Abstract
The following report outlines the detailed design process followed by the construction of a 3D printer prototype was conducted throughout this project. The purpose of the project was to create a 3D printer with tool changing capabilities, a high degree of resolution, and a print volume of 300x300x300mm. The final product was handed over to Stephen McMillan, at which point it was added to BCIT's fleet of rapid prototyping technologies. The design process followed that of typical iterative engineering design methodology. Initially, the process began with rough hand sketches and conceptual design reviews, followed by solid modelling in SolidWorks, and finally the construction of a physical prototype. Initial difficulties included finding the optimal placement of the critical components throughout the frame such as the electronics and the X, Y, and Z motion control systems. Deciding on the placement and orientation of each of the major components required the use of much foresight into the latter stages of project progression. Throughout the manufacturing process, it was found that many of the design choices required an immense amount of time in the shop due to lack of experience and high tolerances - this further extended the project length due to the vast number of custom parts created. Testing and calibration procedures had to be performed in a systematic manner due to the inherent dependency of systems between one another, requiring an extensive trial and error process to achieve the desired results. A project scope change was required to be made after the final design was agreed upon due to the tool changing components not being made commercially available, and were instead stuck in beta testing phases. The shift from this major scope change required a high degree of adaptability in order to work around the road block while still providing the proof of concept and infrastructure required to meet the initial goal. Throughout the manufacturing process, the design of the model also changed, allowing for a significant decrease in the total time required for construction, making predominantly minor adjustments where needed. Once the manufacturing was complete, tolerance stack-up was considered and remedied through the extensive foresight of adjustable mounting options. The resulting motion control systems were executed as originally planned, with a rising and lowering Z-axis and a planar CoreXY motion system positioned at the top of the printer. Further results included the successful integration of the electronics with the aforementioned motion systems -providing the adequate power, safety, and maintenance requirements. Through the employment of an extensive design process backed up by key resources and expertise, the revised project goals set forth during the project were successfully completed. The total cost of the project was just over $2,300 CAD, a fraction of comparable products available on the market.