Faculty Guide John Kaemmerlen
Primary Customer Denis Cormier
Michael DiRoma
ISE (PM)
Rachel Levine
ME (Lead Engineer)
Amy Ryan
ISE (Lead Programmer)
Sam Perry
ME
Kwadwo Opong Mensah
EE
The primary objective of this project is to create a
projected image 3D printer with the ability to produce
a three-dimensional part.
Specification
Target Value
 Build a 3D Part
 Yes
 Built with Photopolymer
 Yes
 Layer Thickness
 25 – 250 Microns
 Feature Resolution
 Able to report process
 Part Size Dimension
capabilities
 Max Size of 3” by 4”
 Fully Automated
 Software to control all
aspects
 Photopolymer: Light sensitive resin that cures when
light hits it
 A black and white image or “slice” is a way to
selectively cure the resin
Black and white
image from DLP
projector
 Physical Setup
 Bath glass is covered with Teflon
 Bath glass is secured between top and bottom bath
assembly
 Bath assembly is attached to the platform
 Bath filled with resin
 Build Platform lowered Completely
 Platform is lowered using the jog buttons
 Inputs to LabView
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STL file
Units (millimeters and inches)
Slice Thickness – 50 Microns (ideal conditions)
Base Speed – 1600 (ideal conditions)
Cure Time – 3 seconds (ideal conditions)
 Windows Command Line and Slicer
 Information Gathered
 3D Object size (length, width, and height)
 Functions Performed
 Object sliced
 Images background changed to black and core changed to
white
 Images saved to desktop
 LabView, the projector, and the Microcontroller
 Steps to move determined by layer thickness
 Build Platform moves up to far enough to separate from
the Teflon then down to the appropriate distance
 The image will project for the set cure time then it will
display a black screen.
Stepper Motor
Lead Screw, Linear Guide
Sandblasted Aluminum Build Platform
Resin Bath and Teflon Film
Jog Buttons
Motion Assembly
Motion Controller
Macro Lens Optics
DLP Projector
 Sandblasted Aluminum Build Platform
 Increased adhesion
 Teflon Film
 Decreased adhesion
 Lead Screw
 Anti-backlash nut
 12.7μm (0.0005”) resolution per step
 Linear Guide
 High loading support with low deflection
 Motion Controller
 Integration with software
Successes
Failures
 Multiple complete parts
 Inconsistent adhesion to
produced
 System fully automated
build platform
 Unable to use different
photopolymers
 Utilizing past teams
materials (projector,
case, formula, etc)
 Resolution of parts is low
 Improve Teflon Film
 Permanent glass coating
 Hard limit switches
 Dedicated software
 Encoder support
 Test different photopolymer resin formulas
 Clean up LabView Programing Code
 Continue Detailed testing to determine optimal
settings
 All risks can not be accounted for
 Unidentified risks, external to the project
 Overlooked sources of help
 “Secret formula” found on past teams poster in week 8 of
the second quarter
 Better testing structure earlier in the quarter
 Manipulate one variable at a time in a controlled manor