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Client: Sarah Brownell
Sponsor: Cortera, Duet 3D, Dolomite Group, & 3D-Fuel
Team:
| Member | Major | Role | Contact |
|---|---|---|---|
| Anthony Ambrose | EE | Communicator | axa6841@rit.edu |
| Meghan Britt | ISE | Project Manager | mab3485@rit.edu |
| Derek Gagnon | MECE | Systems Engineer | |
| Nicola Gnecco | MECE | Purchaser | ngg6057@rit.edu |
| Tyler Swidler | MECE | Facilitator | tas7134@rit.edu |
Project Overview: In recent years, multiple MSD teams have needed to prototype concrete objects that required an expensive, time consuming, and inaccurate molding processes. Concrete was used in their projects due its low cost and high durability. The rapid prototyping capabilities and reduced waste of additive manufacturing methods would remedy these problems, therefore a medium-scale 3D was requested. Our team started off where the previous team (P20652) left off. This gave our team the opportunity to complete the design and build of the printer as well as improve upon many aspects of the previous design.
Solution:
Our team redesigned the mortar extruder, mounted it to an updated motion system, and controlled it by a Wi-Fi control board. The print area of 36” x 36” x 18” allows for a variety of objects to be printed. An extruded aluminum 8020 frame supports the Cartesian motion system. The axes consists of ball-screws driven by stepper motors that move the gantries along precision ground guide rods. Mounted to the motion system is a novel mortar extruder featuring a vertical auger inside a PVC shell powered by a windshield wiper motor. A Duet Wifi control board simultaneously moves the axes while controlling the flow rate of mortar. Sakrete Type-S mortar was selected for its fine powder consistency, low cost, strength, and working time. In addition to these features a steel hopper capbale of being lifted was investigated and produced so that it would utilize gravity to feed the mortar mixture to the extruder allowing for a consistent flow of material to the extruder. The final product featured precise movement in three axes, a solid structure, removable print beds, a mortar extruder, and more.
