麻豆传媒映画

Project Summary

The 3D Filament Recycler project focuses on sustainability, aiming to reduce waste generated by the 3D print farm at our customer location, the L3 Harris Student Design Center (L3HSDC). This device will convert failed PLA prints and scrap into usable spools of filament, reducing plastic waste and lowering the material costs of purchasing PLA for the print farm. This machine begins the recycling process by breaking down scrap filament using its reclaimer subsystem. The material is then collected in a storage basin before moving into the extruder subsystem. During the extrusion process, the processed filament scrap is heated to 180 掳C. The extruded filament is then moved through the cooling subsystem to maintain the desired diameter. Finally, the extruded filament is tensioned and spooled by the tensioning and spooling subsystems. Ultimately, this process allows the collected waste filament to be reprocessed into a new usable spool.

Project Objective

The purpose of this project is to design and manufacture an integrated system for the L3HSDC that can recycle 3D filament waste by shredding, heating, and extruding it.

Manufacturing Design Methods

The system is designed with a modular approach, comprising 6 separate subsystems that each accomplish a specific task in the recycling of PLA filament. The reclaimer is made from two waterjets and milled aluminum plates with bolted flange bearings. The 25 blades/blade guides, made of steel, and 25 spacers/spacer guides, made of aluminum, are cut using the waterjet. The reclaimer assembly is simple due to its tight tolerances, yet it still allows the blades to travel after being driven by the shaft. The blades and shaft are turned by a large motor via a 192:1 gearbox. The high-torque motor assembly is held to the reclaimer side plate by four 10-32-thread steel standoffs and an additional PETG-printed support carriage. The steel hexagonal shaft that holds the blades and spacers was lathed to 15 mm diameter to fit the side flange bearings, with an outer diameter tolerance of 卤0.5 mm. The entire reclaimer is then held together with stainless-steel threaded rods, paired with a large PLA front block that serves as an inlet. The extruder was purchased commercially and sits on a slide-in modular support frame made from waterjet-cut and milled aluminum. The storage box and filter shelf are made of laser-cut acrylic panels and PETG/PLA-printed railings, with a total capacity of 2kg. The cooling fans are commercial PC fans mounted on a PETG/PLA-printed support frame. The tensioner subsystem is made of a PETG/PLA-printed housing for both stepper motors and uses a linear screw attached to a NEMA 17 stepper motor, allowing it to traverse vertically. The tensioner wheels are printed from PETG/PLA and have a rubber grip along the outside to grip passing filament. The spooler is entirely made of PETG/PLA for the frame, shifter, and screw mechanism, with each being driven by two additional stepper motors. The entire system sits inside a 20mm x 20mm aluminum t-slot frame, allowing for modularity and easy switching of subsystems. The brackets that hold the frame together are made from both PETG and waterjet-cut/milled aluminum. The frame is then fully enclosed with laser-cut acrylic panels that allow bolts to pass through to be easily fastened to the frame. Each subsystem is controlled and powered via the electronics board, which sits on its own removable acrylic panel under the cooling fans. This allows air to be sucked from under the frame, away from the electronics and into the hot filament.

Specification

Dimensions: 1040 mm x 260 mm x 740 mm Reclaimer Inlet: 230 mm x 150 mm Blade: 114 mm Spacer: 90 mm Storage Box: 23 mm x 9 mm x 6 mm Electronics: Arduino MEGA,1000W 12V Industrial Power Supply, 12V 192:1 DC Motor, 12V DC Extruder Motor, 3 40W Heating Cartridges, 3 28BYJ Stepper motors with ULN2003 drivers, 3 12V DC cooling fans, 4 N-mosfet 5A modules, 12V-5V buck converter, and 2 NEMA 17 Stepper motors with A988N motor driver.

Analysis

All structural components of this project were analyzed in ANSYS Workbench. Specifically, the static structural tool was used to analyze the machine's structural stability and identify potential deformation locations. The static structural tool was also used to analyze the reclaimer鈥檚 blades to see where deformation and deflection will occur during the filament breakdown process. The fluent and transient heat tools were used within the ANSYS Workbench to determine the rate of heat transfer throughout the extruder system. These tools were also used to analyze heat distribution throughout the extruder system. Altogether, these simulations provided strong evidence that the 3D Filament Recycler would function as intended under ideal conditions.

Future Works

Future work for this project includes expanding its operating capabilities to include processing PET-G. Currently, the L3HSDC print farm uses both PLA and PETG filaments to create student projects, producing waste from both. While the 3D Filament Recycler project focused on PLA and its material properties, the machine has the potential to process PETG because the extruder can extrude both filaments. This machine could easily expand its operating capability by creating a code in the user interface that allows PETG to be processed within the material properties specified for it.

Acknowledgement

We would like to thank especially our GSA Sebastian Donall, Royce Jacobs, Lewis Moth, and Zac Schardt, along with the L3 Harris Student Design Center and Machine shop staff, who have contributed meaningfully to our experience.

Project Summary

Most industrial complexes contain heavy items and machinery that often need to be moved quickly and precisely. Limiting the amount of time that is spent on moving items while keeping all operators safe and efficient is critical for this project. Currently, all competition comes from existing solutions such as those presented by Hovair and AeroGo. This new design aims to separate the pallet and handles, creating a drive tractor and pallet system. The finalized design for this project is made up mostly of an aluminum 6061 tubular frame supported by Omni-Ball wheels. These wheels allow for 360-degree rotation of two hemispheres around a central axis, creating smooth, omni-directional movement for the tractor. The device will facilitate air flow from an external source, feeding said airflow to the air pallet (which is carrying the load). All pneumatics for the system will have multiple fail safes throughout the design. Multiple points where the air can be dumped and stop system motion are included as well as pressure regulators at the operator鈥檚 position. To connect the device to the air pallet, a locking mechanism is employed to create a rigid connection between the tractor and pallet. The device also splits the airlines into 4 outlets that plug into the air pallet, creating another connection. This project could be scaled to facilitate another pallet. The device has been ensured to withstand the force of two pallets, though only one is required for demonstration purposes. The team has ordered $4291.30 in materials with $708.70 unspent following the completion of the project. The total budget for this project was $10,000 split between the air pallet and drive tractor teams equally and was not exceeded by either team.

Project Objective

There is a need to develop an Air Bearing System that will provide smooth, level, omnidirectional movement of a significant Load for facility operations. The current system has experienced issues with structural rigidity and requires complex maintenance operations using hazardous solvents, adhesives, and coatings. Additionally, it is aged and due for a design refresh focusing on efficient use of space, manpower, and time. The goal is to minimize these factors and improve environment and economic efficiency, while ensuring the safety and precision of the Load operations. The resulting product will benefit an internationally-collaborative global defense program.

Manufacturing Design Methods

The majority of the device has been created with 1.5in / 2in Aluminum 6061 tubing. This was extruded aluminum ordered from McMaster Carr. These were then cut and welded within the on-site machine shop. The other major manufacturing component was additive manufacturing in the form of 3D printing. Many clips and most of the Omni-Ball wheels were created with 3D printing methods.

Specification

The Drive Tractor has a few key specifications that make the device special. At the operators position, there is a plate that houses an emergency dump valve as well as a filter and gauge combination. Below this, attached to the frame, is the 4-station manifold. This manifold allows for the individual regulation of air flowing the the separate castors within the air pallet. It intakes air from a single source and splits it into 4 separate lines. Finally, at the bottom of the device is the locking mechanism. This consists of a plate that sits on two T-slotted framing pieces, negating the need for suspension. This allows the lock to slide up and down with the Pallet as it inflates. On the plate is a store bought 2in x 2in trailer hitch, that allows for positive engagement between the Tractor and Pallet.

Analysis

All analysis for this device was performed in ANSYS. Structural stress tests were performed to ensure project stability. It was important to conduct these tests so that the lightest, yet strongest material could be chosen while staying within the required design parameters (such as factor of safety). This also helped to point out critical stress points that were addressed during the manufacturing phase.

Future Works

For the future, more focus can be given to the translation. We were unable to finish the Omni-balls in time for showcase (a separate back-up translation device was available). Focusing on this would be imperative for the novelty of the project in the future. Other things to consider are the stability of the connection at the hitch as there is a small amount of play which produces slop in the operation.

Acknowledgement

The Drive Tractor team gratefully acknowledges customer support from Lockheed Martin representatives Lauren Bowers and Anderson Crookshanks, and Armstrong Ekpete of the U.S. Navy.