To provide process optimization of metal fabricating self-replicating rapid prototyper (RepRap) 3-D printers requires a low-cost sensor and data logger system to measure current (I) and voltage (V) of the gas metal arc welders (GMAW). This paper builds on previous open-source hardware development to provide a real-time measurement of welder I-V where the measuring circuit is connected to two analog inputs of the Arduino that is used to control the 3-D printer itself. Franklin firmware accessed through a web interface that is used to control the printer allows storing the measured values and downloading those stored readings to the user's computer. To test this custom current and voltage monitoring device this study reports on its use on an upgraded all metal RepRap during the printing of aluminum alloy (ER1100, ER4043, ER4943, ER4047, and ER5356). The voltage and current data were analyzed on a per alloy basis and also layer-by-layer in order to evaluate the device's efficacy as a monitoring device for 3-D printing and the results of the integrated design are discussed.
Lowcost gas metal arc welding (GMAW)based 3D printing has proven effective at additive manufacturing steel and aluminum parts. Early success, however, was based on handwriting Gcode, which is inadequate for the majority of potential users. To enable automated slicing a 3D model and generating Gcode for an acceptable path for GMAW 3D printing, this paper reports on upgrading of the free and open source CuraEngine. The new slicer, MOSTMetalCura, provides the following novel abilities necessary for GMAW 3D printing: i) change the perimeter metric from width to track count, ii) avoid movement that overlaps previous weld beads, iii) have infill start immediately after the perimeter finished and in the direction that eliminates translations, iv) add a variable pause between layers to allow for substrate cooling, v) configure GPIO pins to turn on/off the welder, and vi) set optimized wire feed speed and voltage of the welder based on printing speed, layer height, filament diameter, and tool track width. The process for initiating these changes are detailed and the new slicer is used to help improve the function of the printer for ER70S6 steel. To find the printing function with the smallest bead width based on volume of material, the line width, layer height, and printing speed are varied to provide wire feed speed calculated by MOSTMetalCura, then the settings are used to print 3D models. The results of 3D printing three case study objects of increasing geometric complexity using the process methodology improvements presented, which show resolution of 1mm bead widths.
3-D printing has entered the consumer market because of recent radical price declines. Consumers can save substantial money by offsetting purchases with DIY pre-designed 3-D printed products. However, even more value can be obtained with distributed manufacturing using mass customization. Unfortunately, the average consumer is not technically sophisticated enough to easily design their own products. One solution to this is the use of an overlay on OpenSCAD parametric code, although current solutions force users to relinquish all rights to their own designs. There is thus a substantial need in the open source design community for a libre 3-D model customizer, which can be used in any design repository to democratize design. This study reports on the design, function, and validation of such software: the Free Open Source 3-D Customizer. It is demonstrated with a case study of the customization of 3-D printable external breast prosthetics. The results showed that novice users can adjust the available parameters according to their needs and save these to a new file on a website. This PHP (recursive acronym for PHP: Hypertext Preprocessor) library is free and open source and has potential for increasing the usefulness of online repositories to enable distributed manufacturing using consumer customized 3-D printable products.
This paper analyzes the findings of an international survey questionnaire to which responses were received from over 500 members from different technical societies of the Institute of Electrical and Electronics Engineers (IEEE). The survey is primarily intended to uncover members' perceptions of patent filing and research-driven innovation. Our thesis statement is twofold. First, the introduction of basic intellectual property (IP) courses to university Science, Technology, Engineering, and Mathematics curricula would teach students valuable basics of IP and associated issues, technology protection; and possibly stimulate novel/innovative R&D outcomes. Second, studying relevant active/lapsed/expired patent documents could provide stimulating input for ongoing academic research. After analyzing the survey results we conclude that IP coursework could be a catalyst for students and researchers to explore patent opportunities related to their specific interests. The resulting knowledge would further enable researchers to prepare more compelling funding applications. In our experience, IEEE conference publications are often closely aligned with inventions to solve pressing
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