Advanced Materials Processes - 3D Printer Design by Tim Harris

Timothy Harris Adv. Materials of Design

DSID 143

Retail 3D Printer

Timothy Harris DSID 143

Problem Statement

Using a wide variety of manufacturing methods, design a low and high volume 3d printer.

Timothy Harris DSID 143

Dirk Slightly Recently escalated into the social-elite class, Dirk, 31 years old and an entrepreur, struck it rich with a gold mine deal on Shark Tank and a phenominally successful launch. Suddenly rich, Dirk is now able to enjoy his Tag Heuer watch while maintaining his casual but sporty style. Contrasting Floral print oxford under a Slim Sport jacket. Sophisticated and fresh. Raw Denim APC jeans, durable, long lasting. Rayban Aviators complete a fresh take on his timeless style.

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Living in a penthouse studio now that he is able to afford one, Dirk has a bold style preference. Bang and Olaufson speakers for quality and design, and strong geometric forms are abundant in his furniture. Much like his shirt, his wallpaper provides contrast to reduce the sterility of his decoration style. His electric Mercedez is parked under his apartment in an automatic retrieval garage.

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3D Printer Technologies

Selective Laser Sintering (SLS)

Stereolithography (SLA)

An additive manufacturing technique that uses a laser as the power source to coalesce powdered material, aiming the laser automatically at points in space defined by a 3D model, binding the material together to create a solid structure. Powder is added as each layer is built.

A form of additive manufacturing technology used for creating models, prototypes, patterns, and production parts in a layer by layer fashion using photopolymerization, a process by which light causes chains of molecules to link together, forming polymers. The model is built in layers as a laser scans across a surface to induce polymerization.

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3D Printer Technologies

Digital Light Processing(DLP)

Fused deposition modeling (FDM)

Similar to SLA, however the light source is projected across the surface instead of scanned. Instead of a laser, typically an arc lamp is used as a light source. The model is built by a continuous polymerization, drawing the piece out of the liquid.

An additive manufacturing technique where plastic is heated and extruded from nozzles onto a work surface. The model is built up layer by later. Thermoplastics are used and polymerization is unnecessary as the material bonds in a semi-melted state.

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Commercial Printers Top Model Overview

Cube Pro

Formlabs 2

DIY to Pro level FDM 3D printer. Visual form is approachable, no visible screws. Door is entire front face.

Pro-sumer level SLA 3D printer. Visual form is approachable and relies on visibilty of the products â&#x20AC;&#x153;revealâ&#x20AC;? or its ability to watch the machine work. Orange box with blue contrasting information display. Monolitic while petit.

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Commercial Printers

Makerbot Replicator 2

Stratasys Objet30

DIY target 3d printer. Industrial, garage-tool visual form. Looks like a product you can take apart and configure. Visible hardware encourages tinkering.

Pro-end 3D printer. Design language reads much like a medical or product. â&#x20AC;&#x153;Push Playâ&#x20AC;? style stystem where visibility of production is unimportant requiring the user to look downwards into the machine.

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Commercial Printers Aesthetic Variety

Timothy Harris DSID 143

Commercial Printers

Timothy Harris DSID 143

Commercial Printers Aesthetic Variety

Timothy Harris DSID 143

Commercial Printers

Timothy Harris DSID 143

DFMA Design for Manufacturing and Assembly

Minimize Part Count The final cost of a product is directly proportional to the number of parts. As the number of parts is reduced, product quality and reliability typically increase. This comes about because fewer parts are present to break or work loose and reduces the chances of misalignment.

Standardize Components Use of standard parts and material reduces the cost, delay, and risk of processing problems. The primary advantage of standard parts and materials is that these are known quantities. As such they should minimize the potential for problems.

Reduce The Number of Screws and Screw Types Decreasing the number of fasteners reduces assembly weight, cost, and complexity. The alternative to fasteners is to incorporate self-aligning features into parts design. If fasteners are necessary then use a common size and/or self-tapping screws.

Facilitate Parts Handling Use of standard parts and material reduces the cost, delay, and risk of processing problems. The primary advantage of standard parts and materials is that these are known quantities. As such they should minimize the potential for problems.

Encourage Modular Assembly Modular designs simplify assembly operations and make problem identification easier by reducing the number of parts. Modular assembly also simplifies inventory and improves maintenance and serviceability. By designing parts as separate, self-contained modules, disassembly time is reduced, fewer tools are required, and overall repair time is reduced. Timothy Harris DSID 143

DFMA Use Stack Assemblies Assembly operations should use, not fight, gravity. One way to do this is to design parts for stack assembly (i.e., assembly components from the bottom up). This makes automatic assembly possible. Stack assemblies require less reorientation of the components which speeds the assembly process. Not using gravity generally requires the use of additional tooling and fixturing.

Design Parts With Self-Locating Features Self aligning parts can be placed into an exact location with no adjustment required. This makes assembly easier and faster for the assembly workers. Examples of self-locating features include projections, indentations, chamfers, molded keyways, etc.

Minimize Number of Surfaces Minimizing the number of surfaces can reduce the manufacturing and assembly requirements of a system or subsystem. This is realized by minimizing the number of times that an item must be picked up and repositioned.

Assemble in the Open Assemblies should be designed so that assembly operations are accessible and in the open. Blind assembly can increase assembly time, cost, complexity and most importantly safety.

Simplify and Optimize the Manufacturing Process Simplification and optimization of the manufacturing process reduces recurring direct and overhead costs. In designing the production process the focus should be on: smoothing material flow; minimizing the number of material moves; using processes that are easily controllable; avoiding, where possible, processes that are difficult to control (i.e., welding, brazing, etc.); performing like operations simultaneously; and separating manual and mechanized operations. Timothy Harris DSID 143

3D Printer Hype

Timothy Harris DSID 143

3D Printer Market Researchers estimate that the 3D printing market will reach $7.3 billion in 2016. The primary market â&#x20AC;&#x201C; including 3D printing systems, materials, supplies and service â&#x20AC;&#x201C; has grown at least 30% each year from 2012 to 2014. The rest of the growth comes from the secondary market, including tooling, molding and castings. Western countries (North America and Europe) account for more than two-thirds (68%) of the 3D printing market revenue and Asia Paci c accounts for 27%.

The consumer electronics and automotive industries each contribute 20% of the total 3D printing revenue. These early-adopter industries use the technology primarily during the prototyping stage of production. For example, smartphone manufacturers are slowly using 3D printing for more than just prototypingâ&#x20AC;&#x201D;some component parts are now manufactured with 3D methods. The medical device industry (15%) is the third largest 3D printing market and uses 3D printing for mass customized nished goods such as hearing aids.

Fun Fact: 98% of hearing aids worldwide are manufactured using 3D printing.

Timothy Harris DSID 143

3D Printer Future New combinations of 3D printing materials, as well as improvements to existing materials, will not only enable unprecedented 3D printing applications, but also will help reduce prices. There will be an emphasis in metals that is likely to grow over the next three years. Respondents to a 2015 Stratasys survey report that metal 3D printing is expected to grow faster than plastic. Eighty-four percent of respondents reported they would like to see further development with metal in the future compared to 60% with plastic.

Source: UPS, 3D Printing: The Next Revolution in Industrial Manufacturing, PDF

Timothy Harris DSID 143

3D Printer Future While Star Trek’s replicator was little more than a modification of their teleportation system, the idea with current technology is not entirely far fetched. Realistic-Sci-Fi author Kim Stanley Robinson postulated in his book Aurora that there will be “printers printing printers” and that the future printers will simply need a feedstock of atoms as opposed to synthetic polymers. Currently some printers are alble to replicate themselves, such as the makerbot (to an extent.) A more appropriate hypothesis may be that printers will begin a revolution of individualized design. End users can create their own custom anything in their home based on preconfigured specificiations of tolerance such as cutsom shoes, custom tools, or custom prosthetics. At the very least, the idea of 3D printing and piracy should get people excited In an ironic twist on the much-parodied MPAA you wouldn’t steal a purse campaign, you can indeed download a car. Source: Star Trek: The Next Generation

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Ideation

Timothy Harris DSID 143

Ideation

Timothy Harris DSID 143

Concept 1 Extrusion / Resin System

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Concept 1

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Concept 2 Resin System

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Concept 2

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Concept 3 Delta Extrusion System

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Concept 3

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Delta Printer

Faster than Cartesians (on average) due to design differences. You can get a Cartesian to go fast but it takes a little more modification and know how. Cheaper than Cartesians (on average) requiring mostly 3 sets of identical parts, a few 1 or 2 offs, and overall fewer total structural parts. Can build taller Projects much more easily. Identical Electronic requirements to Cartesian Printers. Require more computational processing than Cartesians because they have to convert Cartesian coordinates into moves trigonometrically. Delta printers have a different build envelope (the area that the printer can perform inside). Cartesian printers have a cubic space, while delta is more of an oblate triangle. Deltas have a non uniform resolution map. The movement per motor steps is not the same in the middle of the build plate as it is near the towers. Cartesians are uniform in all 3 axis. Deltas have a much more limited print head, and therefore are potentially less capable. Because of tight space constrictions, delta printers are typically limited to one extrusion head.

Orionâ&#x201E;˘ Delta Desktop 3D Printer

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Delta Printer Internals

The Kossel Delta printer internals from grabcad were chosen to build the hardware around. https://grabcad.com/library/be-kossel-delta-robot-3dprinter-1

Timothy Harris DSID 143

Low Volume

Timothy Harris DSID 143

Low Volume

Fiber Composite Forming Acrylic Bending Adhesive Bonding Casting + Milling

Rivets Glued Thru Hole

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Low Volume Manufacturing Processes

Part

Lower Mold Tool

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Low Volume Manufacturing Processes Composite Forming Carbon fiber forming is practically identical to fiberglass forming. A sheet of porous material (carbon fiber in this case) is fitted into a mold, saturated with an epoxy, and vacuum formed to remove all air and ensure an exact-fit to the supporting mold. It is a time consuming and laborious process but yeilds exceedingly strong and lightweight parts.

Timothy Harris DSID 143

Low Volume Manufacturing Processes Adhesive Bonding aka Glueing A variety of adhesives exist to attach composites to metal. In this case, a flexible but permanent adhesive would be used to attach to the base to allow for some movement and shock-treatment to be expected in a home product.

Casting and Milling The base can be made with either die casting or sand casting with additional milling. Due to the simplicity of mill work, sand casting should be sufficient without investment in a die for higher-quality die casting. Milling is the machining process of using rotary cutters to remove material from a workpiece by advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a wide variety of different operations and machines, on scales from small individual parts to large, heavy-duty milling operations. It is one of the most commonly used processes in industry and machine shops today for machining parts to precise sizes and shapes. Minimal milling would be required (two cuts) to remove the material needed to fit the composite.

Cold Rivets The composite sides will be supported internally from the structure of the 3d printing mechanism, but additional support beyond simple adhesion might be a good idea. Inspired by old fashioned riveted car bodies, the rivets here are glued into place to prevent displacement of the composite and ensure the adhesive will remain undisturbed from lateral shearing forces.

Timothy Harris DSID 143

Low Volume Manufacturing Processes Strip Heating Acrylic Bending Line bending is a method of forming a sharp bend in the acrylic sheet. The radius of the bend can be controlled by adjusting the width of the heated area. Routing a V-groove into the acrylic prior to bending will produce a very sharp bend. Heating elements such as nicrome wire, infrared, rods, or wide strips can be used. Heat the area to be bent to a pliable state then place the sheet in a fixture to cool.

Adjust heating time, element temperature, and distance from the heating element, dependent on acrylic thickness, to eliminate scorching and bubbling, or stress and crazing. Bend the acrylic sheet away from the heat source. Accelerate the cycle time by placing heating elements above and below the acrylic sheet. Visible bowing of the acrylic sheet may occur on bends that are longer than 24â&#x20AC;?. To reduce the amount of warpage, minimize the width of the heated area, heat the entire bend evenly, perpendicular to the sheetâ&#x20AC;&#x2122;s manufacturing direction, and clamp the sheet in place while being heated and cooled.

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High Volume Printer

Timothy Harris DSID 143

High Volume Printer

Thermoforming Blow Molding Injection molding

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High Volume Manufacturing Processes Injection Molding

The injection molding process uses a granular plastic that is gravity fed from a hopper. A screw-type plunger forces the material into a heated chamber, called a barrel, where it is melted. The plunger continues to advance, pushing the polymer through a nozzle at the end of the barrel that is pressed against the mold. The plastic enters the mold cavity through a gate and runner system. After the cavity is filled, a holding pressure is maintained to compensate for material shrinkage as it cools. At this same time, the screw turns so that the next shot is moved into a ready position, and the barrel retracts as the next shot is heated. Because the mold is kept cold, the plastic solidifies soon after the mold is filled. Once the part inside the mold cools completely, the mold opens, and the part is ejected. The next injection molding cycle starts the moment the mold closes and the polymer is injected into the mold cavity. Timothy Harris DSID 143

High Volume Manufacturing Processes Injection Molding

Wall Thickness Cost savings are highest when components have a minimum wall thickness, as long as that thickness is consistent with the partâ&#x20AC;&#x2122;s function and meets all mold filling considerations. As would be expected, parts cool faster with thin wall thicknesses, which means that cycle times are shorter, resulting in more parts per hour. Further, thin parts weigh less, using less plastic per part. On average, the wall thickness of an injection molded part ranges from 2mm to 4mm (.080 inch to .160 inch). Thin wall injection molding can produce walls as thin as .05mm (.020 inch).

Warpage The dynamic of thin and thick sections and their cooling times creates warping as well. As would be expected, as a thick section cools it shrinks, and the material for the shrinkage comes from the unsolidified areas causing the part to warp. Other causes for warping might include the molding process conditions, injection pressures, cooling rates, packing problems, and mold temperatures. Resin manufacturersâ&#x20AC;&#x2122; process guidelines should be followed for best results.

Consider careful boss placement to increase strength and reduce visible warping Timothy Harris DSID 143

High Volume Manufacturing Processes Injection Molding

Simplified Tool

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High Volume Manufacturing Processes Injection Molding

Ribs Ribs are used in a design to increase the bending stiffness of a part without adding thickness. Ribs increase the moment of inertia, which increases the bending stiffness. Bending Stiffness = E (youngâ&#x20AC;&#x2122;s Modulus) x I (Moment of Inertia) Rib thickness should be less than wall thickness to minimize sinking effects. The recommended rib thickness should not exceed 60 percent of the nominal thickness. Plus, the rib should be attached with corner radii as generous as possible.

Draft Mold drafts facilitate part removal from the mold. The draft must be in an offset angle that is parallel to the mold opening and closing. The ideal draft angle for a given part depends on the depth of the part in the mold and its required end-use function. Allowing for as much draft as possible will permit parts to release from the mold easily. Typically, one to two degrees of drafts with an additional 1.5 degrees per 0.25mm depth of texture is enough to do the trick. The mold part line will need to be located in a way that splits the draft in order to minimize it. If no draft is acceptable due to design considerations, a side action mold may be required.

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High Volume Manufacturing Processes Blow Molding

Timothy Harris DSID 143

High Volume Manufacturing Processes Blow Molding

Blow Molding The blow molding process begins with melting down the plastic and forming it into a parison or in the case of injection and injection stretch blow moulding a preform. The parison is a tube-like piece of plastic with a hole in one end through which compressed air can pass. The parison is then clamped into a mold and air is blown into it. The air pressure then pushes the plastic out to match the mold. Once the plastic has cooled and hardened the mold opens up and the part is ejected.

A blow molded birdhouse

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High Volume Manufacturing Processes Plastic Forming

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High Volume Manufacturing Processes Thermoforming

Thermoforming Thermoforming is a manufacturing process where a plastic sheet is heated to a pliable forming temperature, formed to a specific shape in a mold, and trimmed to create a usable product. The sheet, or â&#x20AC;&#x153;filmâ&#x20AC;? when referring to thinner gauges and certain material types, is heated in an oven to a high-enough temperature that permits it to be stretched into or onto a mold and cooled to a finished shape. Its simplified version is vacuum forming.

Timothy Harris DSID 143

High Volume Manufactuing Process Thermoformed Lid covers filament reel

Secondary OPs on blow molded body cut out bottom, face for door and screen, and hole for filament reel.

Adhesive Bonding adheres sides to base

Injection molded base also serves as door-stop

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Manufacturer Selection Low Volume

Composite Forming

Casting

Milling

Local

Glasforms - San Jose, CA ISO 9001 certified fiberglass fabricators.

Valley Pattern - Stocton, CA Metal Casting of non-ferrous metals.

Granett Engineering - Berkeley, CA One-man operation specializing in small jobs. Slow Turn around but cheap.

Grace Composites - Lonoke, AR Custom fiberglass fabrication services. Capabilities include hydro or proof testing, machining, designing.

Plymouth Foundry, Inc. - Plymouth, IN ISO 9001:2008 certified custom manufacturer of castings. Available up to 28â&#x20AC;? * 28â&#x20AC;? sizes

Fox Valley Machining - North Aurora, IL CNC machine shop specializing in milling and turning, as well as cylindrical and bore grinding. Works with various materials

World

Formtech Composites - UK Specialise in the design, engineering & manufacture of lightweight composites structures & components.

A-CAST ALLOY - India Variety of metals, Smaller parts.

ProMechanica - Belgium European Standard, Extremely high quality. High Volume.

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Manufacturer Selection High Volume

Injection Molding

Blow Molding

Thermoforming

Local

The Manufactory - Santa Maria, CA Plastic injection molding services. Additional capabilities include prototyping and designing services.

Plastikon Industries, Inc.

Rapid Accu-Form, Inc. - Benicia, CA

Blow molding services. Decoration, finishing, assembly, filling, thermoforming, rapid prototyping and engineering.

Specialize in deep drawing. Capabilities include products thermoforming of heavy gauge plastics.

Abtec, Inc. - Bristol, PA Services include molding, overmolding, insert molding, in-house tooling, computer-aided design and manufacturing, product development.

Custom Pak - Clinton, IA Custom-Pak designs and manufactures blow molded products in six manufacturing plants containing over 200 blow molding machines.

Penz Products, Inc. - Mishawaka, IN Thermoforming for heavy gauge plastics. Capabilities include assembly, designing, fabrication, forming, stamping, welding.

World

LK MOULD - Hong Kong Younger company producing molds from CAD. Does design.

S.T. Soffiaggio Tecnica - Italy Manufactures blow molding machines and parts. Excellent knowledge base due to their machine production.

FRIMO - Germany

tailor-made tooling and system used to produce cockpit and door components, as well as all kinds of interior trims.

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Manufacturer Choice

Low Volume

High Volume

Glasforms - Due to the availability of the other two manufacturers being local, there was not a strong reason to go outside the local region.

Abtec, Inc. - In-House tooling and American made allow for quick turn around and faster service for this bleeding-edge industry.

Valley Pattern - Their wide variety of metals allows me to work with precious and semi-precious if I desire.

Custom Pak - The capability to do sophiscicated blow modling will ensure the body has the correct structural integrity needed for the design.

Granett Engineering - Due to the highprice and very low volume, and simple work that must be done on the casting, a one man job is most appropriate because setup and work is so minimal.

Penz Products, Inc. - In order to avoid cheap, to-go carton apperances, a heavy gauge of thermoforming will be used. Their speciality here ensures a quality product.

Timothy Harris DSID 143

Regulatory Agencies

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The UL An American worldwide safety consulting and certification company headquartered in Northbrook, Illinois. It maintains offices in 46 countries. Established in 1894 as the Underwritersâ&#x20AC;&#x2122; Electrical Bureau (a bureau of the National Board of Fire Underwriters),[1] it was known throughout the 20th century as Underwriters Laboratories and participated in the safety analysis of many of that centuryâ&#x20AC;&#x2122;s new technologies, most notably the public adoption of electricity and the drafting of safety standards for electrical devices and components.

The CE and the CSA are close equivalents for the UL in Europe and Canada respectivley, however they are required for their country. The CSA may also replace the UL in the USA if they have done the inspection.

Importance: UL provides safety-related certification, validation, testing, inspection, auditing, advising and training services to a wide range of clients, including manufacturers, retailers, policymakers, regulators, service companies, and consumers.

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OSHA

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ISO

The ISO ISO, the International Organization for Standardization, is an independent, non-governmental organization, the members of which are the standards organization of the 164 member countries. It is the worldâ&#x20AC;&#x2122;s largest developer of voluntary international standards and facilitates world trade by providing common standards between nations. Nearly twenty thousand standards have been set covering everything from manufactured products and technology to food safety, agriculture and healthcare.

Importance: Use of the standards aids in the creation of products and services that are safe, reliable and of good quality. The standards help businesses increase productivity while minimizing errors and waste. By enabling products from different markets to be directly compared, they facilitate companies in entering new markets and assist in the development of global trade on a fair basis. The standards also serve to safeguard consumers and the end-users of products and services, ensuring that certified products conform to the minimum standards set internationally.

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CPSC

The CPSC The CPSC regulates the sale and manufacture of more than 15,000 different consumer products, from cribs to all-terrain vehicles. The CPSC fulfills its mission by banning dangerous consumer products, establishing safety requirements for other consumer products, issuing recalls of products already on the market, and researching potential hazards associated with consumer products.

Importance: The CPSC makes rules about consumer products when it identifies a consumer product hazard that is not already addressed by an industry voluntary consensus standard, or when Congress directs it to do so. Its rules can specify basic design requirements, or they can amount to product bans. For certain infant products, the CPSC regulates even when voluntary standards exist. The CPSC learns about unsafe products in several ways. The agency maintains a consumer hotline through which consumers may report concerns about unsafe products or injuries associated with products.

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FDA

The FDA The Food and Drug Administration (FDA or USFDA) is a federal agency of the United States Department of Health and Human Services, one of the United States federal executive departments.

Importance: The FDA is responsible for protecting and promoting public health through the regulation and supervision of food safety, tobacco products, dietary supplements, prescription and over-the-counter pharmaceutical drugs (medications), vaccines, biopharmaceuticals, blood transfusions, medical devices, electromagnetic radiation emitting devices, cosmetics, animal foods & feed and veterinary products.

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EPA

The EPA The Environmental Protection Agency (EPA) is an agency of the United States government. It works to protect human health and the environment. The EPA does this job by writing rules and making sure that they are followed.

Importance: The EPA has regulations overseeing use use of products that change the conditions of Air, Water, or land, Produce Hazardolus waste, or imapct wildlife.

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FCC

The FCC The Federal Communications Commission (FCC) is an independent United States government agency that is directly responsible to Congress. The FCC was established by the Communications Act of 1934 and is charged with regulating interstate and international communications by radio, television, wire, satellite and cable. The FCCâ&#x20AC;&#x2122;s jurisdiction covers the 50 states, the District of Columbia, and U.S. possessions.

Importance: FCC creates regulations on any device sold in America that uses any type of electronic mode of communication.

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Design Sustainably Innovation Rethink how to provide the benefit. Design for flexibility or technological change. Provide product as service. Serve needs provided by associated products. Share among multiple users. Create opportunity for local supply chain.

Reduced Material Impacts Avoid materials that damage human or ecological health. Avoid materials that deplete natural resources. Minimize quantity of materials.Use recycled or reclaimed materials.Use renewable resources. Use material from reliable certifiers. Use waste byproducts.

Manufacturing Innovation Minimize manufacturing waste. Design for production quality control. Minimize energy during use in production. Use carbon-neutral or renewable enrgy sources. Minimize number of production steps. Minimize number of components / materials. Seek to eliminate toxic emissions.

Reduced Distribution Impact Reduce product and packaging weight. Reduce product and packaging volume. Develop reusable packaging systems. Use lowest-impact transport systems. Source or use local materials and production.

Timothy Harris DSID 143

Design Sustainably Reduced Behavior Impact Design to encourage low consumption behavior. Reduce energy during use. Reduce material consumption during use. Reduce water consumption during use. Seek to eliminate toxic emissions during use. Design for carbon-neutral or renewable energy.

System Longevity Design for durability. Foster emotional connection to product. Design for maintenance and easy repair. Design for reuse and exchange of products. Create timeless aesthetic appeal.

Transitional Systems Design upgradeable products. Design for second life with different function. Design for reuse of components.

Optimized EOL Design for fast manual or automated disassembly. Design recycling buisness model. Use recyclable non toxic materials. Provide ability to biodegrade. Intergrate methods for used product collection. Design for safe disposal.

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Phone-Printer Interfacing + Branding Connect and send 3D files to your printer wirelessly over Bluetooth or Wifi, and check on the status of your print remotely. Branding doesnâ&#x20AC;&#x2122;t need to be limited to the printers face either. Allowing a similiar GUI displayed on the interface of the phone and printer allows for updates to the GUI as well as brand logo.

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Price Amortization Low Volume

Timothy Harris DSID 143

Price Amortization Low Volume

Low Volume Manufactured Units

800

400

200

20000

2000

200

400

1600

160

Carbon Fiber Material (based on expected output)

30000

3000

300

CNC for Base

10000

1000

100

1700

64110

9070

3121

2412

2117

2114

Casting tool for Base Base Material (Priced based on expected output) Component internals Tool for Sides

Rivets Assembly

Total (per assembled piece)

100 1000 10000 50000

The graph of the high-volume BOM rapidly approaches horizontal and any additional units provide an unimportant price savings, all things considered.

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Price Amortization High Volume

Timothy Harris DSID 143

Price Amortization High Volume

High Volume Manufactured Units

100

Plastic injection tool for base

75000

7500

750

7.5

1.5

0.75

Thermoforming mold tool for top

10000

2000

200

Blowmolding tool for body

30000

3000

300

0.6

0.3

Plastic Forming

200

100

Component internals

400

Assembly

200

115800

13300

1950

775 662.5

613.1

610.3

Total (per assembled piece)

1000 10000 50000 100000

The margin of profitability is maximized at 50,000 individual units. Going any further in manufacturing before determining demand introduces a negligable cost (per unit) but important risk assessment.

Timothy Harris DSID 143

Color, Finish, Materials Low Volume

Body

Doors

Base

Carbon Fiber High strength and low weight. High price. Somewhat Brittle.

Acrylic Moderately priced. Easily bent. Somewhat scratch resistent. Low weight. High clarity.

Aluminum Moderately priced. Easily machined. Low weight. Excellent color variety.

Fiberglass Equivalent strength to carbon fiber, lower price, higher weight. Somewhat Brittle.

Glass Moderately priced, difficult to bend. Very scratch resistent. Very Heavy. Brittle.

Magnesium Expensive, difficult to machine. Very scratch resistent. Light weight. Unusually white metal.

Aramid (Kevlar) Equivalent strength to carbon fiber, price varies, higher weight. More durable than carbon.

Polycarbonate Very Inexpensive. Easily bent or formed. Low scratch resistence and clarity.

Brass Very Expensive. HighAesthetic Color. Very Heavy. Can tarnish.

Carbon Fiber is the best choice since there will be no performance gains from kevlar, and fiberglass will add unnecessary weight.

To keep weight low and performance high, acrylic will be used for its high clarity and workability, as well as its low wight.

Any of the options may be appropriate for the Race-Inspired form. Aluminum may be most appropriate due to its versatility, however.

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Color, Finish, Materials High Volume

Body & Lid

Base

Styrene Moderately priced. Easily formed. Impact resistent and rigid.

ABS Moderately priced. Excellent durability and can be solventglued easily.

Polyethylene Very Inexpensive. Impact resistent. Easily Scratches. Very Flexible.

PVC Inexpensive. Huge color variety. Can be painted, sanded, glued. Rigid.

HDPE Inexpensive. Translucent, can be colored. Very durable. Difficult to glue.

The body and lid will be the same material because they are both contact points. PVC is chosen due to its low cost and extremely high versatility.

The base will be made of ABS to support the weight of all the compoenents and allow for a durable bottom. Both materials were also chosen for their easy of gluing.

Timothy Harris DSID 143

CMF Test Low Volume

The AMG Business Class at its finest. Mercedez is known for its luxury and performance. The AMG black series has a dark finish with red highlights echoed here. The carbon fiber only lends to the image, but the softness of its radii gives it an approachable finesse. Brushed anodized aluminum is used for the base to give full attention to the accents.

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CMF Test Low Volume

The Lamborghini Bright and Flashy, Lamborghini is known for being noisy! The high performance colors are bright and vibrant, but its subtle curves still allow this race-inspired printer to remain business-like and fashionable. The magnesium base is light-weight, sharp, and an excelent pedestal for the garish top.

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CMF Test Low Volume

The Ferrari Supermodel or Super-Car? Ferrari highperformance competition on the road and in Formula 1 has won it outstanding attention and respect as a racing machine. A toy for the rich, the brass base on this only adds to the aflluence of this design.

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Title Test CMF High Volume

Low Contrast With a fresh look and a minty-green interface, this high volume printer will look good next to anyones Mac or even sitting in a kitchen. The green takes away from the stirility, and the contrasting lid and base cap the ends and give a visual cue to its contact points.

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CMF Test High Volume

High Contrast At home or in the office this high contrast look will fit nicely. The Sunday-Best type of 3D printer that you wont mind having anywhere. The high contrast look allows it to stand out - something appropriate for a 3D printer.

Timothy Harris DSID 143

CMF Test High Volume

Tangerine Dream Right in your face! Your kids dream 3D printer - or maybe for the kid still inside you. The bright colors make this relativley new technology playful and approchable. The plastics chosen allow for a large variety of color ways to be chosen to allow for limitless customization if the vendor decides to allow for user-designed creations.

Timothy Harris DSID 143