TeamExtruder_Project_Plan_Document_Final

TeamExtruder_Project_Plan_Document_Final

• 1.
        Composites  Extruder   Head  Development         Colin  Biery   (720)216-­‐7625   [email protected]       Ryan  Dunn   (303)229-­‐8358   [email protected]       Michael  Hansen   (720)427-­‐1687   [email protected]     Logan  Rutt   (303)495-­‐8382   [email protected]     Tristan  Vesely   (925)876-­‐2343   [email protected]   Colorado  State  University,  Mechanical  Engineering,   Senior  Practicum  Projects  Program   October  6,  2015     ____________________________   ___________________________     ____________________________   ___________________________     ____________________________     ____________________________   Advisor:  Dr.  Don  Radford            
• 2.
      Composites  Extruder  Head  Development       Table  of  Contents   Introduction  ...................................................................................................................................................  2   Background  ....................................................................................................................................................  2   Composites  Properties  ..........................................................................................................................  2   Composites  Manufacturing  .................................................................................................................  3   Additive  Manufacturing  ........................................................................................................................  3   Current  Solutions  ....................................................................................................................................  4   Problem  Statement  .....................................................................................................................................  5   Goals  .................................................................................................................................................................  6   Design  Constraints  .......................................................................................................................................  7   Work  Plan  and  Design  Evaluation  ..........................................................................................................  7   Design  Evaluation  .....................................................................................................................................  11   Management  Plan  ....................................................................................................................................  11   Meeting  times  .......................................................................................................................................  11   Timeline  and  Milestones  ...................................................................................................................  13   Concluding  Statement  .............................................................................................................................  14   Budget  Breakdown  ...................................................................................................................................  14   References  ...................................................................................................................................................  15          
• 3.
      Composites  Extruder  Head  Development       Introduction   Fiber  reinforced  thermoplastic  composites  are  incredibly  useful  materials  due  to   their  impressive  specific  stiffness  as  well  as  their  specific  strength.  Specific  stiffness  is   measured  by  Modulus  of  Elasticity  divided  by  density,  and      specific  strength  is   measured  by  tensile  strength  divided  by  density.  Unfortunately,  composite   manufacturing  is  a  difficult  and  costly  process  that  makes  the  practicality  of  composite   parts  unsuitable  for  many  designs.  In  contrast  additive  manufacturing  is  a  relatively   simple  manufacturing  processes,  but  creates  weaker  parts.  Combining  the  ease  of   additive  manufacturing  techniques  with  the  strength  of  composites  would  enable   designers  to  rapidly  create  components  that  meet  structural  requirements.  This  will   eliminate  lag  time  for  prototypes  and  reduce  market-­‐level  manufacturing  times.  The   proposed  solution  to  this  challenge  is  a  hot  end  extruder  head  capable  of  manufacturing   consolidated  thermoplastic  composites  through  3D  printing.  Advancement  of  composite   materials  in  engineering  design  strongly  depends  on  the  availability  of  new   manufacturing  processes  [7].     Background   Composites  Properties   Composite   materials   offer   mechanical   properties   for   engineering   applications   that  traditional  materials  cannot  compete  with.  Their  high  specific  strength  can  provide   the   same   capabilities   as   high-­‐grade   aluminum   at   five   to   ten   times   less   weight   [2].   Additionally   they   have   remarkable  durability  and  resistance  to   fatigue   [2].   Thermoplastic   fiber   composites   function   by   transmitting   external   energy   through   the   thermoplastic   matrix   material   to   the   hard,   brittle   fiber   reinforcements   within.  The  fibers  take  the  applied  load   while   the   matrix   protects   them   from   damage.   Properties   of   composites   heavily  depend  on  the  properties  of  the  matrix,  reinforcement,  and  the  ratio  of  matrix   to  reinforcement,  which  is  traditionally  stated  as  the  percent  weight  of  fiber  [2,8].     Fiber  orientation  is  one  factor  that  determines  the  properties  of  a  composite.  As   seen  from  Figure  1,  there  are  several  techniques  for  fiber  and  reinforcement  placement.   The  most  widely  practiced  fiber  placement  for  composites  is  continuous  and   discontinuous  (chopped)  fiber  [8].  Fibers  are  categorized  by  their  aspect  ratio  (length   divided  by  the  diameter  of  the  fiber),  where  continuous  fibers  have  long  aspect  ratios   and  discontinuous  fibers  have  short  aspect  ratios  [1].  Composites  are  most  effective   when  fibers  are  continuous  and  parallel,  increasing  their  ultimate  tensile  strength  and   Figure  1  -­‐  Continuous  vs.  Short  Fibers  [11]  
• 4.
      Composites  Extruder  Head  Development       stiffness.  Continuous  fiber  composites  have  anisotropic  material  characteristics,  and  fail   at  lower  stress  values  when  transversely  loaded  [2,8].  In  contrast,  Discontinuous  short   fiber  composites  tend  to  possess  more  isotropic  material  properties  when  compared  to   continuous  fiber  [2],  but  have  lower  tensile  strength  and  Modulus  of  Elasticity.   Consolidation  is  an  important  issue  when  dealing  with  composite  materials.   Consolidation  describes  how  effective  the  matrix/thermoplastic  is  at  reaching  and   spreading  between  all  of  the  fibers.  Proper  consolidation  uniformly  arranges  the  fiber   reinforcement  throughout  the  material  with  fiber  volumes  at  50%  or  above.  One  reason   composites  are  advantageous  over  other  materials  is  how  the  matrix  distributes  the   external  forces  experienced  by  the  composite  to  the  stronger  (and  more  brittle)  fibers   [5].  The  transfer  of  energy  between  the  matrix  and  fiber  is  accomplished  through  proper   wetting  of  the  composite.  Proper  wetting  provides  adequate  bonding  between  the   matrix  and  fibers,  and  transfers  loads  through  shear  to  the  fibers  [2].  With  inadequate   wetting  out  of  the  fiber  composite,  the  structural  strength  decreases  and  does  not   provide  proper  mechanical  properties  for  engineering  use.    Without  the  stiff,  brittle   fibers  the  thermoplastic  alone  is  far  weaker  and  has  a  lower  modulus  of  elasticity,   because  the  matrix  has  lower  tensile/compression  strength  and  modulus  of  elasticity   than  the  fibers.  Without  proper  consolidation  and  wetting  of  the  fibers,  these  material   advantages  can  be  lost.  If  the  fibers  are  not  distributed  evenly  through  the   thermoplastic  matrix  and  not  adequately  transferring  energy,  you  do  not  achieve   consistent  material  properties  throughout  the  composite.   Composites  Manufacturing   Although  composites  provide  strong  and  stiff  engineering  materials,  the   manufacturing  process  can  be  costly  and  time  consuming.  Manufacturability  is  a  limiting   factor  for  commercialization  of  these  materials,  where  the  process  involves  multiple   steps  and  require  bulky  molds  [7].    The  tooling  required  to  create  composite   components  are  expensive  to  design  and  manufacture  and  do  not  offer  adaptability  for   design  changes.  In  addition  to  expensive  tooling,  the  manufacturing  process  often   requires  human  intervention  [6].  With  high  labor  necessities  the  price  of  production   increases  due  to  lack  of  automation,  and  exposes  individuals  to  unhealthy  work   environments  containing  fumes  and  high  temperatures.     Additive  Manufacturing     Additive  manufacturing  (AM)  refers  to  the  process  of  building  3-­‐D  objects  by   adding  layer  upon  layer  of  material  to  create  a  complete  part  [10].  There  are  many   different  types  of  additive  manufacturing,  the  most  common  and  commercially  available   being  Fused  Deposition  Modeling  (FDM).  FDM  generally  uses  thermoplastic  filament  as   the  stock  material.  The  filament  is  fed  into  a  heated  extrusion  nozzle  where  it  is  melted   and  then  extruded  onto  a  base  plate  through  a  hot  end  extruder  head.  The  rate  at  which   the  filament  is  extruded  is  dependent  on  the  specified  printing  speed  of  the  extruder   head.  The  faster  the  printing  speed,  the  faster  the  filament  is  extruded  [10].  The   extruder  head  and  base  plate  move  on  a  minimum  of  three  axes  to  outline  the  geometry  
• 5.
      Composites  Extruder  Head  Development       of  the  part.  Currently,  most  of  these  printers  move  in  the  x-­‐y  plane  to  create  a  layer  and   then  move  in  the  z-­‐direction  to  begin  printing  the  next  layer.       FDM  manufacturing  requires  no  tooling  or  user  interaction  to  create  finished   parts.  Parts  are  built  up  directly  on  the  base  plate  from  the  ground  up.  This  is   advantageous  as  it  requires  no  tooling  but  disadvantageous  because  it  is  limited  in  what   geometries  at  can  build  vertically.  They  are  built  up  using  G-­‐code  generated  from  3D   specific  software.  This  software  reads  stereolithography  (STL)  files  and  generates  the   code  directly  from  them.  This  form  of  AM  is  extremely  useful  for  developing  geometries,   however  it  is  disadvantaged  when  developing  structural  properties  for  application   purposes.     Current  Solutions       There  are  a  few  current  ways  that  composites  are  being  implemented  into  AM.   These  include  using  hot  end  extruder  heads  to  pull  and  consolidate  fibers,  use  plastic   filament  pre-­‐impregnated  with  chopped  fibers,  and  using  printing  plastics  and  fibers  in   series  using  multiple  extruder  heads.     A  laboratory  scale  extruder  head,  developed  by  engineers  in  Zurich  Switzerland,   is  capable  of  of  processing  continuous  composite  lattice  structures  [7].  The  method  of   manufacturing   is   inspired   by   conventional   3D-­‐ printing,   and   uses   a   novel   two-­‐stage   extrusion   head   to   manufacture   the   composite   as   seen   in   Figure   2.   This   novel   manufacturing   method   is   currently   patented   for   a   continuous   fiber   lattice   fabrication   (CFLF). CSU  currently  has  two  graduate  students  working  with  composite  additive   manufacturing.  They  are  printing  commingled  tow,  a  form  of  composite  stock  material,   onto  a  rotating  mandrel  using  3D  extruder  heads.  This  method  requires  tension  on  the   stock  material  in  order  to  achieve  good  consolidation.     There  are  multiple  companies  that  are  selling  thermoplastic  filament  with  short   chopped   fibers   pre-­‐impregnated   into   the   filament.   This   composite   filament   can   be   Figure  2  –  Commingled  tow  extruder  head  developed  by  ETHZ  Structures  [7]  
• 6.
      Composites  Extruder  Head  Development       Figure  3  -­‐  Mark  Forged  MarkOne  Printer  [3]   printed  in  many  commercially  available  printers  but  does  not  add  the  desired  benefit  to   properties  that  can  be  achieved  from  traditional  composite  manufacturing  methods.     The   only   commercially   available   FDM   printer   that   prints   continuous   fiber   composites  is  the  Mark  One©  by  MarkForged  [3].  It  uses  a  dual  head  extruder  system  to   print  nylon  out  of  one  head  and  pre-­‐preg  fibers  out  of  the  other.  This  is  called  follow   behind  consolidation   because  the  matrix  is   extruded   on   top   of   the   fiber   after   extrusion.   This   method   gives   much   higher   strength   values   than   a   purely   nylon   part   would   achieving   a   tensile   strength  of  590  MPa   for   nylon-­‐fiberglass   composite  [3].   Problem  Statement     Composite  material  production  is  a  time-­‐intensive  and  expensive  process  when   creating  highly  complicated  parts.  Tooling  is  difficult  and  must  have  a  high  level  of   precision  to  create  quality  parts.  Molds  created  for  a  part  are  specific  to  that  part,  they   cannot  be  used  to  manufacture  anything  else.       Fused  deposition  modeling  is  incredibly  easy  to  use  and  can  create  unique   shapes  for  virtually  no  overhead  cost.  It  is  versatile  and  capable,  but  the  parts  created   are  weaker  than  thermoplastic  parts  created  with  traditional  methods.    Being  able  to   produce  composite  materials  in  unique  shapes  via  additive  manufacturing  is  an  enabling   technology  opening  up  countless  opportunities  to  save  money  by  avoiding  costly   production  techniques.  Additive  manufacturing  is  a  rapidly  growing  field  that  keeps   making  breakthroughs  in  the  potential  it  has.  Composites  are  one  of  the  few  types  of   material,  if  not  the  only  one  left,  that  is  not  yet  being  printed.  Research  labs  are  already   starting  to  experiment  with  this  technology  [7].  Before  additive  manufacturing  of   composites  can  become  commercial  there  has  to  be  a  reliable  foundation  built  in   research  labs.  Researchers  who  make  the  most  strides  in  composites  extrusion  stand  to   gain  a  great  amount  as  many  commercial  companies  will  undoubtedly  begin  producing   as  many  composites  as  possible  this  way.  Ultimately  those  manufacturing  composites   stand  to  benefit  from  composites  extrusion  because  they  are  paying  the  outstanding  bill   for  current  production  methods.  Currently  Boeing®  requires  the  use  of  carbon  fiber   thrust  reversing  cascade  baskets  for  their  jet  engines.  There  is  only  one  company  in  the  
• 7.
      Composites  Extruder  Head  Development       world  which  produces  the  baskets  and  they  use  an  expensive  hand-­‐laying  process.  The   proposed  fused  deposition  modeling  method  of  composite  manufacturing  has  the   potential  of  being  a  viable  alternative  to  the  current  cascade  manufacturing  process.     Goals     The  designated  task  is  to  design  and  build  a  progression  of  laboratory  scale   composite  extruder  heads  capable  of  being  mounted  on  a  conventional  or  non-­‐ conventional  3D  printer.  The  heads  developed  must  successfully  print  fiber  reinforced   composite  material.  Each  extruder  head  will  be  capable  of  printing  composites  with   different  stock  material  options:   ● One  head  capable  of  using  commingled  tow  and  of  wetting  out  dry  continuous   fiber.   ● One  head  that  is  able  to  use  lower  cost  forms  of  plastic  feedstock  than  the   commercial  fused  deposition  plastic  filament.   ● One  head  capable  of  extruding  continuous  patterns  of  plastic  and  reinforcing  dry   fiber  with  plastic  pellets  as  the  feedstock.   ● Print  composites  made  up  of  a  polypropylene  thermoplastic  matrix  and  glass   reinforcing  fibers  in  order  to  demonstrate  capability  of  printing  composites  made   up  of  a  Peek  thermoplastic  matrix  and  carbon  reinforcing  fibers     Objectives   Table  1  -­‐  Design  Objectives   Objective  Name   Priority*   Method  of   Measurement   Objective   Direction   Target   Consolidation   5   Photo  Microscopy   Maximize   Evenly  distributed   fibers   Fiber  Volume   Fraction   4   Volume  of  fibers   (cc)   Maximize   60%   Hot  End   Temperature   Capability   3   Head  temperature   (degrees  C)   Maximize   500°C   Operating   Temperature   3   Head  temperature   (degrees  C)   Optimize   TBD  via   experimentation   Composites  Stiffness   2   Specific  Modulus   (GPa)   Maximize   26.5  GPa  [9]**   *      Priority  is  weighed  on  1-­‐5  scale  with  5  most  important   **  Value  provided  for  60%  by  volume  glass  fiber  reinforced  PP  composite.  Value      will   change  based  on  material  produced    
• 8.
      Composites  Extruder  Head  Development         Design  Constraints   Table  2  -­‐  Design  Constraints   Constraint   Method  of  Measurement   Limits   Material  Stock  Form   Thermoplastics  and   Reinforcing  Fibers  Stock   Commingled  tow,  thermoplastic  filament,   dry  fiber,  thermoplastic  pellets   Size   Dimensions  (mm  x  mm  x  mm)   54  x  65  x  65   Commercial  Software   Compatible  slicing  and   controls  software   Cura,  Slic3r,  etc.   Manufacturing   Methods   Compatible  types  of  additive   manufacturing   Fused  Deposition  Modeling   Budget   Dollars  Spent   $2000   Safety   Possibility  of  Serious  Injury   0         Work  Plan  and  Design  Evaluation     The  work  plan  for  our  project  is  crucial  to  developing  a  successful  product  and   will  be  executed  in  three  iterative  design  and  manufacturing  processes,  each  of  which   are  determined  by  the  type  of  material  stock  to  be  extruded.  These  processes  are   broken  down  in  detail  in  tables  3-­‐5.  
• 9.
      Composites  Extruder  Head  Development       Table  3  -­‐  1st  Extruder  Head  Iteration  -­‐  Commingled  Tow  Design  Process   Process  step   Task  Breakdown  (with  number  of  hours  allocated  to   each  task)   1. Acquire  3D  FDM  printer,   extruder  head,  and  commingled   tow  Polypropylene  (PP)  Twintex   stock  material   • Develop  printer  criteria  to  be  approved  by  Dr.   Radford  (3  hrs.)   • research  and  buy  printer  approved  by  Dr.  Radford  (8-­‐ 10  hrs.)   • Communicate  with  Kent  Warlick  to  receive  PP   Twintex  material  (1-­‐2  hrs.)   2.)  Attempt  extruding  commingled   tow  through  original  standard   extruder  head   • use  small  amount  of  PP  Twintex  in  test  extrusion  of   commingled  tow  using  the  original  extruder  head   that  was  purchased  with  the  printer  (3  hrs.)   3.)  Determine  Procedure  for   effective  pultrusion,  consolidation,   and  extrusion  of  commingled  tow   with  extruder  head   • Meet  with  Kevin  Hedin  and  Kent  Warlick  to   determine  current  methods  of  tensioning,   consolidating  extruding,  commingled  tow  on  spinning   mandrel  printer  (1-­‐2  hrs.)   • identify  and  isolate  most  important  components  of   extruder  head  for  effective  tensioning,  consolidation,   and  extrusion  (3-­‐5  hrs.)   4.)  Develop  extrusion  angle  and  flat   plate  printing  techniques   • Use  information  acquired  from  initial  testing  and   mandrel  methods  to  generate  concepts  for   tensioning  consolidation  and  extrusion  (10-­‐15  hrs.)   5.)  Design  angled  extruder  head  to   consolidate  and  print  Commingled   tow   • Design  mechanical  components  necessary  to  achieve   goals  determined  in  concept  generation,  using  as   much  technology  from  prior  commingled  extrusion   process  as  necessary  (  10-­‐15  hrs.)   6.)  Manufacture   • Using  the  I2P  lab  and  the  team  printer,  print  any   parts  necessary  that  are  not  temperature  sensitive   (printing  time:  10-­‐20  hrs.)   • Machine  any  temperature  dependent  components,   either  in  house  or  professionally,  depending  on   complexity  of  geometry  (5-­‐15  hrs.)    (up  to  three   weeks  of  lead  time  for  professional  manufacturing)   7.)  Assemble  and  test  extruder  head   • Test  extruder  head  and  parts  printed  based  on   current  testing  methods  used  by  Kevin  Hedin  and   Kent  Warlick  and  previously  found  in  research  (15-­‐20   hrs.)   8.)  Revise  design  and  modify   extruder  as  necessary  based  on   testing   • Based  on  testing,  modify  or  redesign  components  of   extruder  head  to  increase  composite  print  quality   and  use  on  2nd  and  3rd  iteration  of  extruder  head  (5-­‐ 20  hrs.)  
• 10.
      Composites  Extruder  Head  Development       Table  4  -­‐  2nd  Iteration  -­‐  E-­‐glass  fiber  tow  and  thermoplastic  filament   Process  step   Task  Breakdown  (with  number  of  hours  allocated  to   each  task)   1. Acquire  E-­‐glass  Fiber  feedstock   and  PP  filament  feedstock   • Purchase  E-­‐glass  fiber  tow  feedstock  (2-­‐3  hrs)     • Purchase  PP  thermoplastic  filament  feedstock  (<1   hr)   2.)  Modify  1st  iteration  of  extruder   head  design  to  accommodate  for   thermoplastic  filament  feedstock.   • Generate  concepts  to  accommodate  for  new   feedstock  material  types  (5-­‐10  hrs)   • Modify  designs  of  first  iteration  of  head  to  be   capable  of  tensioning  consolidating,  and  extruding,   composite  as  separate  feedstocks;  dry  fiber  and  PP   filament  (14-­‐18  hrs.)   3.)  Manufacture  new  components   of  extruder  head   • Print  any  parts  necessary  that  are  not  temperature   sensitive    and  were  not  previously  manufactured   from  1st  iteration  (printing  time:  5-­‐10hrs)   • Machine  hot  end  extruder  head,  either  in  house  or   professionally,  depending  on  complexity  of   geometry  (5-­‐15  hrs)    (up  to  three  weeks  of  lead   time  for  professional  manufacturing)   4.)  Assemble  and  test   • Test  extruder  head  and  parts  printed  based  on   current  testing  methods  used  by  Kevin  Hedin  and   Kent  Warlick  and  previously  found  in  research  (15-­‐ 20  hrs)   5.)  Revise  design  and  modify   extruder  as  necessary  based  on   testing   • Based  on  testing,  modify  or  redesign  components  of   extruder  head  to  increase  composite  print  quality   used  on  1st  and  to  be  used  on  3rd  iteration  of   extruder  head  (5-­‐20  hrs)  
• 11.
      Composites  Extruder  Head  Development       Table  5  -­‐  3rd  Iteration  -­‐  E-­‐glass  fiber  tow  and  pellet  stock  Polypropylene  feedstock Process  step   Task  Breakdown  (with  number  of  hours  allocated  to  each   task)   1.)  Acquire  matrix  pellet   feedstock   • purchase  PP  pellet  stock,  preferably  premixed  and   ready  to  be  used  as  is  (1-­‐3  hrs.)   2.)  Develop  compact  process   for  melting  and  extruding   pellet  feedstock   • Working  off  of  existing  technology,  develop  a  method   to  use  thermoplastic  feedstock  that  can  be  integrated   into  3D  printing  process  (8-­‐12  hrs.)   3.)  Modify  2nd  iteration  of   extruder  head  design  to   incorporate  pellet  feedstock   system   • Design  components  to  use  method  developed  to  use   pellet  feedstock  (10-­‐15  hrs.)   • Modify  designs  to  be  capable  of  dealing  with  the   addition  of  components  for  pellet  feedstock  (10-­‐15   hrs.)   4.)  Manufacture  new   components  of  extruder  head   • Print  any  parts  necessary  that  are  not  temperature   sensitive    and  were  not  previously  manufactured  from   1st  iteration  (printing  time:  5-­‐10hrs)   • Machine  any  components  that  are  temperature   dependent,  either  in-­‐house  or  professionally,   depending  on  complexity  of  geometry  (5-­‐20  hrs.)  (  up   to  three  weeks  of  lead  time  for  professional   manufacturing)   5.)  Assemble  and  test   • Test  extruder  head  and  parts  printed  based  on  current   testing  methods  used  by  Kevin  Hedin  and  Kent  Warlick   and  previously  found  in  research  (15-­‐20  hrs.)   6.)  Revise  design  and  modify   extruder  as  necessary  based   on  testing   • Based  on  testing,  modify  or  redesign  components  of   extruder  head  to  increase  composite  print  quality  used   in  1st  and  2nd  iteration  of  extruder  head  (5-­‐20  hrs.)      
• 12.
      Composites  Extruder  Head  Development       Design  Evaluation   Our  main  design  objective  is  to  produce  a  high  quality  composite  so  there  must   be  a  way  to  test  for  quality.  Extrusion  temperature,  feed  rate,  and  nozzle  diameter  are   crucial  test  variables  that  need  structured  experiments  to  determine  optimum  printing   conditions.  Consolidation  will  be  measured  with  density  measurements  and  fiber   volume  fraction  will  be  measured  with  a  resin  burnout  method.  Resin  burnout  involves   weighing  the  produced  part  and  then  baking  it  and  letting  the  resin  evaporate  so  only   fibers  are  left.  Those  fibers  can  then  be  weighed  with  respect  to  the  original  weight  to   find  the  percentage  of  fiber  in  the  material.     Other  engineering  analysis  tools  that  will  be  required  for  a  successful  product   involve  mathematical  consideration  and  control  systems.  Mathematical  heat  transfer   calculations  will  be  required  to  determine  the  optimal  temperature  to  extrude  the   matrix  at  to  ensure  proper  wetting  out  of  fibers  and  solidification  upon  contact  with  the   print  plate  or  previous  layers.  Die  swell  will  be  an  important  variable  to  take  into   consideration  when  designing  and  testing.  Die  swell  is  determined  from  the  diameter  of   the  extrudate  and  the  diameter  of  the  extrusion  nozzle.     Material  selection  software  such  as  Cambridge  Engineering  Selector  will  be  a   valuable  asset  for  any  engineering  decisions  needing  to  be  made  regarding  material   selection,  this  is  most  likely  to  occur  in  nozzle  design.  Control  systems  will  be   implemented  in  regards  to  extruder  head  temperature.  Controls  should  be  user  defined   and  consistent  in  nature  and  therefore  a  system  of  heat  detection  is  necessary.     Management  Plan   Meeting  times     Team  Extruder  meets  Tuesday  and  Thursday  afternoons  starting  around  1:30pm   (depending  on  when  senior  design  lecture  get  out).  On  Tuesday  afternoons  Team  3D   Contour  and  Team  Extruder  Head  meet  in  order  to  coordinate  between  the  two   projects.  Team  Cascade  joins  this  collaborative  meeting  the  first  Tuesday  of  every  month   to  update  everyone  on  current  progress  and  to  prepare  the  interfacing  of  the  three   projects.  Cascade’s  involvement  in  the  collaborative  meetings  will  increase  as  the  design   process  progresses,  and  the  time  comes  to  start  interfacing  the  projects.    After  the   multi-­‐team  meetings  are  finished  Team  Extruder  continues  working  on  the  composite   extruder  head  specifically.  On  Thursday  the  team  initially  meets  with  Dr.  Radford,  along   with  the  other  Boeing  composite  teams  for  a  short  period.  Afterwards  Team  Extruder   has  its  own  meeting  to  prepare  questions  and  concerns,  while  the  3D  contour  team   meets  with  Dr.  Radford.  After  meeting  with  the  team’s  advisor  there  is  another  short   team  meeting  to  discuss  what  was  just  covered  and  what  needs  to  be  done  for  the  next   week,  including  goals  and  specific  tasks  for  each  team  member.      
• 13.
      Composites  Extruder  Head  Development       Every  Wednesday  night  before  our  team  meeting  with  Dr.  Radford  everyone  in   the  team  completes  an  individual  progress  report  which  details  what  they  accomplished   in  the  last  week  and  what  they  hope  to  accomplish  in  the  upcoming  week.  The  project   manager  also  completes  a  progress  report  for  the  entire  team  that  is  sent  to  Dr.   Radford.  The  team  progress  report  also  includes  questions  and  concerns  that  the  entire   team  would  like  to  discuss  and  any  additional  documentation  that  is  separate  from  the   report.  These  progress  reports  are  sent  to  Dr.  Radford  no  later  than  8:00  AM  the  day  of   the  meeting  and  are  stored  in  a  folder  on  the  team’s  drive  for  reference.  Every  other   week  the  team  also  gives  a  PowerPoint  presentation  to  Dr.  Radford  covering  much  of   the  same  information.   Other  meetings  times  are  scheduled  as  needed  to  complete  certain  tasks.     Table  6  -­‐  Team  Meeting  Times   Tuesday   Wednesday   Thursday   Other  Days   1:30pm  -­‐  Combined   meeting  with  3D   Contour  Team  and   Boeing  Cascade  Basket   team(Cascade-­‐First   Tuesday  of  the  month)   -­‐  Separate  team   meeting  afterwards   Individual  and  team   progress  reports  finished   and  sent  by  the  end  of   the  day  Bi-­‐weekly   progress  report  finished   and  sent  every  other   week   2:00pm  -­‐   Combined  advisor   meeting   2:15pm     -­‐  Team  meeting   time  3:15pm     -­‐  Meeting  with  Dr.   Radford   3:45pm     -­‐  Quick  team  recap   Meetings  as   necessary  to   complete  tasks          
• 14.
      Composites  Extruder  Head  Development       Timeline  and  Milestones     The  main  team  schedule  is  set  in  a  Gantt  chart  built  in  Microsoft  Project.  Important   milestones  which  are  closer  to  the  present  have  more  exact  dates  assigned  to  them.  In   order  to  complete  three  prototypes  within  the  allowed  time  for  this  project  milestones   are  set  very  close  together  and  sometimes  overlap.  Some  important  milestones  are:     ● Oct.  6th:  Turn  in  project  plan  document     ● Week  of  Nov.  9th:  Complete  concept  generation  and  evaluation  for  fiber-­‐ filament  and  fiber-­‐pellet  extruder  heads     ● Week  of  Nov.  16th:  Complete  testing  and  evaluation  of  commingled  tow   extruder  head     ● Dec.  3rd:  Critical  decision  meeting  to  determine  focus  on  commingled  tow  or   fiber-­‐filament  extruder  head  development     ● Week  of  Dec.  14th:  Complete  full  3D  CAD  and  2D  drawings  for  fiber-­‐filament  and   fiber-­‐pellet  extruder  heads,  begin  fiber-­‐filament  extruder  head  manufacturing     ● Week  of  Jan.  18th:  Finish  fiber-­‐filament  extruder  head  manufacturing     ● Week  of  Jan.  25th:  Finish  fiber-­‐filament  extruder  head  assembly  and  begin   testing,  begin  fiber-­‐pellet  extruder  head  manufacturing     ● Late  Feb.:  Critical  decision  meeting  to  determine  focus  on  fiber-­‐filament  or  fiber-­‐ pellet  extruder  head  development,  finish  fiber-­‐pellet  extruder  head  assembly     ● Mid  Apr.:  E-­‐Days,  finish  extruder  head  project  and  present,  begin  integration   with  other  Boeing  Composite  teams  to  print  composite  cascade  basket     ● Early  May:  Finish  integration  with  other  Boeing  Composite  teams  and  attempt   full  composite  cascade  basket  print        
• 15.
      Composites  Extruder  Head  Development       Concluding  Statement     This  project  plan  was  intended  to  communicate  what  the  Composites  Extruder   Head  Development  Team  will  be  working  on  for  the  academic  year.  Three  iterative   design  processes  will  be  used  to  develop  the  capability  to  print  with  three  different   forms  of  feedstock  material.  Difficulties  of  the  development  lie  in  achieving  wetting   between  fibers  and  matrix  as  well  as  between  layers  and  the  previously  produced  layer.   Evaluation  of  the  successes  put  forth  by  the  team  most  notably  involve  producing  a   composite  material  of  high  quality.     Budget  Breakdown     Table  7  -­‐  Team  Budget  Allotment   Item     Description   Estimated  Cost   3D  printer   A  commercially  available  3D  printer  which  can   fit  our  extruder  head.  Will  be  used  to  print   test  articles  for  all  three  prototypes.  Split  with   Contour  Team   $600  ($1200  split   evenly  with  contour   team,  printer  may  be   donated/discounted)   Pico  B3  hot   end   Commercially  available  hot  end  for  extruder   which  will  allow  printing  of  commingled  tow   $150  (includes   shipping,  base  plate   cost)   Glass  fiber   and  PP   commingled   tow   Commingled  glass  fiber  inside  PP  matrix  to  be   used  for  first  prototype   $0  (provided  by   advisor)   Glass  fiber   E-­‐glass  fibers  used  as  reinforcing  material  in   second  and  third  prototypes   $40  (6  kg  of  fiber)   PP  filament   PP  matrix  in  filament  stock  form,  for  use  in   prototype  two   $80  (2  kg  of  filament)   PP  pellet   stock   PP  matrix  in  pellet  stock  form  for  use  in   prototype  three   $45  (10  lbs  of  pellets)   Production  of   custom  hot   ends   Professional  machining  for  prototype  two  and   three  hot  ends   $600  ($60  per  hour)   I2P  printer  lab   printing   Printing  of  dual  extruder  head  and  prototype   parts  for  all  three  prototypes       In  total  the  Team  was  allocated  2,000  dollars  to  complete  all  three  prototypes.   This  money  was  granted  through  our  advisor,  Dr.  Radford,  for  use  on  this  project.      
• 16.
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