labeled diagram. Then solder the components by following the soldering tutorial in the following section.

Final Result after assembly and soldering!

SIX

PCB Soldering Tutorial

Tasnim Hussain | FAB Engineer 01| 01| 2019

HAKKO FX- 888D Soldering Station

MACHINE DESCRIPTION The HAKKO FX- 888D is a safe digital soldering iron station with adjustable temperature control. Moreover, it has a compact body and requires a space of only 100(W) x 120(L) mm. Additionally, it has very simple and easy operation only using the UP and ENTER buttons to adjust the temperature of the iron tip.

It is very IMPORTANT to note that the operating voltage of the soldering station is 120V while the voltage from the main is 240V, then it is crucial to use a step down transformer (220V - 110 V). otherwise, the machine will immediately get damaged once connected to the wall outlet and powered directly.

For more details refer to the following datasheet: https://cdn.sparkfun.com/datasheets/Tools/fx888d.pdf

SOLDERING BASICS

Soldering is the a process where two or more metallic items are joined together by melting and then reﬂowing a ﬁller metal into the joint. Soldering is used to establish almost permanent connection between electronic components.

The metal to be soldered is heated with soldering iron and then the solder is melted connected parts being soldered. Therefore, the solder is considered to be a metallic glue that holds the parts together and forms a connection that allows the ﬂow of an electrical current.

Digital Display: The digital display of FX-888D makes it very easy to check the set temperature. Once the temperature is adjusted, the settings are locked by pressing “ENTER”.

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Present Mode: The present mode is a very convenient feature that allows you to change the set temperature to suit a particular workpiece, component or tip chape. This is done by selecting the desired temperature from a selection of pre-saved present temperatures. Up to ﬁve present temperatures can be registered.

Adjustment Mode: This allows the temperature adjustment by either entering a particular desired temperature or switching to another present mode temperature. The default temperature is 750 °F. The following diagram shows the steps to do a manual adjustment for the temperature.

SAFETY PRECAUTIONS: ●

CAUTION: The soldering iron can heat to around 400°C which can burn or establish small ﬁre. USE IT CAREFULLY and ALWAYS KEEP THE IRON IN ITS STAND WHEN IT IS HOT.

●

Always switch OFF the iron when it is not used.

●

Keep hands away from the soldering tip and avoid touching the soldering iron on a power line.

●

Never put the soldering iron down on the work bench even for a moment!

●

Work in a well-ventilated area and keep the smoke absorber open while soldering to ensure the suction of the toxic fumes.

●

The smoke produced from the soldering is mostly ﬂux which can be irritating. Avoid breathing it and work from the side not directly from above the circuit.

●

Solder contains lead, which is poisonous metal. Wash your hands well after soldering.

Tasnim Hussain | FAB Engineer 01| 01| 2019

Items Needed to do Soldering:

● A soldering iron The soldering iron is used to melt soldering wire over the electronic connection to be soldered. ● Soldering wire The soldering wire is a wire that has a melting point lower than that of metals being connected. This special wire melts when heated by the soldering iron; however, the metals being connected will not melt. The soldering wire core acts as a flux and prevents oxidation of the metals that are being connected. For most of electronics work, a soldering wire with a diameter of 0.75 mm to 1.0 mm is usually used. Thicker soldering wire makes soldering small joints difficult and increases the chances of creating solder bridges between connected copper pads which might lead to short circuits and damaging the electronic ICs. It is very IMPORTANT to deal with the soldering wire with care as it consists of an alloy of 60/40 (60% tin, 40% lead) which are toxic materials. Thus, always use the fume/ smoke absorber to avoid inhaling the toxic fumes and wash your hands once done with soldering. ● Soldering Stand It is important to keep the soldering iron in its stand when it is not used. DO NOT put the soldering iron on any surface as it can melt and damage it. ● Sponge The sponge is used to clean the tip of the iron. ● Solder Braid This is used to remove solder in case any connection needs to be fixed or removed. To do this simply place it over the solder to be removed and heat it from the side over the braid until the solder flows into the braid and the connection is removed. Moreover, the solder braid is used to reduce the amount of solder on a connection. ● Prototype Board A prototyping board is used to assemble the circuit and has a copper tracks and pads for connecting components. ● Cutter To cut the soldering wire and components leads after soldering is finished. ● Fume/ Smoke Absorbing Fan This is used to extract the smoke produced from the melting of the soldering wire.

Tasnim Hussain | FAB Engineer 01| 01| 2019

Power ON the 220/110 V transformer, then power ON the soldering station and the smoke absorbing fan.

Note that, selecting the right/ proper soldering tip is very essential. This is decided based on the type of components to be soldered.

The default temperature is 750Â°F.

The temperature is adjusted to suit the type of the soldering board -copper board or FR1 board- and the type of conductive traces used. When turning ON the iron, it starts with a temperature of 000Â°F and after few seconds it switches to the previously saved temperature.

Wipe the iron tip on the sponge to clean the tip.

Wait for the soldering iron to heat up and moisten the sponge using few droplets of water.

Melt a little solder on the tip of the iron. The soldering wire will melt over the tip and produce a bright shiny surface. When tip is tinned, excess solder is removed by wiping over the sponge.

Tasnim Hussain | FAB Engineer 01| 01| 2019

The soldering iron tip should always has a shiny silver color. If its color got black, sink the tip over the solder paste and then clean it with the brass sponge.

Prepare the prototyping board and all components to be used in the electronics circuit.

Use the board holder to hold the prototyping board and assemble all components over the prototyping board.

Use the tape to hold the components ďŹ xed in their places. Bend out the long components leads to stay in places.

Turn the board down carefully.

Use the soldering iron tip to heat the pad of the component and hold it for few seconds. Then touch both the pad and the lead.

Tasnim Hussain | FAB Engineer 01| 01| 2019

Now feed the soldering wire right under the tip of the iron. Then stop feeding for one second and the solder will ďŹ&#x201A;ow properly to hold the lead.

Cut the leads off with cutter.

Final Result!!

A good connection covers the whole pad and holds the leads completely with solder.

The board after soldering and ďŹ nishing all the components.

Desoldering can be done simply using the soldering iron and the solder braid. It is a very good practice to enhance better soldering.

Tasnim Hussain | FAB Engineer 01| 01| 2019

RECAP

Professional PCB Soldering and Assembly Using Flux and Solder Paste: ● Flux is a chemical agent used to aid the ﬂowing of the lead-free solder. Moreover it helps making the solder joints better looking and is highly recommended to be used with soldering SMDs especially due to their small pins and high sensitivity to the temperature. In fact SMDs can get overheated and damaged if their soldering is done like regular solder of regular components treating the joints’ connections one by one. Check the following link for more techniques to solder SMDs using the ﬂux and soldering iron: https://www.youtube.com/watch?v=5uiroWBkdFY ●

Solder Paste is a form of solder used in PCB assembly when reflow soldering techniques are used. It is mainly a mixture of solder spheres and special type of flux. Solder paste works highly efficient with SMDs assembly rather than through hole components. http://www.radio-electronics.com/info/manufacture/soldering/solder_paste/how-to-use-solder-paste.php

Pick and Place: To assemble a large number of small ICs the Pick & Place machine is used as manual assembly can be difﬁcult especially for the proper alignment of the very tiny ICs. The following video shows how to operate the Neoden 4 Pick & Place machine to assemble components.

Tasnim Hussain | FAB Engineer 01| 01| 2019

Soldering Surface Mount Components Surface Mount (SMDs) components are categorized by different standardized packages as illustrated below. -

Passive rectangular components

These SMT components are mainly resistors and capacitors. There are several different sizes which have been reduced as technology has enabled smaller components to be manufactured and used. The following table shows the different packages and their corresponding dimensions.

Semiconductor SMD packages

There is a wide variety of SMT packages used for semiconductors including diodes, transistors and integrated circuits. The reason for the wide variety of SMT packages for integrated circuits results from the large variation in the level of interconnectivity required. Transistor & diode packages SMD transistors and diodes often share the same types of package. While diodes only have two electrodes a package having three enables the orientation to be correctly selected. The most popular transistors and diodes packages are listed below:

●

SOT-23 - Small Outline Transistor: This is SMT package has three terminals for a diode of transistor, but it can have more pins when it may be used for small integrated circuits such as an operational ampliﬁer, etc. It measures 3 mm x 1.75 mm x 1.3 mm.

●

SOT-223 - Small Outline Transistor: This package is used for higher power devices. It measures 6.7 mm x 3.7 mm x 1.8 mm. There are generally four terminals, one of which is a large heat-transfer pad.

Integrated circuit SMD packages There are many forms of package that are used for SMD ICs. Although there is a large variety, each one has the areas where its use is particularly applicable.

●

SOIC - Small Outline Integrated Circuit : This SMD IC package has a dual in line conﬁguration and gull wing leads with a pin spacing of 1.27 mm

●

SOP - Small Outline Package: There are several versions of this SMD package:

●

○

TSOP - Thin Small Outline Package: This SMD package is thinner than the SOIC and has a smaller pin spacing of 0.5 mm

○ ○ ○ ○

SSOP - Shrink Small Outline Package: This package has a pin spacing of 0.635 mm TSSOP - Thin Shrink Small Outline Package: QSOP - Quarter-size Small Outline Package: It has a pin spacing of 0.635 mm VSOP - Very Small Outline Package: This is smaller than the QSOP and has pin spacing of 0.4, 0.5, or 0.65 mm.

QFP- Quad ﬂat pack: The QFP is the generic type of ﬂat package for ICs. There are several variants as detailed below.

○

LQFP - Low proﬁle Quad Flat Pack: This package has pins on all four sides. Pin spacing varies according to the IC, but the height is 1.4 mm.

○

PQFP - Plastic Quad Flat Pack: A square plastic package with equal number of gull wing style pins on each side. Typically narrow spacing and often 44 or more pins. Normally used for VLSI circuits.

Tasnim Hussain | FAB Engineer 01| 01| 2019

○ ○ ● ●

CQFP - Ceramic Quad Flat Pack: A ceramic version of the PQFP. TQFP - Thin Quad Flat Pack: A thin version of the PQFP.

Read more about the QFP - Quad Flat Pack BGA - Ball Grid Array: A package that uses pads underneath the package to make contact with the printed circuit board. Before soldering the pads appear as solder balls, giving rise to the name.

Each package has a speciﬁc technique for soldering, in the following links are some tutorials for soldering different SMD components:

https://www.sparkfun.com/tutorials/96 https://www.sparkfun.com/tutorials/100

To solder SMD components, soldering iron could be used; however, in most cases soldering is done using solder paste. To apply solder paste, the footprint of all components in the PCB layout should be cut as a stencil using vinyl cutter to ensure that the solder paste is applied directly over the footprints exactly.

SEVEN

References

Tasnim Hussain | FAB Engineer 01| 01| 2019

● Introduction to PCB: https://learn.sparkfun.com/tutorials/pcb-basics ● Electronics Assembly: https://learn.sparkfun.com/tutorials/electronics-assembly ●

Soldering Through Hole Components:

https://learn.sparkfun.com/tutorials/how-to-solder-through-hole-soldering https://www.sciencebuddies.org/science-fair-projects/references/how-to-solder#soldering https://mightyohm.com/ﬁles/soldercomic/FullSolderComic_EN.pdf ●

Soldering SMD Components:

https://www.youtube.com/watch?v=It2eLGzGm_I ● Troubleshooting: https://www.sciencebuddies.org/science-fair-projects/references/how-to-solder#troubleshooting

TUTORIAL: WEEK 6: 3D SCANNING AND PRINTING

PAG. 65-66 PAG. 67-74 PAG. 75-89 PAG. 90-93

Introduction to 3D Scanning & 3D Printing and the Assignment of the Week 3D Scanning Using RangeVision Scanner 3D Printing Using Ultimaker 2+ Printer 3D Printing Using FormLabs 2 Printer

ONE

Introduction to 3D Scanning & 3D Printing and the Assignment of the Week

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 12| 2019

Introduction to 3D Scanning Fab Foundation Link: http://academy.cba.mit.edu/classes/scanning_printing/index.html 3D scanning is a process of determining the shape of an object’s surface or its volume in three-dimensional space. By collecting information about the real-world object using a 3D scanning device, this makes 3D measurement and 3D visualization possible. Accurate 3D measurements derived from a scanned object are useful for material inspection and quality control. If a 3D scanning technology is capable of collecting a lot of 3D data from the scanned object, it has the ability to recreate a high resolution, accurate 3D digital model of the real-world object. This is known as 3D visualization.

Common 3D Scanning Technologies Displacement, Proﬁle, and Snapshot (aka, Scanner). Displacement devices use a single point laser beam projection to measure the height, thickness, or position of an object.

Line Profile devices typically use a projected laser line to create a cross section profile for measuring aspects of an object’s contour. Moving an object under the laser line creates many profiles that can be combined into a complete 3D shape.

Snapshot devices use structured light (non-laser) and stereo-vision to generate full 3D volume data. Because Snapshot technology captures so much 3D data at one time, objects need to remain stationary during the scanning process.

3D Sensor: A 3D sensor is a single device that uses ﬁxed optics, a light source (typically laser) and at least one digital imager to acquire 3D data. Typically 3D sensors are pre-calibrated and operate in manufacturing facilities as part of an automated production line. Much like the human eye, a 3D sensor merely collects and transmits the data for processing. An external computer or controller acts like our brain. This ‘brain’ takes in the data the 3D sensor generates and processes it to perform measurements, analysis, or visualization.

3D Scanner: A 3D scanner is a device for creating high resolution, accurate digital 3D models from real-world objects. The scanner is built around stereo-vision (normally two digital imagers) and structured light projection in order to generate 3D. The scanner is controlled by 3D scanning software that runs on a computer. A 3D scanner is also capable of capturing the color map of an object. By merging the color map onto the 3D model, a color 3D digital model is created.

Refer to: http://www.cimtecautomation.com/promo/pdfs/EBOOK_A_Simple_Guide_To_3D.pdf

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 12| 2019

Introduction to 3D Printing Fab Foundation Link: http://academy.cba.mit.edu/classes/scanning_printing/index.html

3D printing or additive manufacturing is a process of making three dimensional solid objects from a digital ﬁle. The creation of a 3D printed object is achieved using additive processes. In an additive process an object is created by laying down successive layers of material until the object is created. Each of these layers can be seen as a thinly sliced horizontal cross-section of the eventual object. 3D printing enables you to produce complex (functional) shapes using less material than traditional manufacturing methods. There are many different techniques used for 3D printing as shown in the following diagram.

The main focus of this training will be FDM and SLA 3D printing technologies only. Refer to the following table to understand the difference between the two technologies:

FDM 3D Printing

SLA 3D Printing

FDM is the abbreviation for Fused Deposition Modeling. In FDM, a strand of material (in this case: thermoplastics) is deposited in layers to create a 3D printed object. During printing, the plastic ﬁlament is fed through a hot extruder where the plastic gets soft enough that it can be precisely placed by the print head. The melted ﬁlament is then deposited layer by layer in the print area to build the workpiece.

SLA is the abbreviation for Stereolithography Apparatus, or simply stereolithography. Like FDM, SLA is an additive method: Models are built layer by layer. SLA, however, uses a curable photopolymer – typically a liquid resin – that is hardened by applying focused light or UV light (this process is called curing). SLA printers usually build the models from top to bottom, the build platform lifts the model upwards, out of the resin bath.

The build plate moves downwards after printing each layer. i.e. z- axis is becoming lower in level after ﬁnishing each layer.

The build plate moves upwards after printing each layer. i.e. zaxis is becoming higher in level after ﬁnishing each layer.

z x

The Assignment of the Week ● Group assignment: Test the design rules for your 3D printer(s). ●

Individual assignment: ○ Design and 3D print an object (small, few cm3, limited by printer time) that could not be made subtractively. ○ 3D scan an object (and optionally print it).

TWO

3D Scanning using RangeVision Scanner

Rania Zarandah| Fab Engineer 06| 20 | 2018

Q5_3D SCANNING | Q5_1| RangeVision Spectrum 3D Scanner| SPECTRUM DESIGN SOFTWARES (LICENCES) : https://rangevision.com/en/products/software/ FAB FOUNDATION REFERENCES: http://academy.cba.mit.edu/classes/scanning_printing/index.html

MACHINE DESCRIPTION RangeVision Spectrum is a new high resolution 3D scanner based on the safe-to-use structured light technology. It is designed for scanning small, medium, and larger objects. The 3D scanner has three fields of view and is equipped with 3.1 Mpix industrial color cameras. RangeVision Spectrum captures complex geometry, flat and long objects, as well as small details with constantly high 3D resolution while keeping the accuracy up to 0.04 mm. It has many advantages including: 1. 3-in-one scanner: Three scanning zones to capture different-sized objects from 1cm up to 3m. RangeVision Spectrum is a multi-purpose device capable of scanning objects of different sizes simply by changing the scanner’s field of view. No need to look for the options or another 3D scanner- Spectrum is 3 scanners in one. This device provides highly detailed scans of any type of objects, from jewelry to large automobiles, with accuracy up to 0.04 mm and 3D resolution up to 0.072 mm. It is perfect solution for companies that specialize in 3D scanning services, reverse engineering, product design or productions of all kind of small or medium-sized objects. 2. 3.1 Mpix industrial cameras. For highly detailed and full-colour scans. Industrial colour cameras with 3.1 Mpix sensors can capture the finest details and curved surface of the object-up to 0.07 mm. 3. Three scan modes. To render complex geometry of objects of any size and shape. There are two cameras to capture the geometry of the object, while making a scanning process more accurate and stable, reducing the need to calibrate the scanner during operations to a minimum. Spectrum is an ideal device for creating accurate visualization of objects with complex shape. Moreover, thanks to the possibility to scan with targets and adjustable fields of view the size of the scanned objects is limited only by your imagination and the power of your PC. INTRODUCTION TO: RangeVision ScanCenter RangVision ScanCenter software is designed to conduct 3D scanning and post-processing of the obtained data. The easy Setup Wizard of the software allows to calibrate 3D scanner with ease even if the user don’t have any experience of using 3D technology. The software gives the ability to use three modes of digitizing: on the rotary table, with markers and free mode. RangeVision ScanCenter allows to capture colorful texture with automatic white balance. It is important if the user intends to use the data for colorful 3D printing or computer graphics, animation and presentations. The software gives you a perfect opportunity of choice of camera resolutions. The user can choose between scanning speed and details. Changing the resolution is particularly relevant when scanning large and smooth surfaces, for example the body of the car. Most importantly, the software provides support of photogrammetry which is the import of reference networks. It makes possible to accurately and quickly scan areas of the object located far apart from each other without collecting all the surfaces between them.

Rania Zarandah| Fab Engineer 06| 20 | 2018

Main Features

Camera Resolution 3.1 Mpix

Field of View in mm 520×390×390 280×210×210 133×100×100

3D resolution in mm 0.26 0.17 0.072

Align modes By markers, by geometry, on the automatic turntable

3D point accuracy in mm 0.12 0.06 0.04

Three in One Scanning Three scanning zones to capture different-sized objects from 1cm up to 3m. RangeVision Spectrum is a multi-purpose device capable of scanning objects of different sizes simply by changing the scanner’s ﬁeld of view. No need to look for the options or another 3D scanner- Spectrum is 3 scanners in one. This device provides highly detailed scans of any type of objects, from jewelry to large automobiles, with accuracy up to 0.04 mm and 3D resolution up to 0.072 mm. It is perfect solution for companies that specialize in 3D scanning services, reverse engineering, product design or productions of all kind of small or medium-sized objects.

Rania Zarandah| Fab Engineer 06| 20 | 2018

Preparing Range Vision (Spectrum) Calibration:

The ﬁrst step you need to do before starting the 3D scanning procedure is to make sure that your scanner is calibrated. To do so you should open the RangeVision Spectrum software which is the RangeVision ScanCenter. Make sure that the USB that comes with RangeVision Spectrum package is connected to your PC for the software to work.

When you ﬁrst open the RangeVision ScanCenter the following panel will appear with the following choices; Create project, open project, conﬁguration wizard, and go to ScanManger.

Also you should power on your scanner, make sure that the camera and the datashow are connected to your PC as shown in the above picture.

Go to conﬁguration wizard to calibrate your RangeVision Spectrum scanner.

Rania Zarandah| Fab Engineer 06| 20 | 2018

After choosing conﬁguration wizard the software will ask you to select the scanning area which is the most suitable for your scanning area.

For the selected scan area use the calibration field 2 box (approximation size 237 mm). The exact of your field is written on the reserve side. Enter the size of the calibration field, or selected from the list.

After this you should sit the calibration ﬁeld in front of the scanner, using the holder. Approximate the distance between the scanner and the ﬁeld should be almost 50 cm.

The program will give three different ranges of size. (0.4-1m), (0.15-0.5m), and (0.05-0.15m). For our case let us go with (0.15-0.5m) choice.

The RangeVision Spectrum came with three calibrations boards with different sizes. These are the boards used for the calibration process.

You can measure the distance between the scanner and the ﬁeld using an analog meter tape.

Rania Zarandah| Fab Engineer 06| 20 | 2018

After that you need to check the brightness of the image. If the camera image is very dark or too bright, loosen the ﬁxing screw without removing them on the lense diaphragm ring to get acceptable image.

The above picture is illustrating the place of the camera’s lense diaphragm.

Then you need to make sure whether the cameras are correctly arranged and that the images are ﬂipped. You can use the buttons place in the below side of the massage in case of disarrangement.

Then by varying the distance between the camera and calibration ﬁeld, set the ﬁeld in a position where the blue lines will cross the central and lateral rows of the markers on ONE camera only.

You can do this by moving the scanner stand to the front or to the back to adjust the alignment correctly.

After that, the software will ask you to adjust the projector focus until the lines on the calibration ﬁeld become the most sharp.

Rania Zarandah| Fab Engineer 06| 20 | 2018

You can do this by playing on the sliding key indicated on the above picture which controls the focus of the projector.

Then loosen the camera screws and consecutively move the cameras so that the projected line matches the blue line on the image. After that, securely ﬁx the cameras with the screws.

There is a kit that comes with RangeVision Spectrum that has screw ﬁxer tool which can be use to loosen or tighten the cameras screws.

You can use them to tighten or loosen the screws as shown in the above picture.

Then, place the calibration ﬁeld in front of the scanner in such way that the projected cross hits the center marker and matches the blue lines on the cameras image.

After that, loosen but without remove the ﬁxing screw on the lens focus ring. Adjust the sharpness. It it convenient to zoom in by the left clicking on the image. Don’t forget to re-tighten the screws!

Rania Zarandah| Fab Engineer 06| 20 | 2018

Then, close the lens diaphragm so that the image lines and stripes are as bright as possible, but without any signiﬁcant overexposure. The brightness of the images of both cameras must be the same

Before calibration check that all adjustment and tightening screws are tightened. It’s not allowed to change cameras positions or lense setting after calibration.

Finally, to complete scanner setup, perform calibration by taking several shots of calibration ﬁeld in different positions. After last shot the calibration value will be displayed.

You can also go to Settings - Calibration to ﬁnalize the last step.

Rania Zarandah| Fab Engineer 06| 20 | 2018

To ﬁnalize the calibration process, the software will ask you to place the calibration ﬁeld in 11 different positions like; 50 cm away from the scanner.

Place the calibration ﬁeld further from the scanner.

Rotate the calibration ﬁeld: left side near to scanner.

Finally your Calibration process will be done and you are ready to start the Scanning process.

THREE - 1

3D Printing using Ultimaker 2+ Printer

Rania Zarandah | FAB Engineer 06 | 04 | 2018

Q4 3D PRINTING | Q3-1| Ultimaker 2+ | Ultimaker 2 family DESIGN SOFTWARES (OPEN SOURCE | LICENCES) : Cura ( https://ultimaker.com/en/products/ultimaker-cura-software) FAB FOUNDATION LINK: http://academy.cba.mit.edu/classes/scanning_printing/index.html

MACHINE DESCRIPTION Ultimaker is a 3D printer manufacturing company, they make 3D printers, develop 3D printing softwares, and sell bounded 3D printing materials. Their product line includes the Ultimaker 3 series, Ultimaker 2+ series and Ultimaker Original+. These printers are used by industries such as automotive, architecture, healthcare, education, and small-scale manufacturing. What is available in QBIC Fablab is the Ultimaker 2+ printer, and after this tutorial you will be able to use the machine easily without any problem. Read more: ● Ultimaker printer: https://ultimaker.com/en/products/ultimaker-2-plus. ● Ultimaker printing materials: https://ultimaker.com/en/products/materials. INTRODUCTION TO: Ultimaker 2+ The Ultimaker 2+ is a powerful 3D printer that uses filament (such as PLA, Nylon, and ABS) to print the object. The idea is basically that we have a solid material (filament), and we are reshaping it to our own 3D model. This is done by melting the filament to become liquid, and then we start to build the model by constructing layer by layer until we get the final shape. The idea is similar to when we build a house, we align bricks layer by layer until we have our own house in its final shape. The following two figures show the front and back sides of Ultimaker 2+.

1 Build plate 2 Print head 3 Bowden tube

4 Print head cable 5 Build plate clamps 6 Push/rotate button

7 Display 8 SD card slot 9 Build plate screws

Rania Zarandah | FAB Engineer 06 | 04 | 2018

1 2 3

Bowden tube Print head cable Feeder

4 Power switch 5 USB connector 6 Power connector

Spool holder

SAFETY PRECAUTIONS The Ultimaker 2+ generates high temperatures and has hot moving parts that can cause injury. Never reach inside the Ultimaker 2+ while it is in operation. Always control the Ultimaker 2+ with the button at the front or the power switch at the back. Allow the Ultimaker 2+ to cool down for 5 minutes before reaching inside. Do not change or adjust anything on the Ultimaker 2+ unless the change is authorized by the manufacturer. Do not store items in the Ultimaker 2+. The Ultimaker 2+ is not intended for use by persons (including children) with reduced physical and/or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning the use of the appliance by a person responsible for their safety. Children should be under constant supervision when using the Ultimaker 2+. 1. Electrical Safety: The Ultimaker 2+ operates on 24 volts (Extra-low-voltage) and is therefore outside the scope of the low voltage directive. The power supply meets all CE mark regulations and is protected against short-circuit, overload, overvoltage and overtemperature. For more information concerning electrical safety aspects, please refer to the Mean Well EC-Conformity Declaration for the GS220AX power adapters. Only use the Ultimaker 2+ with power supplies and cables supplied by Ultimaker B.V. 2. Mechanical Safety: The Ultimaker 2+ contains many moving parts, but the stepper motors do not have enough power to cause serious injuries and the moving gears have been covered. Still, it is advised to only reach in the machine when it is turned off. 3. Risk of Burns: There is a potential risk of burns, as the print head can reach temperatures of up to 260°C and the heated bed can reach temperatures of up to 120°C. The nozzle of the print head is mostly surrounded by an aluminum cover to prevent contact, but we still advise against reaching into the machine when the print head and/or heated bed are hot. 4. Health: The Ultimaker 2+ is designed to print with PLA and ABS filaments. The use of other materials is at your own risk. When printing with ABS, small concentrations of Styrene vapor can be released. In some cases, this can cause headaches, fatigue, dizziness, confusion, drowsiness, malaise, difficulty in concentrating, and a feeling of intoxication. Therefore, good ventilation is required, and long-term exposure should be avoided. It is advisable to use a fume hood with active carbon filtering for ductless extraction. Fume extraction is mandatory for use in offices, classrooms, etc. Printing with pure PLA is considered safe, although good ventilation is still advised for possible unknown vapors released from coloring dyes in colored PLA.

Rania Zarandah | FAB Engineer 06 | 04 | 2018

Preparing Ultimaker 2+ for Printing Step-by-Step:

Start by plugging in your Ultimaker 2+, and then switch it on using the power switch.

Before starting the operation, you need to check whether your printer has enough ﬁlament for you to print your object, or you need to insert a new ﬁlament for your printer. The small screen shown in the printer has three options; print, material, and maintenance. Choose the material option.

After choosing the material option, another screen will pop up with the options; change, settings, and returns. Choose the change option

When you choose the “change” option the printhead will start heating up in order to remove the ﬁlament from the ﬁlament Bowden tube.

The ﬁlament will start ﬂow back from the Bowden tube.

Until the ﬁlament comes out completely from the Bowden tube.

Rania Zarandah | FAB Engineer 06 | 04 | 2018

Then you can remove the ﬁlament spool from the printer spool holder.

After pressing ready, the printer will ask you to choose the type of material you want to print with. Choose your printing material!

Make sure that you insert the ﬁlament spool very well to not cause any problem while pulling the ﬁlament into the tube during printing procedure.

After changing the ﬁlament, the printer will indicate that the material has been removed, and whether you are ready to add new material. Press Ready!

Insert new ﬁlament in the spool holder.

Keep in mind the flow of the filament into the tube, therefore to insure smooth flow, please oriented as shown in the picture above.

Rania Zarandah | FAB Engineer 06 | 04 | 2018

From the hall shown in the picture above insert the ﬁlament starting point. At the beginning you need to insert the ﬁlament manually into the printer.

You have to feel that the printer is pulling the ﬁlament upward!

Then you have to go back and press ready from the printer screen.

You will start notice that the ﬁlament will start to ﬂow into the tube.

Then it will start to ﬂow out from the print head nozzle.

Finally, your printer is ready and now you can prepare your ﬁle to 3D print your model!

Rania Zarandah | FAB Engineer 06 | 04 | 2018

Preparing the 3D Model For Printing: For the Ultimaker 2+, it is recommend to use Cura software to prepare your 3D print files. Cura quickly and accurately converts 3D models into 3D print files within seconds, showing you a preview of the print so you can be sure everything is as you would like it to be. The Cura software can be found at www.ultimaker.com/software. After downloading, open the installer and run the installation wizard to complete the installation. When opening Cura for the first time, you will be asked to select your 3D printer, the Ultimaker 2+. No other configuration is required and you can directly start using Cura. You can also return back to Introduction to Ultimaker 2+ section and download the software from the link provided in the description area. Note that you cannot use the software for designing purposes, you can only upload your design there and adjust the printing parameters to as preparation for the printing procedure.

This is the front view of Cura, we will go section by section to introduce you to every tool you need to use to prepare your 3D model for 3D printing.

Then open!

There are two ways to insert an object into Cura, go to ﬁle!

Find your ﬁle in wherever you save it and click open! And the other way is to drag your model into Cura front view, and it will be inserted directly.

Rania Zarandah | FAB Engineer 06 | 04 | 2018

Keep in mind that your model should be saved as one of the following formats, and preferably in either STL, OBJ, DAE or AMF ﬁle.

There two important windows you need to use to adjust your 3D model to prepare it for the 3D printing procedure.

For the ﬁrst window there is ﬁve main key parameters you can adjust! Move, in this icon you can move the object over the x, y, and z axis.

Scale, from this icon you can maximize or minimize the size of your 3D object from x, y, and z axis.

Rotate, from this icon you can rotate your object over the x, y, and z axis, manually using the circle that indicate each rotation axis.

Mirror, the mirror icon will allow you to mirror image your 3D model over the x, y, and z axis. And the ﬁnal icon is similar to the second window.

Rania Zarandah | FAB Engineer 06 | 04 | 2018

For the second window there are three important parameters that need to be adjusted; material, nozzle, and print setups.

Material, As we mentioned above, Ultimaker 2+ uses different materials for the printing procedure like; PLA, ABS, and CPE.

The nozzle is the round spout at the end of the print head used to control the ﬂow of the ﬁlament. Keep the default option (0.4 mm) for the nozzle.

In printer setups there two options; recommended, and custom. For recommended, the software will recommend speciﬁc setups for your print.

For the custom, you can customize your own setup, by changing the parameters to go with your own print setups, like quality, shell, and inﬁll, etc.

These setups will control the printing speed, solidness of the print, and whether the print require support and build plate adhesion.

Rania Zarandah | FAB Engineer 06 | 04 | 2018

The infill section gives you the ability to play with the infill density of your 3D model, the percentage can change to make it less solid or completely filled.

Generate support to support parts of your model which have overhangs. Without these support, such parts would collapse during printing procedure.

Build plate adhesion type is a different option that help to improve both priming your extrusion and adhesion to the build plate.

Brim adds a single layer ﬂat area around the base of your model to prevent warping.

Rafts adds a thick grid with a roof below the model.

Skirt is a line printed around the model but connected to the model.

Rania Zarandah | FAB Engineer 06 | 04 | 2018

Print your 3D Model:

Insert back the SD card into the printer following the previous procedure. Then from the small screen in the printer you have three different choices; print, material, and maintenance. Choose Print!

Then the SD card file will open and will show you all the file saved in the SD card. Go and find your file and then click on it!

Printing order will start once the machine ﬁnishes heating up, and by this your done with placing your printing order and now all you need to do is to wait!

Rania Zarandah | FAB Engineer 06 | 04 | 2018

How to Control Your 3D Print Order?

During the printer procedure the screen will indicates the time required to ďŹ nish the printing job.

Together with two choices; Tune and pause. Choose the pause option!

Other choices will pop up; resume print, change material, or tune. Choose the Tune option!

When choose tune a menu will appear with different choices. Choose abort!

A massage will pop up asking you whether you want to abort the printing job or not. Choose yes!

And by this you successfully aborted the print job, and the printer will start to cool down.

THREE - 2

References

Rania Zarandah | FAB Engineer 06 | 04 | 2018

1. Material used for 3D printing using Ultimaker 2+: When you select a print material, it is important to consider the characteristics of the object you want to print and the environment in which it will be used. Ideally, to select your print material based on material characteristics such as: a. Technical properties. b. Aesthetic qualities. c. Processing abilities. The following material description will help you select the right material for your 3D printing application. 1.1

PLA (polylactic acid)

PLA is a biodegradable polymer that is ideal for 3D models with pleasing aesthetics. It has good surface quality, is somewhat glossy, and prints details with high resolution. PLA is a reliable and easy to print material that can be printed at low temperatures. It has a low shrinkage factor and does not require the use of heated build plate. It is the perfect choice for creating concept models, visualization aids, or for use of education. Overall, PLA is not as strong as more technical material but does have a high tensile strength. It is not recommended for functional and mechanical parts. Items printed with PLA can lose their mechanical properties and may become brittle over time. 1.2

ABS (acrylonitrile butadiene styrene)

ABS is well-known material used by professionals for mechanical and technical applications. It has excellent mechanical properties and can be used for objects that require toughness and durability. With a thermal resistance of up to 85 , ABS can be used in warm environments. These properties make ABS a good choice for prototyping and fit testing. Ultimaker ABS is specially formulated to minimize wrapping and ensure consistent interlayer adhesion. This makes it easier to use that standard ABS filaments. Ultimaker ABS has pleasing aesthetics and results in a matte finish when printed. However, ABS is adversely affected by exposure to UV light, so it is strongly recommended not use ABS for applications that are exposed to UV light for extended periods. 1.3

CPE (co-polyester)

CPE is a popular material for mechanical application. It has the same strength as ABS but also has high tensile strength, dimensional stability, and chemical resistance. This means that CPE can be used in combination with most industrial oils and chemicals without adverse effects. CPE is odorless and emits few UFPs (ultraﬁne particles) and VOCs (volatile organic compounds) during printing. This makes it safer choice than any other material. However, CPE should not be used for parts exposed to high temperature as it may deform at temperature above 70. 1.4

CPE+ (co-polyester)

CPE+ is stronger that CPE, which makes it suitable for applications where the strength of the object is key. CPE+ is primarily used for functional prototyping and modeling. It has greater thermal resistance than CPE, and therefore parts printed in CPE+ can be used at temperature up to 100 without deforming. However, printing in CPE+ is more challenging than CPE because of the high temperature requires to print. 1.5

PC (polycarbonate)

PC can be used for various engineering applications. It’s one of the toughest print materials, making it a perfect choice for printing strong objects. PC has high mechanical strength, good UV stability, and high thermal resistance. It retains its form at temperature up to 110. In addition, PC has a good dimensional stability, is chemical resistance, and has ﬂame-retardant characteristics. These properties make it suitable for lighting molds, engineering parts, tools, functional prototyping, and short-run manufacturing. However, printing in PC can be challenging due to high temperature required to print.

Rania Zarandah | FAB Engineer 06 | 04 | 2018

1.6

Nylon (polyamide)

Nylon is well-known material used for printing tools, functional prototyping, and end-use parts. It combines strength, impact resistance, and flexibility. Nylon 3D prints are both strong and slightly flexible. Ultimaker nylon is very durable due to its abrasion resistance and corrosion resistance to alkalis and organic chemicals. Unlike standard nylon filaments, Ultimaker nylon is considerable easy to use- it features reduced humidity absorption for easy and reliable printing. 1.7

TPU 95A (thermoplastic polyurethane)

TPU 95A is a semi-flexible material for use in application that demand qualities of rubber and plastic. TPU 95A has a score of 95 on the Shore A Hardness Scale, with an elongation break of up to 580%. TPU 95A is flexible, strong, and can withstand high impacts deforming or breaking. It is also resistant to many common industrial oils and chemical and easily resists normal wear and tear. Unlike other semi-flexible materials, Ultimaker TPU 95A is easy to use, print quickly, and does not require a high level of expertise to use effectively. TPU 95A is not recommended for applications that will be exposed to UV light, moisture, or high temperature for extended periods. 1.8

PP (polypropylene)

As the second used polymer worldwide, PP offers many possibilities for both prototypes and end-use parts. Ultimaker PP is durable with a high toughness and fatigue resistance. This means that PP retains its shape after torsion, bending, or flexing. It has very low friction, allowing parts that are in contact with each other to move smoothly over each other. PP is also semi-flexible. While it’s not as flexible as TPU 95A, it can still be a good option if you’re looking for material with slight flexibility. Besides this, it has a good chemical resistance and high electrical resistance, so it is ideal as an electrical insulator. Another key advantage of PP is that it has a low density, making it perfect for creation of lightweight parts. Furthermore, it has a good translucent properties. 1.9

PVA (polyvinyl alcohol)

Although PVA is typically used for printed objects, it is an ideal material to choose if you’re looking for removable support structures. Ultimaker PVA is biodegradable, has a good thermal stability, and is less moisture sensitive than other PVA ﬁlaments. After printing in combination with other material, PVA support structures can easily be removed by dissolving in water. This makes PVA a good support material and allows you to print models with large overhangs and complex geometries. However, PVA is only supported on the Ultimaker 3 and is currently optimized to serve as support structure for either PLA or Nylon. To read more about the material used for 3D printing in Ultimaker 2+: https://ultimaker.com/en/resources/manuals/materials

2. Choosing the right nozzle: There is no clear or direct way to choose the right size of nozzle, but you should keep in mind that you need to play with the printing setups (layer height, printing speed, material choice, and printing temperature) to ensure perfect printing results same as the one you get from using the 0.4 mm nozzle. Therefore, there is no way to do comprehensive guide as what would be preferred to have for the using different size of nozzles, and even we cannot recommend a certain temperature for each nozzle size as this varies even just by the color of the ﬁlament. However, there are some guidelines that can be helpful from other users regarding; layer height, volume, speed, and temperature.

Rania Zarandah | FAB Engineer 06 | 04 | 2018

2.1

Layer height:

Printing up to around 50% to 75%-layer thickness of the nozzle size is usually ďŹ ne so for 0.4mm nozzle up to around 0.2mm or 0.3mm layers. For 0.8mm that would be around 0.6mm thick max (it is better to stick to 0.4mm), and so on. e.g. you cannot go over 0.12mm layer height with 0.25mm nozzle.

Layer Resolution

Nozzle

150 to 60 micro

0.25 mm

200 to 20 micro

0.4 mm

400 to 20 micro

0.6 mm

600 to 20 micro

0.8 mm

2.2

Volume:

The area is the square of the diameter and resistance goes down linearly by the area so you can print faster (volume of plastic per second) on the "square law". Cura shows the volume if you hover over the speed (at least some versions do). So that means for example if you normally print 0.2mm layer using 0.4mm nozzle 50mm/sec you can multiply those 3 numbers to get a volume of 4 . But with the 0.8mm nozzle you can do 4 times as fast no problem. So, if you should be able to print 16 easily (e.g. 0.4-layer height using 0.8 nozzle 50mm/sec). and of course, you need to print so much slower for the 0.25mm nozzle (or 0.15mm or 0.1mm nozzles) 2.3

Speed:

For very good dimensional accuracy (corners not blobby) it's best to keep the speed low. For really beautiful parts you want to go no faster than around 25 mm/sec regardless of layer height and nozzle size. This has to do with speed changes at corners. The printer has to slow down to 14 mm/sec on a right-angle corner so only slowing by about 2 times is barely a problem but if you are at 50mm/sec or faster the corners are noticeably bulging. This is regardless of nozzle size or layer height. That's why it's so great to print with a bigger nozzle instead of just printing faster. Extrusion speed

Nozzle

Up to 8 (mm^3/s)

0.25 mm

Up to 16 (mm^3/s)

0.4 mm

Up to 23 (mm^3/s)

0.6 mm

Up to 24 (mm^3/s)

0.8 mm

2.4

Temperature:

You will get consistently better quality at lower printing temperatures but this means you also have to slow down as it's harder to get ďŹ lament through the nozzle. For high quality 210-220 is a good compromise. For extra high-quality print extra slow (10mm/sec?) and at 190. That way the ďŹ lament is more like cement and is better at not moving in the second before it cools. For the 0.8mm nozzle and larger it's best to print hotter as it is hard for the heat to penetrate to the center and so Ultimaker recommends printing a bit hotter with 0.8mm and larger nozzles.

Rania Zarandah | FAB Engineer 06 | 04 | 2018 3. Useful software and platforms for 3D modeling:

Software (unlicensed)

Software (licensed)

Platforms

Sculptris

SolidWorks

Thingiverse

Rhino

Instructurables

SketchUp

Sketchfab

AutoCAD

Tinkercad

Inventor

OnShape

Fusion 360 Cinema 4D 3DS Max Alias Maya

FOUR - 1

3D Printing using FormLabs2 Printer

Rania Zarandah| Fab Engineer 06| 23 | 2018

Q4_3D PRINTING | Q3_2 | FORMLABS | FORM 2 DESIGN SOFTWARES (OPEN SOURCE | LICENCES) : https://formlabs.com/tools/preform/

MACHINE DESCRIPTION Form 2 is one of the most reliable 3D printer ever created. It delivers high resolutions parts at the fraction of the cost and footprint of industrial 3D printer. Formlabs printer uses the stereolithography (SLA) 3D printing technology which is also known as resin printing. This technology used for creating models, prototypes, pattern, and production of parts in a layer by layer fashion using photopolymerization, a process which light causes chains of molecules to link, forming polymers. Those polymers then make up the body of a three-dimensional solid. Stereolithography or SLA can be used to create things such as prototypes for products still in early design, medical models, and computer hardware as well as many other applications. While SLA is fast and can produce almost any design, even if it can be expensive design. The advantage Form 2 3D printer has is that it has integrated resign technology, meaning that it has different resin packages that can be used in different application that requires specials resigns. To read more about the Form 2 3D printer: ● Form 2: https://formlabs.com/3d-printers/form-2/ ● Pre-form: https://formlabs.com/tools/preform/ ● FormLabs resin library: https://formlabs.com/materials/

INTRODUCTION TO: Stereolithography technology Stereolithography is additive manufacturing process that works by focusing an ultraviolet (UV) laser on to a vat of photopolymer resin. Together with the help of computer aided manufacturing or computer aided design (CAM/CAD) software, the UV laser is used to draw a pre-programmed design or shape on to the surface of the photopolymer vat. photopolymers are sensitive to ultraviolet light, so the resin is photochemically solidified and forms a single layer of the desired 3D object. then, the build platform lowers one layer and a blade recoats the top of the tank with resin. This process is repeated for each layer of the design until the 3D object is complete. Completed parts should be washed with a solvent to clean wet resin off their surfaces. It is also possible to print objects “bottom up” by using a vat with transparent bottom and focusing the UV or deep blue polymerization laser upward through the bottom of the vat, and this is actually the technology used in Form 2. What the Form 2 does is that it start a print by lowering the build platform to touch the bottom of the resin-filled vat, then moving upward the height of one layer. The UV laser then writes the bottom-most layer of the desired part through the transparent vat bottom. Then the vat is “rocked”, flexing and peeling the bottom of the vat away from the hardened photopolymer; the hardened material detaches from the bottom of the vat and stays attached to the rising build platform, and the new liquid photopolymer flows in from the edge of the partially build part. The UV laser then writes the second-from-bottom layer and repeats the process.

An advantage of the bottom up technique that the Form 2 is using is that the build volume can be much bigger than the vat itself, and only enough photopolymer is needed to keep the bottom of the build vat continuously full of photopolymer.

Rania Zarandah| Fab Engineer 06| 23 | 2018

IMPORTANT FEATURES

Dimensions 35 × 33 × 52 cm 13.5 × 13 × 20.5 in

Temperature Control Self-heating Resin Tank

Connectivity Wiﬁ, Ethernet and USB

Weight 13 kg 28.5 lbs

Power Requirements 100–240 V 1.5 A 50/60 Hz 65 W

Technology Stereolithography (SLA)

Operating Temperature Auto-heats to 35° C Auto-heats to 95° F Laser Speciﬁcations EN 60825-1:2007 certiﬁed Class 1 Laser Product 405nm violet laser 250mW laser Peel Mechanism Sliding Peel Process with wiper

SAFETY PRECAUTIONS The Form 2 is a precision tool that requires respect and care to ensure safe operation. You should follow all safety consideration during operation. When used properly, it will help you create beautiful prints. Like any professional equipment, you should treat the printer, material, and accessories with respect and care t ensure a safe working environment and long-lasting machine. ●

●

Supervision: The Form 2 is an excellent educational tool. Fab engineers should supervise young, inexperienced users to ensure enjoyable and safe operation. Laser: The Form 2 is a class 1 Laser product. Accessible radiation is within Class 1 limits. The laser diode used inside the device has the following speciﬁcations: Diode: Violet (405nm) Max Output: 250 mW Never remove the front or back panels of the printer unless instructed to do so by Support. This will expose you to danger and void your warranty. The laser beam is harmful to the eyes, so avoid direct contact. The Form 2 contains an interlock system to automatically shut off the laser when the orange cover is opened. If this system is tampered with, or fails, there is risk of exposure to Class 3B laser light.

●

Resin: Respect Formlabs resin like any household chemical. Follow standard chemical safety procedures and Formlabs resin handling instructions. Wear gloves whenever handling liquid resin. In general, formlabs resin is not approved for use with food, drink, or medical applications on the human body. However, biocompatible resin, such as Dental SG, are biologically safe for speciﬁc type and length of exposure to the human body. Refer to information about each speciﬁc resin found in the introduction section for more details. Never ingest resin liquid or solid form.

●

Isopropyl Alcohol (IPA): Carefully follow the safety instructions provided with the isopropyl alcohol that purchase. Isopropyl alcohol can be ﬂammable, even explosive, and should be kept away from heat, ﬁre, or sparks. Any containers holding isopropyl alcohol should be kept closed or covered when not in use. It is also recommended that you wear protective gloves and have good ventilation when working with IPA.

●

Sharp Tools: The accessories kit includes sharp tools such as: tweezers, ﬂush cutter, a scraper, and a part removal tool. Using these tools on slippery surfaces (such as a resin-coated build platform) can result in sudden movement.

Tasnim Hussain | FAB Engineer 01| 14 | 2019

The software used to send the printing request to Form 2 printers is Pre-Form.

https://support.formlabs.com/s/article/Set-Up-Your-Print?language=en_US

Tasnim Hussain | FAB Engineer 01| 14 | 2019

Lift the printer’s cover. Remove the resin tank’s black lid and align the four small feet of the resin tank into the corresponding holes in the tank carrier. Push the tank until it is ﬂush against the front of the tank carrier. The printer will not properly detect the tank unless the tank is fully inserted.

Lock the Wiper: Ensure the wiper is straight, then align the foot of the wiper with the wiper mount.Push the wiper toward the tank to align it with the front of the mount. The wiper should be ﬁrmly mounted.

Insert the Build Platform: Align the build platform with the build platform carriage and push into place. Lock the handle down to secure the build platform.

Shake the Resin Cartridge: Before inserting a new cartridge, shake the cartridge to ensure the resin is well-mixed.

Insert the Resin Cartridge: Align the cartridge with the opening at the back of the printer. Push down on the cartridge handle until the top of the cartridge is level with the printer.

Be sure to press open the vent cap before starting a print, so that your resin tank ﬁlls correctly. Make sure the material in your resin tank always matches the resin type in the installed cartridge.

Power the Printer On.

TUTORIAL: WEEK 7: ELECTRONICS DESIGN

ONE

Introduction to Electronics Design and the Assignment of the Week

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

Electronics Design FAB Foundation Link: http://academy.cba.mit.edu/classes/electronics_design/index.html The main purpose of the Electronics Design session in FAB Academy is to learn the basics of Eagle software and how it can be used to design the schematics and PCB of an electronic circuit.

EAGLE is one of the most professional PCB CAD softwares that is commonly used by electronics designers. It has many features below are the most important ones. ● ●

●

Cross-platform – EAGLE can run on anything: Windows, Mac, even Linux. This is a feature not too many other PCB design softwares can boast. Lightweight – EAGLE is about as svelte as PCB design software gets. It requires anywhere from 50-200MB of disk space (compared to the 10+GB more advanced tools might require). The installer is about 25MB. So you can go from download to install to making a PCB in minutes. Free/Low-Cost – The freeware version of EAGLE provides enough utility to design almost any PCB in the SparkFun catalog. An upgrade to the next license tier (if you want to make a proﬁt off your design) costs at least two orders of magnitude less than most high-end tools. Community support – For those reasons, and others, EAGLE has become one of the go-to tools for PCB design in the hobbyist community. Whether you want to study the design of an Arduino board or import a popular sensor into your design, somebody has probably already made it in EAGLE and shared it.

Recommended Reading Here are a few tutorial and concepts you may want to familiarize yourself with before dropping down into this rabbit hole: ● ● ●

PCB Basics How to Read a Schematic? Voltage, Current, Resistance, and Ohm’s Law

There are a few limitations when using Eagle to be aware of when using the free version: ● ● ●

Your PCB design is limited to a maximum size of 100 x 80mm (3.94 x 3.15in). . Only two signal layers allowed. If you need more layers check into the Hobbyist or Standard licenses. Cannot make multiple sheets in your schematic editor.

Those limitations still make EAGLE an amazing piece of software. When designing a circuit board on Eagle, you will need to create a schematic for the circuit and then convert the schematics into a board layout.

The Assignment of the Week: ●

Group project: Use the test equipment in your lab to observe the operation of a microcontroller circuit board.

●

Individual project: ○ Redraw the echo hello-world board, add (at least) a button and LED (with current-limiting resistor. ○ Check the design rules, make it, and test it ○ Extra credit: simulate its operation.

TWO

References

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

Please refer to the following links for tutorials needed to do the assignment: â&#x2014;? What is Eagle? â&#x2014;? References

How to read Schematics? https://learn.sparkfun.com/tutorials/how-to-read-a-schematic

TUTORIAL: WEEK 8: COMPUTER-CONTROLLED MACHINING

PAG. 96-97 Introduction to Computer-Controlled Machining and the Assignment of the Week PAG. 98-111 ShopBot CNC Router PAG. 112-126 X-Carve CNC Machine

ONE

Introduction to Computer-Controlled Machining and the Assignment of the Week

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

Computer-Controlled Machining FAB Foundation Link: http://academy.cba.mit.edu/classes/computer_machining/index.html

CNC stands for Computerized Numerical Control which is a programmable automation in which process is controlled by Numbers, Letters, and symbols. CNC Machining is a process used in the manufacturing sector that involves the use of computers to control machine tools like lathes, mills and grinders. The CAD tool works with design, or the initial creative step of any project. After that, when there is the need to manufacture it - and therefore CNC technology is demanded - another kind of software is needed: CAM is the software that creates the machine program from a digital design. Basically, CAM software produces a G-CODE that is a preparatory word, used as a communication device to prepare the MCU. The G-code indicates that a given control function such as G01, linear interpolation, is to be requested. The following block diagram and ﬁgure illustrate the building blocks, structure and parts of a CNC router machine.

Input CAD 2D Design on the computer.

Interface

Output

CAM Software converts the CAD design into instructions for the machine to implement the design. These instructions are usually called a “Code”.

The code produced by the CAM software will be executed by the machine’s controller and will drive the spindle and motors to start milling/ cutting.

BASICS The The concepts are fairly simple, but it is not surprising that many operations struggle with these questions once we consider all the variables in machines, materials and tools. ● Tools Structure:

●

Feed, speed and ﬂutes: ○ Feed rate: When milling or drilling, or creating a tool path for a CNC machine the feed rate must be determined. Materials have rated surface speeds for a given type of cutter. The harder the material the slower the speed. Given the diameter of the tool and the surface speed, the RPMs of the spindle can be calculated. Then if the tooth load for the cutter is know, and the number of teeth, the feed rate can be determined. ○ Speed: Most spindles (the term for the router attached to your cnc router) will go from about 7,000rpm to 18,000rpm. This speed is termed ‘spindle speed’ and is directly related to the feed rate or surface speed, which most machines are capable of doing up to about 200rpm.

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

○

Flutes: Flutes are the sharp slots that corkscrew upwards along the length of a milling bit. They are responsible for doing the cutting work when the bit is spinning.

Bits come with 2, 3, or 4 flutes / A bit with more flutes has more cutting edges and consequently cuts faster and smoother than a bit with fewer flutes / The more flutes a bit has, the thinner these flutes are and the more likely they are to get clogged with material when cutting. There are 4 main types of flute patterns for router bits, plus many types of specialty bits.

ChipLoad x CutterDiameter x NumberOfFlutes x SpindleSpeed = FeedRate Where chipload is the amount of material cut per tooth (feed per tooth). Feed rate is the surface speed of the cutting tool in inches per min, spindle speed is the rotational speed of the cutting tool in revolutions per min, number of ﬂutes and cutter diameter are determined by your tool. There are some online calculators for chipload, Fedd rate,and milling speed. Some machines have standard values like Shopbot Refer to https://static1.squarespace.com/static/59efc96d90badec50a4afa15/t/5a21f4b6e2c483bcf39a2c84/1512174775486/FeedsandSpee ds.pdf In FAB Academy, you will learn how to use small and big scale CNC Machines to make something.

Assignment of the Week: ● ●

Group assignment: Test runout, alignment, speeds, feeds, and toolpaths for your machine. Individual assignment: Make something big

TWO - 1

ShopBot CNC Machine

Rania Zarandah | Fab Engineer 06 | 10 | 2018

Q1_STATIONARY MACHINES| Q1-3| CNC Router PRSalpha| Cutting Machine DESIGN SOFTWARES (LICENCES) : VCarvePro ShopBot Edition (http://www.shopbottools.com/mProducts/software_vcarve.htm )

INTRODUCTION TO: ShopBot 3D cutting, machining and sculputuring can be used in many different types of projects. ShopBot CNC tools are fully 3D capable, as are most CNC routers(this capability is technically described as 3-axis interpolation, which means that moves are made smoothly in 3D space using diagonals and curves). Full 3D CNC involves both designing in 3D and during cutting simultaneous CNC motion in x, y, and z axes. In 3D shaping, the CNC cutter tip follows paths at 3D angles or in 3D curves in order to mill or curve complex shapes into the materials. This tutorial covers topics required to get started with a ShopBot PRS, safety, how to start the machine, how to use the software, and how to start cutting your 3D model.

SAFETY PRECAUTIONS This safety summary contains general safety warnings that should be understood during operation of this machine. Failure to observe these precautions could result in injury: ●

Learn and understand safe use of the machine. Do not allow untrained individuals to operate the machine without supervision. Be aware of the location of the Emergency Stop switches at all times.

●

Eye and ear protection MUST be worn by the machine operator as well as any bystanders or observers. Flying sawdust, material chips, and other debris can cause serious eye injury.

●

Wear closed-toe shoes at all times.

●

Make sure that your material is properly secured before cutting, and be aware of any small parts that may come loose after being cut. If a small part catches the edge of a spinning bit, it can be thrown forcefully in any direction, causing injury or damage.

●

Never place your hands on the rails of the ShopBot. Be aware that the machine may move unexpectedly in any direction, which can cause serious injury if your hands are in the path of movement.

●

Never wear gloves while operating the machine. As with any power tool, a glove can get caught in moving or spinning parts and pull your hand into the machinery.

●

Never leave a machine running and unattended. Understand that a spinning tool generates friction and heat, creating a risk of ﬁre. This risk is minimized by using correct chip load, using sharp bits, and by always double-checking your ﬁles before cutting. Be prepared to pause or stop the cut if something seems incorrect or unsafe.

●

Keep a working ﬁre extinguisher within reach of the machine, for the reasons listed above.

Rania Zarandah | Fab Engineer 06 | 10 | 2018

Preparing the CNC Machine: The ﬁrst step you have to do before designing and CNC cutting is prepare your ShopBot. There are few thing you need to check or adjust before starting: 1. 2.

Material, you need to ﬁx or insert the material you want to use on the spoil board. Bit, you need to check whether the bit inserted in the spindle is actually the one that ﬁt your cutting purposes. If not you need to change it.

For placing or removing your material prepare your drill and drill bits.

Prepare your new material, that you need to use for the CNC cutting job.

First remove the old material inserted in the spoil board. By drilling out the screws used to ﬁx the material.

Also, you will need some screws and screws washer to adjust your material on the spoil board.

100

Rania Zarandah | Fab Engineer 06 | 10 | 2018

Adjust your material on the spoil board as shown in the above picture.

To change or replace the cutting bit, ďŹ rst choose the bit for your project from the bit toolbox.

Remove the collect from the spindle by rotating both wrenches in the opposite direction.

Now your material is ready!

Move the spindle into an easily accessible position.

Note that if the collect pieces is the one ďŹ tting your bit no need to change the collect just untighted it and put the new bit you want to use.

101

Rania Zarandah | Fab Engineer 06 | 10 | 2018

Prepare your Design Introduction to ShopBot 3 and VCarve Pro:

There are three main parts in the â&#x20AC;&#x153;ShopBotEasyâ&#x20AC;? panel. In this section we will introduce each and every part in details.

The x, y, and z location indicator will show you the live location of the spindle. It will keep on changing while the spindle is moving.

The second part of the easy menu has 4 important icon, the origin point icon, zero x, and y axis, zero z axes, and the keypad.

In the keypad panel you can change the location of the spindle, back, front, up, and down across the x, y, and z axes using the arrows shown in the menu.

In this panel you can locate the x, and y origin location of the spindle to where you want it to start the CNC job from.

Locate the x, and y origin manually using the arrows then press zero axes from keypad panel. Choose the axes you want to zero then press the ZERO button.

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Rania Zarandah | Fab Engineer 06 | 10 | 2018

By this you can see from the axes location indicator that the point the spindle is standing in is the zero point for the x, and y axes.

To zero the z axes, you need to use both the machine and the software together. In the “ShopBotEasy” panel there is an icon to set the z zero height. Press this icon.

A pop-up message will ask you whether the z plate is ready. For this you need to return back to the machine.

In the shopbot you will ﬁnd this plate together with the clipper. Take it out from its place.

Place the plate under the spindle and exactly under the bit.

Take the clip and clip it on the collect nut as it is shown in the above picture.

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When you are done get back to the pop-up massage and press OK.

Then slightly moves up, and then it moves down again and touches the plate gently to ﬁnalize the location of the z axis.

The software used to design or import ﬁle to prepare it for CNC cutting or curving is the (VCarve Pro.)

The spindle will start to move down the z axis until it touches the plate once.

Then ﬁnally in the software a massage will pop up identifying that the z axis height has been speciﬁed, and remind you to remove the clip and the plate and return it back to their original places.

To open new ﬁle just go directly from small menu in the left of the screen, or you can just go to ﬁle- (open, new) in the top far left of the screen.

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When you press new, this will be the front page of the software.

In the left menu it will ask you about the parameters of the material you are using like; width, height, and the thickness. Set these parameters and press ok.

You can measure the height and the width using meters.

And the thickness using the Vernier caliper.

After pressing ok, a menu will show up, you can use this menu to start design your model. For example, let's design a star

In this page you can design your model and set different parameters such as number of point, and the location. When you are done press apply!

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When you are done you will get back to the previous page you were in, and by this you will be done from modeling. Go to toolpath tab.

In the toolpaths tap you can prepare your model for either cutting or curving. In toolpath panel you will ďŹ nd two important options; the material setup, and the toolpath operations.

In the material setups, you can adjust the parameters of your material like the width, height, and thickness.

To measure the width, height, and thickness of your material you can use Vernier caliper for accurate measurements.

In the toolpath operations you can choose whether you want to cut or curve or any other options. Choose the cut option for example.

In the cutting panel you can adjust parameters for the cutting job. These parameters including; cutting depths, tool, passes, machine vector, and tabs.

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The cutting depths you will need to adjust the depth the spindle will go after each cutting iteration.

For the tools, you need to add the bit information. You either go with the suggested bit, or you choose “edit” option to sit the parameters of your own bit.

When you press edit, tool database panel will appear and you can choose either to go with the suggested tool list, or you can just custom your own bit information by providing some parameters .

The number of passes is where you can adjust the number of passes the machine will do to ﬁnish your cutting job. To edit press “Edit Passes”.

If you press edit passes the “specify pass depth” panel will appear and it will demonstrate two important things; cutting depth, and the number of passes the machine will take to do the cutting job.

If you increase the number of passes to 3 passes for example you would clearly see that machine will go 4mm/pass until it ﬁnishes 12 mm cutting job in 3 passes.

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Note that: Donâ&#x20AC;&#x2122;t do your cutting job in one pass, this might damage the both the bit and the material you are using.

The recommended number of passes is always between 3-6 passes, depending on the thickness of the material you are using.

Tabs are used to prevent your model from moving during the cutting procedure.

By choosing edit tabs, you can edit the numbers of tabs you want on you model and the distance between them.

When you are done with adjusting the cutting parameters you can preview the machine behavior by pressing on calculate

You can play on this tab to check how the machine would behave on the material you are using.

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And you can check the ﬁnal look of your design.

To prepare your files press cancel to get back to the toolpaths window.From the toolpath list choose your file, in this case the file is Test, then press the save button in the toolpath operations menu.

Then from the new panel press “save toolpath to ﬁle”.

Finally, you can save the ﬁle wherever you want, and now you are ready to cut your model.

To start your cutting job, go back to ShopBotEASY panel and press on “Cut Part” button.

A window will pop up, go and ﬁnd the ﬁle you saved in the previous step. Note that it has to be in the “.sbp” format.

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When you choose your ďŹ le, the software and the machine will be ready for starting the cutting job. Press on start button in the ShopBotEASY panel.

After pressing start from the panel, go to the machine controller and press the start button for the machine to start operating.

If there were any problem while the CNC router is running, you have to press the emergency button found on the machine. There are two emergency button, one is on the gauntry of the ShopBot.

And one is on the controller that comes with the machine. You press any of them and not necessary both, but when you reopen the machine you need to un-press the button in order for the machine to operate.

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References

Rania Zarandah | Fab Engineer 06 | 10 | 2018

●

https://support.shopbottools.com/training/tutorials

●

http://www.shopbottools.com/ShopBotDocs/ﬁles/SBG%2000142%20User%20Guide%2020150317.pdf

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http://www.shopbottools.com/ShopBotDocs/ﬁles/DTQuickStartGuide.pdf

●

http://fab.cba.mit.edu/content/tools/shopbot/index.html

●

https://www.machiningcloud.com/wp-content/uploads/2016/05/MachiningCloud_MillingToolsAndTheirApplication.pdf

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X-Carve CNC Machine

Tasnim Hussain| Fab Engineer 07 | 14 | 2018

Q1_STATIONARY MACHINES| Q1-4| CNC Router| Cutting Machine PLATFORMS: Easel (http://easel.inventables.com/users/sign_in) FAB FOUNDATION REFERENCES: http://academy.cba.mit.edu/classes/computer_machining/index.html X-Carve Machine Description:

3D cutting, machining and sculpurting can be used in many different types of projects. X-Carve tools are fully 3D capable, as are most CNC routers(this capability is technically described as 3-axis interpolation, which means that moves are made smoothly in 3D space using diagonals and curves). The X-Carve is a product of Inventables and it is one of the most popular desktop CNCs on the market. Like other CNC machines, Full 3D CNC involves both designing in 3D and during cutting simultaneous CNC motion in x, y, and z axes. In 3D shaping, the CNC cutter tip follows paths at 3D angles or in 3D curves in order to mill or curve complex shapes into the materials. The only limitation with the X-Carve is the lack of a dust extractor; thus, it is important to strictly follow the safety precautions especially wearing face mask and safety goggles while the machine is operating. Machine Parts and Tools:

Screws

Screw Washers

Holding Steppers

Bits

Spindle Wide MakerSlide

X-Controller

Vernier Caliper

wrenche

Z-Probe

SacriďŹ cial Board

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EASEL Platform: x-Carve uses EASEL platform to operate different machine carving functions. EASEL is a web-based software used to design and carve from a single program. EASEL is user friendly and a truly entry-level interface for CNC operation in making both 2D and 3D designs. IMPORTANT DEFINITIONS ●

Bits:

CNC routers use bits to determine the type of desired carving, the resolution of the design and the speed that should be used to move over a particular material to be designed. Bits come with cutting edges that pull up or push down (sometimes both), they have square or shaped ends, they are made for speed or accuracy, and they come in diameters from a pinpoint to over two inches for standard CNC routing. The following picture shows a basic collection of X-Carve bits.

Choosing the Proper Bit: Choosing the proper bit to be used with X-Carve is one of the most important steps before operating the machine as it is directly and highly affecting the quality and speed of the carving job. To select the suitable bit follow the steps below: ●

For straight cuts in a material like plywood, spiral cutting end-mill is used. Added to that the bit diameter is selected to suit the desired design properties. The following picture shows the 1/4″ and 1/2″ 2-ﬂute upcut square end-mills.

●

For carving large 3D contours, the ball nose bit is used with the appropriate size to match the level of contour detail to be done. These special bits enable the users to design smooth contours and a great details. The following picture shows the 1/4″ and 1/2″ 2-ﬂute ballnose endmills.

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●

For lettering or carving a detailed sign, the “V” shaped bit is used. These bits are sometimes called v-carving bits, v-groove bits, or engraving bits. This is the only way to get a sharp grooved bottom on the inside of those roman numerals for your sundial. They are available in many sizes and angles. The most common and useful angles in order are 60⁰, 90⁰, and 30⁰. The following pictures shows the 1/2″ with 60⁰, 1/4″ with 45⁰, and 1/4″ with 30⁰ V-shaped bits.

SAFETY PRECAUTIONS Before operating the machine, it is very important to be aware of the following safety precautions:

Learn and understand safe use of the machine. Do not allow untrained individuals to operate the machine without supervision. Be aware of the location of the Emergency Stop switches at all times.

Eye and ear protection MUST be worn by the machine operator as well as any bystanders or observers. Flying sawdust, material chips, and other debris can cause serious eye injury.

Wear closed-toe shoes at all times.

Never place your hands on the rails of the ShopBot. Be aware that the machine may move unexpectedly in any direction, which can cause serious injury if your hands are in the path of movement.

Keep a working ﬁre extinguisher within reach of the machine, for the reasons listed above.

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Open EASEL and sign up, then the window shown above will appear. Click on “New Project” to start designing a carving project.

Once you click on “New Project” the window shown above will appear with two windows; one for the design and the other for the simulation of the real working area of X-Carve.

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Before starting with the design, X-Carve should be conďŹ gured with EASEL by adjusting the machine settings.

Adjust material settings. Note that, the Z dimension is the thickness of the material used.

Choose from ready-made icons or import a customized design.

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To import any customized design, the file should be in the form of “SVG” file or “g-code” file.

After selecting the designed icon, its dimensions and the cutting depth could be adjusted. Here, -3mm is used as the cutting depth for the shape.

Note that, the cutting depth is directly related to the thickness of the material; however, it is measured in the negative direction since it indicates the removal of the material (i.e. reducing the material depth). The maximum depth is 0mm which means “NO CUT” , -5.8mm means “MAXIMUM CUT” or “CUT THROUGH”, while anything is between 0mm and -5.8mm indicates “PARTIAL CUT” or “ENGRAVE”.

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The design can be resized and other icons can be added to it and its sizes and cutting depth can be adjusted as desired.

“Outline” has three different styles. “On Path” cuts right on the edge of the design, “Outside” cuts the outer side of the edges of the design and “Inside” cuts the inner side of the edges.

After adjusting the design in the design area, it will be visualized from the simulation area.

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After clicking â&#x20AC;&#x153;Simulateâ&#x20AC;? the model will be showing the motion of the carving bit to over the traces of the design. Note that, 22min indicates the time needed by the machine to ďŹ nish the design.

After simulation, the material should be settled for the machine to start carving. First the material thickness is measured and inserted.

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The surface of the machine board is vacuum cleaned before clamping the material.

Clamp the material using the clamping tools as shown in the ďŹ gure above.

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Select the suitable bit size and type. Since the design is mainly engraving or carving, the straight upcut bit is selected.

Get the tools ready before placing the bit.

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The bit is attached to the support.

Then the Z-Probe is clipped and the cable is connected to the spindle as shown in the ďŹ gure.

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When probing starts, the metallic plate is touched by the bit and will be measured as the zero for the Z-axis. Note that, the movement along the Z-axis is controlled by specifying the steps increment constant and using the arrows.

Set the XY coordinates to zero or homing position. Similarly, the movement along the X-axis and Y-axis is controlled by specifying the steps increment constant and using the arrows.

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Turn the Spindle ON by pressing on the button.

Finally, the machine is ready to start carving simply by clicking on â&#x20AC;&#x153;Carveâ&#x20AC;?.

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Turn the Spindle OFF after the machine ďŹ nish carving and the bit gets elevated.

Clean up with the vacuum cleaner and remove the designed material.

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References

Tasnim Hussain| Fab Engineer 07 | 14 | 2018

● ● ●

X-Carve: https://www.inventables.com/technologies/x-carve https://www.jesspublib.org/_uploads/X-Carve-Quick-Start-1.pdf Machine Parts: https://www.inventables.com/categories/machine-components#category-18765-children Easel software: https://www.inventables.com/technologies/easel

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TUTORIAL: WEEK 9: EMBEDDED PROGRAMMING

ONE

Introduction to Embedded Programming and the Assignment of the Week

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

Embedded Programming FAB Foundation Link: http://academy.cba.mit.edu/classes/embedded_programming/index.html Embedded programming is the programming of an embedded system in some device using the permitted programming interfaces provided by that system. An embedded system is a combination of computer hardware and software, either ﬁxed in capability or programmable, designed for a speciﬁc function or functions within a larger system. The embedded system hardware can be microprocessor- or microcontroller-based. In either case, an integrated circuit is at the heart of the product that is generally designed to carry out computation for real-time operations. ●

●

A microprocessor is an Integrated Circuit (IC) or “computer chip” which typically contains the Central Processing Unit (CPU) or “brain” of the laptops, tablets and smartphones we all use. Typically these chips rely on external Random Access Memory (RAM), Read-Only Memory (ROM), and other peripherals that work together as part of a larger computer system. A microcontroller (or MCU for microcontroller unit) is a simpler computer, which contains a CPU, a ﬁxed amount of RAM, ROM and other peripherals all embedded onto a single chip. It’s basically a micro computer on a single chip. While MCU’s vary in memory and processing speed, these are typically programmed to execute speciﬁc, less complex tasks.

Microcontrollers’ Architecture: Most microcontrollers are based on Harvard architecture where program memory and data memory are kept separate, while microprocessors are based on von Neumann model where program and data are stored in the same memory module. The following block diagram illustrates how a Harvard architecture generally looks like:

In FAB Academy you will learn how to design and program a microcontroller board using ATMEL AVR family of microprocessors. these use the Harvard architecture with RISC (Reduced Instruction Set Computer). The AVR microprocessors are preferred for having quite cheap cost, having an excellent real time performance, they are available in different scales of packages from small to bigger with a nice range of peripherals, and due to the fact that they support great open-source software. One microprocessor IC that will be commonly used is ATtiny44 which has the following pin conﬁgurations:

Reading the Datasheet of ATtiny44: The ATtiny44 is a low-power CMOS 8-bit micro-controller based on the AVR enhanced RISC architecture. This small microcontrollers have very powerful features such as consuming low- power compared to other CMOS 8-bit microcontrollers, having AVR enhanced RISC architecture, it can achieve throughputs of almost 1MIPS (1 Million Instructions Per Second) per MHz and that it is ten times faster than the conventional CISC (Complex Instruction Set Computer) microcontrollers. Refer to the datesheet to know about the microcontroller features. The datasheet consists of 229 pages, so you need to be selective to read only the details you need not the whole document.

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TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

Programming Language: AVR Microcontrollers are programmed using C Language. The C code can be compiled using avr-gcc compiler and send it to the microcontroller with avrdude. Please refer to the link to know more about this. Peripherals: ● ● ●

A/D: Analog to Digital, which reads in analogue voltages. Comparator: compares voltages. D/A: Digital to Analog, which writes out voltages. This could be done in different ways using the following: ○ Timer: Measures time. ○ Counter: Measures events. ○ PWM: Measures pulses that vary in size. These are all essential for controlling lights and motors.

●

USART and USB communicate to the outside world.

Programming with the FabISP: ISP stands for In-System Programming. In the 4th week of FAB Academy you leaned how to make your own FabISP programmer. FabISP programmer is basically a ATtiny44 microcontroller setup to load programs into other microcontrollers. This board is being connected through USB connection to a computer that will tell the FabISP how to load the program. Then the program gets transferred into the board that you need to program via the 6- pin ISP headers. The Assignment of the Week: ●

●

Individual Assignment: ○ Read a microcontroller data sheet ○ Program your board to do something, with as many different programming languages and programming environments as possible. Group Assignment: Compare the performance and development workﬂows for other architectures

To achieve the assignment, you need to go through FAB Academy tutorials: ● ● ● ● ●

Makeﬁle for Embedded Programming Timing a second using an AVR microcontroller ATtiny44A Fuses Echo Keyboard Input Using C ATtiny Embedded Programming with the Arduino IDE

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TUTORIAL: WEEK 10: MOLDING AND CASTING

ONE

Introduction to Molding and Casting and the Assignment of the Week

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

MOLDING AND CASTING FAB Foundation Link: http://academy.cba.mit.edu/classes/molding_casting/index.html In this week,you will learn how to manufacture a 3D model using Roland MDX50 to mill a mold of two complementary parts of the 3D model. Then to attach the two parts of the 3D model together and to pour or inject a liquid material like silicon rubber or plastic. The first method is called “Molding” or “Moulding”, which is a process used of manufacturing by shaping liquid or pliable raw material using a rigid frame called a mold or matrix. This itself may have been made using a pattern or model of the final 3D object. The second process is called “Casting” which is a manufacturing process in which a liquid material is usually poured into a mold. The mold should contain a hollow cavity to fit the desired object, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. The following diagram represents the molding and casting process. Refer to the reference of the diagram is here and the full tutorial.

Refer to the following links to understand more about the process: ● ●

https://www.instructables.com/lesson/Introduction-to-Mold-Making-Casting/ http://archive.fabacademy.org/fabacademy2016/fablabbcn2016/students/375/week12/

The Assignment of the Week: ● ●

Individual Assignment: Design a 3D mold around the stock and tooling that you'll be using, mill it, and use it to cast parts. Group Assignment: Review the safety data sheets for each of your molding and casting materials, then make and compare test casts with each of them.

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ONE

Step-by-Step Milling Using Roland MDX-50

Tasnim Hussain| Fab Engineer 03 | 19 | 2019

Setup Preparation: The first step you have to do before milling in Roland MDX-50, make sure that the following tools are ready: 1. An STL file with the 3D object settled for proper mold milling. 2. Molding material, in this case wax. 3. The milling tool which is preferred to be Ball End or Ball Nose End bits. 4. Follow the steps below. Preparing the milling file using SRP Player CAM Software:

Open SRP Player software. The screen on the right should appear for you.

First step is to ensure that the tool you are going to use is available in the tools’ library. Go to Options → My tools. This will open the library of the predeﬁned tools. In case the tool you are using is not available, you need to add it ﬁrst.

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To add a new tool go to Options → Add/Remove Tool.

A window with Tool Specifications will open up. Give the tool a name, select the tool type and fill the remaining specifications.

Once the tool is registered, it will appear in the tools’ list as shown above.

Now it is time to open your STL ﬁle. Go to File → Open then choose your STL ﬁle.

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The software will start loading the STL ﬁle.

The ﬁgure above shows the uploaded STL ﬁle.

Now you need to edit step-by-step speciﬁcations regarding the milling process in terms of the object size, material type and size, milling quality and resolution and the tool type and slot in Roland MDX-50 tools’ rack.

First adjust the size of the 3D model to ﬁt into the wax brick.

Then edit the milling type. This need to be done wisely as it will affect the milling time.

Next step is to edit and create the tool path of the milling. First add the size of the wax brick, then click Edit. This will open a window where you will have two proﬁles; one for rough milling and the other for ﬁnishing.

Refer to the link for tips to use SRP Player. Refer to the following links for some basic things to consider in your 3D model: ● Injection Molding Undercuts.

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Select to

to see the different options under roughing. Change the bit from by changing the tool from 2mm Square to Milling -the added new tool-.

Then click Apply and a pop up box will appear telling you that the change of the bit will cause some changes in the milling process. Click Ok.

Select It is advised to edit the scan lines direction to be in the Y direction since roughing is in the X direction starting from the lower right corner.

Now you need to edit the ﬁnishing tool. Click on to see the options for ﬁnishing and edit the tool as shown.

Go back and click on Create ToolPath. The software will generate the paths for both the roughing and the ﬁnishing based on some calculations dependant on the tool type, diameter, etc. Refer to the ﬁgure above.

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Now the software will tell you how much your model will need. Here it was 4.2 hours. The milling can be reviewed by simply selecting Preview Cutting which will take few seconds and then shows the millied piece shown at the right side.

Preparing the milling material in the machine:

Prepare the wax brick by attaching it into the machine milling bed using double phase tissue tape and use the Z-probe along with detection pin for Z0 sense measurement as done before.

Prepare the milling bits. ⅛” Ball End for rough milling and 1/16” Ball End for smooth ﬁnishing. Place the tools in slot 1 and 2 respectively in the machine.

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Adjust the origin point by moving the X and Y axis to the middle of the molding wax where the mold is centered. This origin will be the same as the origin of the molding object. *Note that, this is done using the detection pin not the tool. After the X-Y origin is determined, return the detection pin to slot 6 in the machine.

Now you reach the last stage before cutting and sending the ďŹ le to the machine. You need to ensure that the two milling bits are added to the magazine and specify the slots where they will be actually place in the tool holder. Finally click Start Cutting.

The software will double check few things related to tools, origin of the workpiece and Z0 level then will allow you to start the cutting process.

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Now the machine will automatically pick tool 1 for milling process. Npte that the spindle speed will automatically decrease to 15000 rpm. After milling is finished, the machine will return the rough milling bit and pick up the finishing bit and then will start with finishing where it will pick tool 2 and perform fine milling in the Y direction.

When the process is ﬁnished, the software will show “Cutting is ﬁnished” and Roland LEDs will turn blue. REMARK!! Roughing

Before

Finishing

After

Before

After

Since the model size was slightly smaller than the wax brick, it is very important to remove the margins that will be generated to make the border of the mold from the wax. This is done by editing the tool path for both rough milling and ﬁnishing as shown above.

Refer to the following links for SRP Player: ● ● ● Preview Before

Milling with SRP Player SRP PLAYER CUTTING TIPS and TRICKS SRP Player Technical Manual

Preview After

Note that the milling and ﬁnishing time will be much reduced as the boarded will be skipped by the machine.

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Molding and Casting Materials: ●

Molding Materials (Silicon Rubber): ○ Mold Max 10 ○ Mold Max 30 ○ Smooth Sil 940

●

Casting Material (Plastic): ○ Smooth Cast 300

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TUTORIAL: WEEK 11: INPUT DEVICES

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

INPUT DEVICES FAB Foundation Link: http://academy.cba.mit.edu/classes/input_devices/index.html Input Devices: An input device is a device/equipment/sensor used to provide data and control signals to the micro-controller i.e. main processing unit and can able to read the information sent by the these input devices. Examples of input devices can be as simple as a switch and keypads and as complex as cameras and sensors which can sense temperature, humidity, acceleration proximity, motion and other real/ analog parameters.

Sensor (Input)

MCU (Brain)

Actuator (Output)

The following icons represent some basic input devices:

Push Button

Temperature Sensor

Humidity Sensor

Light Sensor

Motion Sensor

Force Sensor

Microphone

Ultrasonic Sensor

Output Signal from Input Devices: The nature of the output signal from the input devices could be either analog or digital. Analog signals are continuous in both values and time. In short, to understand the analog signals – all signals that are natural or comes naturally are analog signals. However, digital signals are not continuous but signals are discrete in value and time. These signals are represented by binary numbers and consist of different voltage values. The following ﬁgure shows how the two form of signals are represented graphically with real time.

An example of an input device with analog output is the temperature sensor. The input of the temperature sensor is an analog physical value of the temperature and the output is usually an electrical analog voltage value. On the other hand, the humidity sensor is an example for an input device with digital output. As the input is analog physical value of the humidity level and the output is just pulse digital signals. Refer to this link for more details about input devices interfacing.

The Assignment of the Week: ●

Individual Assignment: measure something: add a sensor to a microcontroller board that you have designed and read it.

●

Group Assignment: probe an input device's analog levels and digital signals.

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TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

In this assignment you will need to design a board that consists of microcontroller (MCU) and at least one input device. To do so you need to define the following: Q1: What microprocessor IC you want to use? Q2: What device(s) you want to use? Q3: How to interface the device with the MCU? Answers: A1: To answer the first question, you can use any but recommended to use a microprocessor from AVR class such as ATtiny family or ATmega family. As used previously ATinny 44 and ATtiny 45 were used in electronics design and production PCBs. Examples of ATmega could be ATmega16U2 and ATmega32U2 (Refer to datasheet and summary) which are used inside Arduino Boards. A2: You need to define the type of sensor you want to use and investigate its datasheet to know more about its specifications and design requirements. A3: this will be determined after reading the datasheet of the component. If the component is producing an analog output, then you will need to interface it with analog port in the MCU board and if it produces a digital signal it needs to be interfaced with a digital port. (Read more here). You can use the sample boards in FAB Academy website using ATtinny ICs. Also, you can develop your own fabbable Arduino board to do any specific function you are interested at (check the link). The best feature about using fabbable arduino is that you can benchmark the device functionality by building the same circuit but using the real Arduino board. Please note that you can replicate FAB Academy boards but you will need to edit the design significantly so that it is not considered a plagiarism case. Available List of Sensors in QBIC FAB LAB: SENSORS

NAME

QUANTITY

TECHNICAL DATA

HUMIDITY SENSOR

DHT11

Link

DALLAS 18B20

Link

NTC Thermistor 10k

Link

RTD

Link

PHOTOCELL CDS 400 OHM

Link

Single and Dual Tx Modules

Link

IR Tx Modules

Link

SMD Infrared (IR) Emitter 850nm

Link

SMD Phototransistor 940nm

Link

IR Rx

Link

IR Rx Modules

Link

IR Obstacle Avoidance Sensor

Link

TCRT1000 Reﬂective Optical Sensor

Link

2Y0A02 Sharp Distance Sensor

Link

MQ 135 Air Quality Detector Sensor Module

Link

MQ3 - Alcohol Sensor Module

Link

MQ-7 and MQ-9 Carbon Monoxide Combustible Gas Sensor

Link

SFM-27-W Peizo Buzzer

Link

Buzzer Transducer

Link

TEMPERATURE SENSOR

LIGHT SENSOR

IR TRANSMITTER

IR RECEIVER

OPTOCOUPLERS

GAS DETECTOR SENSOR

BUZZER

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TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

SENSORS

NAME

QUANTITY

TECHNICAL DATA

ZMPT101B Voltage Transformer Module Active Single Phase Voltage Sensor Module (ACV)

Link

JT0783 Max 25V Voltage (DCV) Detector Range 3 Terminal Sensor Module for Arduino

Link

ACS712ELC-30A Current Sensor Module

Link

MPU-92/65

Link

ADXL343

Link

CAMERA MODULES

OV7670 Camera Module

Link

GPS MODULE

GY-GPS6MU2 GPS Module

Link

FINGERPRINT READER

Optical Fingerprint Reader Sensor Module for Arduino Mega2560 UNO R3 51 AVR STM32 Red Light DC 3.8-7V

Link

MOTION SENSOR

PIR Motion Sensor

Link

ULTRASONIC SENSOR

HC-SR04 Ultrasonic Sensor Module

Link

HEART RATE MONITOR

Pulse Sensor Arduino Pulse Heart Rate Sensor

Link

PEIZOELECTRIC SENSOR

TV4

Link

SOIL PROPERTIES

Soil Moisture Sensor

Link

WEIGHT

1Kg Digital Weight Sensor

Link

HALL EFFECT

Hall Effect Sensor

Link

Mic Cond Analog

Link

MICS

Arduino KY-037 Sensitive Microphone Sensor Module

Link

RGB

RGB SMD

Link

VOLTAGE SENSOR

CURRENT SENSOR ACCELEROMETER

FAB Academy Alumni references: Ultrasonic Sensor: http://fab.academany.org/2018/labs/fablabamsterdam/students/henk-buursen/week11.html LDR: http://archive.fabacademy.org/2018/labs/fablabirbid/students/shefa-jaber/Input.html Multi Devices: http://archive.fabacademy.org/2018/labs/fablabirbid/students/israa-rabbaa/input.html http://archive.fabacademy.org/2018/labs/fablabirbid/students/nadine-tuhaimer/input_devices.html http://archive.fabacademy.org/2018/labs/fablabirbid/students/moath-momani/input-devices.html

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TUTORIAL: WEEK 12: OUTPUT DEVICES

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

OUTPUT DEVICES FAB Foundation Link: http://academy.cba.mit.edu/classes/output_devices/index.html Output Devices: An output device is an electronic element that when being interfaced with micro-controllers, they allow them to control the real world by making things move for example, the motors or arms of robots, etc. Also output devices can also be used to switch things ON or OFF, such as indicators or lights (e.g. LED). Sometime output devices are referred to as actuators. The following ﬁgures represent some examples of output devices.

LED

Piezo Buzzer

Speaker

Stepper Motor

LCD Screen

Output Signal from Input Devices: Unlike the input devices, the output devices can only receive digital input signals (e.g. PWM) from the microcontroller to give a physical output. This is due to the fact that, the microcontroller cannot generate an analog signal. For instance, the LCD screen and the stepper motor are examples of output devices that converts the an electric digital signal into a physical display and rotational movement respectively. Refer to this link for more details about interfacing output devices.

The Assignment of the Week: ● ●

Individual Assignment: add an output device to a microcontroller board you've designed,and program it to do something. Group Assignment:measure the power consumption of an output device.

How to tackle the assignment? To integrate the output device, you need to study the device from its datasheet and you need to measure the power consumed by the output device. This could be done using Digital control DC power supply. This will give you an idea about the minimum requirement of the device which will help in the design of the PCB. i.e. The measured power will give you an idea about the needed supply voltage and current which will help in deciding if a regulator, boost or buck converters are needed.

FAB Academy Alumni references: Multi Devices: http://archive.fabacademy.org/2018/labs/fablabirbid/students/nadine-tuhaimer/output_devices.html http://archive.fabacademy.org/2018/labs/fablabirbid/students/israa-rabbaa/OUTPUT.html http://archive.fabacademy.org/2018/labs/fablabirbid/students/shefa-jaber/output.html

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TUTORIAL: WEEK 13: APPLICATIONS AND IMPLICATIONS

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

APPLICATIONS AND IMPLICATIONS FAB Foundation Link: http://academy.cba.mit.edu/classes/applications_implications/index.html

The Assignment of the Week: Propose a ﬁnal project masterpiece that integrates the range of units covered, answering: ● ● ● ● ● ● ● ● ● ●

What will it do? Who's done what beforehand? What will you design? What materials and components will be used? Where will come from? How much will they cost? What parts and systems will be made? What processes will be used? What questions need to be answered? How will it be evaluated?

Your project should incorporate: ● ● ● ● ●

2D and 3D design Additive and subtractive fabrication processes Electronics design and production Microcontroller interfacing and programming System integration and packaging

Where possible, you should make rather than buy the parts of your project. Projects can be separate or joint, but need to show individual mastery of the skills, and be independently operable.

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TUTORIAL: WEEK 14: MECHANICAL DESIGN

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

MECHANICAL DESIGN FAB Foundation Link: http://academy.cba.mit.edu/classes/mechanical_design/index.html

This week you will apply the different technical skills acquired from previous weeks to design and implement a machine which will be done as a group project. Refer to this link to provide a simple guide for a 3-Axis CNC machine. Note that, the machine to be developed can be any machine, not necessary to be a CNC machine.

The -

Assignment Design a Build the Document the

of machine that mechanical parts group project

the Week: includes mechanism+actuation+automation. and operate it manually. and your individual contribution.

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WEEK 15: NETWORKING AND COMMUNICATIONS TUTORIAL:

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

NETWORKING AND COMMUNICATIONS FAB Foundation Link: http://academy.cba.mit.edu/classes/networking_communications/index.html

The Assignment of the Week: ● ●

Individual assignment: Design, build, and connect wired or wireless node(s) with network or bus addresses. Group assignment: Send a message between two projects.

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WEEK 16: INTERFACE AND APPLICATION PROGRAMMING TUTORIAL:

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

INTERFACE AND APPLICATION PROGRAMMING FAB Foundation Link: http://academy.cba.mit.edu/classes/interface_application_programming/index.html

The Assignment of the Week: ● ●

Individual assignment: write an application that interfaces with an input &/or output device that you made. Group assignment: compare as many tool options as possible.

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TUTORIAL: WEEK 17: MACHINE DESIGN

TUTORIAL:

Tasnim Hussain | FAB Engineer 01| 01| 2019

MACHINE DESIGN FAB Foundation Link: http://academy.cba.mit.edu/classes/machine_design/index.html

In this week, the group should automate the machine developed in “Mechanical Design” week. The Assignment of the Week: ● ●

Actuate and automate your machine. Document the group project and your individual contribution.

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