System Optimization of a Self-Replicating 3D Printer for Creating Visual Model Designs

Communication difficulties often arise when companies attempt to explain project plans to clients who lack background knowledge.  Companies often enhance their explanations with 2D graphical representations in proposals and presentations, but these methods often do not convey all the information that the client wants.  To address this problem at HNu Photonics, we have assembled a rapid three-dimensional plastic prototyper (“3D printer”) in order to create visual models to better convey 3D products and concepts.  The 3D printer is considered self-replicating because it can make over 50% of the parts needed to build it.  This is an important quality to have because it greatly lowers the cost of subsequent printers if one chooses to expand printing production capacity.  We have optimized the system by generating and printing calibration models that test the accuracy and the limits of the printer.  We will also optimize production time and material usage in printing residential and commercial solar installation models for company proposals. Two plastics, Acrylonitrile Butadiene Styrene (ABS) and Polylactic Acid (PLA), will be used and we will determine which material is best suited for generating different types of prototype models.  Testing will be done to determine which plastic is better suited for specific applications/situations.  Certain plastics are faster to produce and/or have better accuracy at certain temperatures and feed rates.  Further testing and improvements could include the use of different colored plastics for better visual representation and minimizing system vibrations in order to decrease production time.