Access to vacuum systems is limited because of economic costs. A rapidly growing approach to redu... more Access to vacuum systems is limited because of economic costs. A rapidly growing approach to reduce the costs of scientific equipment is to combine open-source hardware methods with digital distributed manufacturing with 3D printers. Although high-end 3D printers can manufacture vacuum components, again, the cost of access to tooling is economically prohibitive. Low-cost material extrusion 3D printing with plastic overcomes the cost issue, but two problems arise when attempting to use plastic in or as part of vacuum systems: the outgassing of polymers and their sealing. To overcome these challenges, this study explores the potential of using post-processing heat treatments to seal 3D printed polypropylene for use in vacuum environments. The effect of infill overlap and heat treatment with a readily available heat gun on 3D printed PP parts was investigated in detail on ISO-standardized KF vacuum fitting parts and with the use of computer vision-based monitoring of vacuum pump down v...
As the additive manufacturing industry grows, it is compounding the global plastic waste problem.... more As the additive manufacturing industry grows, it is compounding the global plastic waste problem. Distributed recycling and additive manufacturing (DRAM) offers an economic solution to this challenge, but it has been relegated to either small-volume 3D printers (limiting waste recycling throughput) or expensive industrial machines (limiting accessibility and lateral scaling). To overcome these challenges, this paper provides proof-of-concept for a novel, open-source hybrid 3D printer that combines a low-cost hanging printer design with a compression-screw-based end-effector that allows for the direct extrusion of recycled plastic waste in large expandable printing volumes. Mechanical testing of the resultant prints from 100% waste plastic, however, showed that combining the challenges of non-uniform feedstocks and a heavy printhead for a hangprinter reduced the strength of the parts compared to fused filament fabrication. The preliminary results are technologically promising, howeve...
This project supports the publication: Open Source Arc Analyzer: Multi-Sensor Monitoring of Wire ... more This project supports the publication: Open Source Arc Analyzer: Multi-Sensor Monitoring of Wire Arc Additive Manufacturing . Adam M. Pringle 1, Shane Oberloier 2, Aliaksei L. Petsiuk 2, Paul G. Sanders 1 and Joshua M. Pearce 1,2,3,* Affiliations: 1. Department of Materials Science & Engineering, Michigan Technological University, Houghton, MI 49931- 1295, USA. 2. Department of Electrical & Computer Engineering, Michigan Technological University, Houghton, MI 49931- 1295, USA 3. Department of Electronics and Nanoengineering, School of Electrical Engineering, Aalto University, Espoo, Finland.
There has been a recent surge in interest in the more accurate snow loss estimates for solar phot... more There has been a recent surge in interest in the more accurate snow loss estimates for solar photovoltaic (PV) systems as large-scale deployments move into northern latitudes. Preliminary results show bifacial modules may clear snow faster than monofacial PV. This study analyzes snow losses on these two types of systems using empirical hourly data including energy, solar irradiation and albedo, and open-source image processing methods from images of the arrays in a northern environment in the winter. Projection transformations based on reference anchor points and snowless ground truth images provide reliable masking and optical distortion correction with fixed surveillance cameras. This allows individual PV module-level snow shedding ratio determination as well as average cumulative snow load by employing grayscale segmentation. The data is used to determine the no-snow losses of two systems during summer and snow losses during winter. The results found monofacial snow losses are in average 33% for winter period, and 16% on an annual basis. Bifacial systems perform better than monofacial in severe winter conditions as average winter snow losses was 16% and the annual losses were 2% in the worst-case scenario. In addition, there was a bifacial gain of 19% compared to monofacial system during winter.
This project supports the paper: RepRapable Automated Open Source Bag Valve Mask-based Ventilator... more This project supports the paper: RepRapable Automated Open Source Bag Valve Mask-based Ventilator Authors: Aliaksei Petsiuk, Nagendra G. Tanikella, Samantha Dertinger, Adam Pringle, Shane Oberloier, Joshua M. Pearce https://www.preprints.org/manuscript/202006.0318/v1
To overcome the challenge of upcycling plastic waste into 3-D printing filament in the distribute... more To overcome the challenge of upcycling plastic waste into 3-D printing filament in the distributed recycling and additive manufacturing systems, this study designs, builds, tests and validates an open source 3-D filament diameter sensor for recycling and winding machines. The modular system for multi-axis optical control of the diameter of the recycled 3-D-printer filament makes it possible to analyze the surface structure of the processed filament, save the history of measurements along the entire length of the spool, as well as mark defective areas. The sensor is developed as an independent module and integrated into a recyclebot. The diameter sensor was tested on different kinds of polymers (ABS, PLA) different sources of plastic (recycled 3-D prints and virgin plastic waste) and different colors including clear plastic. The results of the diameter measurements using the camera were compared with the manual measurements, and the measurements obtained with a one-dimensional digita...
The most abundant e-waste plastic is acrylonitrile butadiene styrene (ABS), which is not typicall... more The most abundant e-waste plastic is acrylonitrile butadiene styrene (ABS), which is not typically processed by municipal programs and is equally one of the most popular 3-D printing filaments. This makes ABS a prime candidate for the distributed recycling for additive manufacturing (DRAM) approach, which has the potential to increase recycling rates by providing economic incentive for consumers to recycle. For DRAM to be globally applicable, this study investigates the role of the ABS e-waste source and processes to fabricate 3-D printing filament and printed components in both Australia and North America. The study used two different open source extruder systems to convert e-waste into 3D printer filament and for material quality to be assessed through standardized tensile and compression testing. Results revealed a modest reduction in mechanical properties compared to virgin ABS, highlighting the potential for recycled e-waste ABS for consumer and industrial uses. We also show DRAM can significantly reduce 3-D printer filament cost, however, carbon emissions from conversion underscored the need for technical efficiency improvements in electricity generating between countries. Finally, the variations in the properties of the ABS e-waste indicates the need for appropriate labeling of materials in order to advance recycling.
Journal of Manufacturing Science and Engineering, 2021
To overcome the challenge of upcycling plastic waste into three-dimensional (3D) printing filamen... more To overcome the challenge of upcycling plastic waste into three-dimensional (3D) printing filament in the distributed recycling and additive manufacturing systems, this study designs, builds, tests, and validates an open-source filament diameter sensor for recycling and winding machines. The modular system for multi-axis optical control of the diameter of the recycled 3D-printer filament makes it possible to scan part of the surface of the processed filament, save the history of measurements along the entire length of the spool, as well as mark defective areas. The sensor is developed as an independent module and integrated into a recyclebot. It was tested on different kinds of polymers (acrylonitrile butadiene styrene (ABS), polylactide (PLA)), different sources of plastic, and different colors including clear plastic. The results were compared with the manual measurements, and the measurements obtained with a one-dimensional digital light caliper. The results found that the develo...
Centrifuges are commonly required devices in medical diagnostics facilities as well as scientific... more Centrifuges are commonly required devices in medical diagnostics facilities as well as scientific laboratories. Although there are commercial and open source centrifuges, costs of the former and required electricity to operate the latter, limit accessibility in resource-constrained settings. There is a need for low-cost, human-powered, verified and reliable lab-scale centrifuge. This study provides the designs for a low-cost 100% 3-D printed centrifuge, which can be fabricated on any low-cost RepRap-class fused filament fabrication (FFF) or fused particle fabrication (FPF)-based 3-D printer. In addition, validation procedures are provided using a web camera and free and open source software. This paper provides the complete open source plans including instructions for fabrication and operation for a hand-powered centrifuge. This study successfully tested and validated the instrument, which can be operated anywhere in the world with no electricity inputs obtaining a radial velocity o...
Access to vacuum systems is limited because of economic costs. A rapidly growing approach to redu... more Access to vacuum systems is limited because of economic costs. A rapidly growing approach to reduce the costs of scientific equipment is to combine open-source hardware methods with digital distributed manufacturing with 3D printers. Although high-end 3D printers can manufacture vacuum components, again, the cost of access to tooling is economically prohibitive. Low-cost material extrusion 3D printing with plastic overcomes the cost issue, but two problems arise when attempting to use plastic in or as part of vacuum systems: the outgassing of polymers and their sealing. To overcome these challenges, this study explores the potential of using post-processing heat treatments to seal 3D printed polypropylene for use in vacuum environments. The effect of infill overlap and heat treatment with a readily available heat gun on 3D printed PP parts was investigated in detail on ISO-standardized KF vacuum fitting parts and with the use of computer vision-based monitoring of vacuum pump down v...
As the additive manufacturing industry grows, it is compounding the global plastic waste problem.... more As the additive manufacturing industry grows, it is compounding the global plastic waste problem. Distributed recycling and additive manufacturing (DRAM) offers an economic solution to this challenge, but it has been relegated to either small-volume 3D printers (limiting waste recycling throughput) or expensive industrial machines (limiting accessibility and lateral scaling). To overcome these challenges, this paper provides proof-of-concept for a novel, open-source hybrid 3D printer that combines a low-cost hanging printer design with a compression-screw-based end-effector that allows for the direct extrusion of recycled plastic waste in large expandable printing volumes. Mechanical testing of the resultant prints from 100% waste plastic, however, showed that combining the challenges of non-uniform feedstocks and a heavy printhead for a hangprinter reduced the strength of the parts compared to fused filament fabrication. The preliminary results are technologically promising, howeve...
This project supports the publication: Open Source Arc Analyzer: Multi-Sensor Monitoring of Wire ... more This project supports the publication: Open Source Arc Analyzer: Multi-Sensor Monitoring of Wire Arc Additive Manufacturing . Adam M. Pringle 1, Shane Oberloier 2, Aliaksei L. Petsiuk 2, Paul G. Sanders 1 and Joshua M. Pearce 1,2,3,* Affiliations: 1. Department of Materials Science & Engineering, Michigan Technological University, Houghton, MI 49931- 1295, USA. 2. Department of Electrical & Computer Engineering, Michigan Technological University, Houghton, MI 49931- 1295, USA 3. Department of Electronics and Nanoengineering, School of Electrical Engineering, Aalto University, Espoo, Finland.
There has been a recent surge in interest in the more accurate snow loss estimates for solar phot... more There has been a recent surge in interest in the more accurate snow loss estimates for solar photovoltaic (PV) systems as large-scale deployments move into northern latitudes. Preliminary results show bifacial modules may clear snow faster than monofacial PV. This study analyzes snow losses on these two types of systems using empirical hourly data including energy, solar irradiation and albedo, and open-source image processing methods from images of the arrays in a northern environment in the winter. Projection transformations based on reference anchor points and snowless ground truth images provide reliable masking and optical distortion correction with fixed surveillance cameras. This allows individual PV module-level snow shedding ratio determination as well as average cumulative snow load by employing grayscale segmentation. The data is used to determine the no-snow losses of two systems during summer and snow losses during winter. The results found monofacial snow losses are in average 33% for winter period, and 16% on an annual basis. Bifacial systems perform better than monofacial in severe winter conditions as average winter snow losses was 16% and the annual losses were 2% in the worst-case scenario. In addition, there was a bifacial gain of 19% compared to monofacial system during winter.
This project supports the paper: RepRapable Automated Open Source Bag Valve Mask-based Ventilator... more This project supports the paper: RepRapable Automated Open Source Bag Valve Mask-based Ventilator Authors: Aliaksei Petsiuk, Nagendra G. Tanikella, Samantha Dertinger, Adam Pringle, Shane Oberloier, Joshua M. Pearce https://www.preprints.org/manuscript/202006.0318/v1
To overcome the challenge of upcycling plastic waste into 3-D printing filament in the distribute... more To overcome the challenge of upcycling plastic waste into 3-D printing filament in the distributed recycling and additive manufacturing systems, this study designs, builds, tests and validates an open source 3-D filament diameter sensor for recycling and winding machines. The modular system for multi-axis optical control of the diameter of the recycled 3-D-printer filament makes it possible to analyze the surface structure of the processed filament, save the history of measurements along the entire length of the spool, as well as mark defective areas. The sensor is developed as an independent module and integrated into a recyclebot. The diameter sensor was tested on different kinds of polymers (ABS, PLA) different sources of plastic (recycled 3-D prints and virgin plastic waste) and different colors including clear plastic. The results of the diameter measurements using the camera were compared with the manual measurements, and the measurements obtained with a one-dimensional digita...
The most abundant e-waste plastic is acrylonitrile butadiene styrene (ABS), which is not typicall... more The most abundant e-waste plastic is acrylonitrile butadiene styrene (ABS), which is not typically processed by municipal programs and is equally one of the most popular 3-D printing filaments. This makes ABS a prime candidate for the distributed recycling for additive manufacturing (DRAM) approach, which has the potential to increase recycling rates by providing economic incentive for consumers to recycle. For DRAM to be globally applicable, this study investigates the role of the ABS e-waste source and processes to fabricate 3-D printing filament and printed components in both Australia and North America. The study used two different open source extruder systems to convert e-waste into 3D printer filament and for material quality to be assessed through standardized tensile and compression testing. Results revealed a modest reduction in mechanical properties compared to virgin ABS, highlighting the potential for recycled e-waste ABS for consumer and industrial uses. We also show DRAM can significantly reduce 3-D printer filament cost, however, carbon emissions from conversion underscored the need for technical efficiency improvements in electricity generating between countries. Finally, the variations in the properties of the ABS e-waste indicates the need for appropriate labeling of materials in order to advance recycling.
Journal of Manufacturing Science and Engineering, 2021
To overcome the challenge of upcycling plastic waste into three-dimensional (3D) printing filamen... more To overcome the challenge of upcycling plastic waste into three-dimensional (3D) printing filament in the distributed recycling and additive manufacturing systems, this study designs, builds, tests, and validates an open-source filament diameter sensor for recycling and winding machines. The modular system for multi-axis optical control of the diameter of the recycled 3D-printer filament makes it possible to scan part of the surface of the processed filament, save the history of measurements along the entire length of the spool, as well as mark defective areas. The sensor is developed as an independent module and integrated into a recyclebot. It was tested on different kinds of polymers (acrylonitrile butadiene styrene (ABS), polylactide (PLA)), different sources of plastic, and different colors including clear plastic. The results were compared with the manual measurements, and the measurements obtained with a one-dimensional digital light caliper. The results found that the develo...
Centrifuges are commonly required devices in medical diagnostics facilities as well as scientific... more Centrifuges are commonly required devices in medical diagnostics facilities as well as scientific laboratories. Although there are commercial and open source centrifuges, costs of the former and required electricity to operate the latter, limit accessibility in resource-constrained settings. There is a need for low-cost, human-powered, verified and reliable lab-scale centrifuge. This study provides the designs for a low-cost 100% 3-D printed centrifuge, which can be fabricated on any low-cost RepRap-class fused filament fabrication (FFF) or fused particle fabrication (FPF)-based 3-D printer. In addition, validation procedures are provided using a web camera and free and open source software. This paper provides the complete open source plans including instructions for fabrication and operation for a hand-powered centrifuge. This study successfully tested and validated the instrument, which can be operated anywhere in the world with no electricity inputs obtaining a radial velocity o...
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