A Mechanical innovation driven by Design
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open-source
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GPL-3.0
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Polyformer
• open-source • GPL-3.0 • Polyformer
@Alextrical @Dréço @Bigzilla @lhong820 @Sean9 @cn @Neo @RedFrox @highcastle @Snoopy2000 @elias @JRT3D
@Alextrical @Dréço @Bigzilla @lhong820 @Sean9 @cn @Neo @RedFrox @highcastle @Snoopy2000 @elias @JRT3D
@Alextrical @Dréço @Bigzilla @lhong820 @Sean9 @cn @Neo @RedFrox @highcastle @Snoopy2000 @elias @JRT3D
@Alextrical @Dréço @Bigzilla @lhong820 @Sean9 @cn @Neo @RedFrox @highcastle @Snoopy2000 @elias @JRT3D
@Alextrical @Dréço @Bigzilla @lhong820 @Sean9 @cn @Neo @RedFrox @highcastle @Snoopy2000 @elias @JRT3D
@Alextrical @Dréço @Bigzilla @lhong820 @Sean9 @cn @Neo @RedFrox @highcastle @Snoopy2000 @elias @JRT3D
Form is a function, they are mutually inseparable. My work in Polyformer highlights my philosophy in industrial design.
I adapt a method that integrates mechanical innovation to deliver an aesthetic and intuitive design.
An open platform designed for evolution
Polyformer is designed with open-source in mind, every part of the machine can be redesigned and reconfigured by the users.
The front panels open to 90 degrees via a bevel gear mechanism. They are miraculously designed to have a perfect dynamic clearance while keeping the tolerance to as minimal as possible so the outer surface looks flush, and the gaps look consistent.
Dynamic Panels
The compliant mechanism allows the clamping pressure to be evenly distributed across a larger surface area without changing the intuitive installation method with the set screw. The result is three times higher clamping force than with just a screw screw, thus resulting in a higher friction.
Compliant Clamp
It is intuitive to have the drive unit situated right in the center of the spool so it looks flush as a whole unit. However, the limited space, extreme load, and long distance to the center of rotation make the drive unit exceedingly difficult to design. I opt for a non-traditional cycloidal gearbox to meet the design goal.
Integrated Drive Unit
The spool interlocks with the drive unit through a screw pattern as it is pulled to prevent the spool from drifting out of the drive unit. Meanwhile, the pattern inside the spool provides an uniform load across its inner circumference when it’s mounted to the 3D printer, preventing the spool from getting tangled on the mount.
Anti-Tangle Spool
I work tirelessly to iterate and design a 3D-printed fan that takes advantage of the high input speed to actively cool the stepper motor. The chamber is cleverly designed to vent the air through a parting line. The result is a 17C temperature reduction in the chamber without any visible vent holes on the outside.
Actively Cooled Gear Box
The result is an extremely compact coaxial gear train system that is concealed and minimal, integrated into the spool cavity.
At the heart of the Polyformer spool system is a parametrically driven compact cycloidal gearbox, featuring 30:1 reduction ratio with minimum part counts and mostly 3D printed, withstanding a maximum load of 300Ncm.
30:1 Cycloidal Drive
To mount a 200C heater block with PLA-printed parts that can only withstand 60C, I designed an air duct that doubles as cooling for the stainless steel mounting screws and for the filament.
MeltZone Cooling System
The ribbon cartridge holder is cleverly designed with a small notch to resist downward force while allowing users to remove the cartridge with ease.
Biased Loading System
The intricately designed planetary gear key enables users to wind the ribbon into the cartridge 5 times faster.
5:1 RapidWinder
The open-source nature of the project necessitates upgradability. Thus, the electronic mounts are cleverly designed to freely move along an XY plane, enabling a wide range of adaptability.
Adaptive Electronics Mount
What if PET bottles have a second life?
“The recycling rate of PET bottles and jars was 29.1 percent in 2018”
— EPA
Traditional recycling requires multiple processes that involves long-distance transportation
What if…
What if there is a PET bottle recycling machine that everyone with a 3D printer can build by themselves…
Can I use my knowledge in design, engineering, and 3D printing to influence and make changes in the world…
User:
-Makers and advanced 3D printer users who are interested in giving plastic bottles a second life.
Why:
-3D printing allows the making of anything to be possible, it is a very efficient way to upcycle.
-I am not interested in profiting from this project, I want more people to join the project and share a collective effort in solving the plastic waste problem.
Design Criteria:
-Can be easily put together by makers with a manual.
-As many 3D printable parts as possible.
-Parts need to be printable on FDM 3D printers.
Main Machine Prototypes
Iteration #1
Iteration #2
A bottle slicer was added to help accelerate the slicing process and to maintain an even width across the entire length.
Study of Architecture
Design Criteria:
-Compact
-User friendly
-Serviceable
-Minimum part counts
Industrial Design Prototype
After having a rough idea of what the pros and cons are for the different architectures. I started trying to figure out the constructions considering the usability and aesthetics.
After testing the prototype printed in ABS, I proceeded to contact a manufacturer who recycles PET bottles into PET filaments at an industrial scale. They agreed to send over 3 rolls of filament in support of my project. Thus the first Polyformer P.001 was created.
A 12:1 cycloidal drive gearbox was used in combination with a 59Ncm Nema 17 stepper motor to drive the red spool, ensuring having enough amount of torque while taking a minimum amount of space so that they could be housed inside the hub.
Bottle Cutter Prototypes
Engineering prototypes
Adjustable cutting width
Adjustable bottle diameter
Fast and easy cutting operation
Designed final product
Andromeda_Release
Polyformer_Andromeda was brought to you with the support from the open-source community 7/14/2022
Special thanks to
@Alextrical @Dréço @Bigzilla
@lhong820 @Sean9 @cn
@Neo @RedFrox @highcastle
@Snoopy2000 @elias @JRT3D
Gearbox Redesign
-50% increase in torque output
-Active cooling (17C drop in temperature, 54C equilibrium at room temperature)
-Modularize the gearbox system
-Decouple shaft knob
-Standardize to 608 bearings from 695 & 6900
-Slicing Seam compensation
-Hub temperature monitoring
Arm Connector Redesign
-Reinforce arm connector
-Change to 16 bolts fastening
-Fully extend the connector, eliminating weak points
Melt Zone Redesign
-Redesigned fan duct and hotend mounting geometry
-Replace M3x60mm bolts with more sourceable M3x30mm bolts
-Modularize hotend mounting wings
-Modularize ribbon guidler
-Add fan duct mounting points
Ribbon Cartridge Redesign
-Change to enclosed cartridge for ribbon storage
-Add geared key to speed up the winding process
-Magnetically attach the cartridge to the mount
-Add storage location for the geared key
PolyCutter Lite
-Increase overall size, strengthen the structural rigidity
-Optimize ergonomics
-Add an adaptive and tool-free cap for the rod
-Increase max supported bottle size to 105mm
-Add bearing sharpening jig
-Change to using all M3x12mm
-Modularize every single part
-Add wash to reduce wear on the sliding gauge
-Overall cutting performance optimization
