Biomedical Engineering Prototype Fabrication Studio. ProFab Studio. Summary of Phase I and Proposal for Phase II. June 08, 2016

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1 Biomedical Engineering Prototype Fabrication Studio ProFab Studio Summary of Phase I and Proposal for Phase II June 08, 2016 Prepared By Eric H. Ledet, Ph.D. Associate Professor Department of Biomedical Engineering

2 Overview: In 2014, the Department of Biomedical Engineering established the Prototype Fabrication Studio as a resource for BME students and faculty to fabricate physical prototypes of products and components. Since its inception, the ProFab Studio has been heavily utilized primarily by Capstone Design teams and undergraduate researchers. Graduate students and faculty have also utilized the ProFab Studio, but priority has been given to undergraduates. The ProFab Studio has been staffed by graduate students under the supervision of Professor Eric Ledet. The graduate students received training by the manufacturers of the equipment. During the summer of 2016, additional undergraduate and graduate students are being trained on the equipment in an effort to make the ProFab Studio a true maker s space. The ProFab Studio will continue its policy that all staff must demonstrate their ability to operate the equipment safely before being allowed independent access to the ProFab Studio. The Pro Fab Studio is located on the 7 th floor of the Jonsson Engineering Center in room JEC This strategic location, near the Biomedical Engineering Departmental Office and faculty research labs, facilitates maximum utilization and safe oversight of the ProFab Studio. While Phase I of the ProFab Studio has focused on fabrication of physical prototypes via 3D printing, water jet cutting, and CNC milling, we are proposing an expansion of the ProFab Studio s capabilities to now include electronic prototyping and testing. The proposed Phase II will expand the physical space of the ProFab Studio to JEC 7118 which has a pass-through door connecting it to JEC Phase II will include electrical diagnostic and electrical prototyping equipment. The Phase II expansion will be initiated during the summer of 2016 and will continue until completed. Residual funds from BME Capstone and future fund raising (coordinated with appropriate parties in SoE) will be used to fund the proposed Phase II expansion. A summary of Phase I and proposed expansion for Phase II are detailed below. Phase I In Phase I, the Pro Fab Studio was equipped with four major pieces of equipment for fabrication of prototypes: 4-axis CNC milling machine. Water jet cutter. 3D printer. Laser scanner. Detailed specs for these key pieces of equipment are described below. In addition to the major equipment, the Pro Fab Studio was equipped with two workstations for CAD/CAM. Significant resources were also used to outfit the ProFab Studio with tooling. Page 2 of 12

3 Major Equipment Phase I: 4-axis CNC Milling Machine A Haas DT-1 CNC mill with 4 th axis rotary table (HRT160) was acquired for fabricating metal and plastic parts. The 20 tool machine has a 15,000 rpm spindle which is suitable for machining large or small parts from a variety of materials including stainless steel. CNC code for milling operations is generated via CAMWorks. Two dedicated CAD/CAM workstations are used for conversion from solid models to CNC code. Conversion is performed by Pro Fab Studio staff. Water Jet Cutter Haas DT-1 CNC Mill A Maxiem 0707 JetCutting Center was acquired for fabricating metal, glass, and plastic parts from sheet stock. The machine has a 30 x 30 cutting area which is suitable for fabricating large components for most biomedical applications. The machine was purchased as a turnkey solution which includes computer interface and pump. Maxiem 0707 JetCutting Center Page 3 of 12

4 3D Printer A Stratasys uprint SE Plus 3D printer was acquired to fabricate complex three-dimensional parts from ABS plastic. The machine has an 8 x 8 x 6 build envelope which is suitable for most biomedical components. Parts can be print in layer thicknesses of or and can print in multiple colors. Support material is water soluble and the system comes with a support cleaning center. Stratasys uprint SE Plus Laser Scanner A NextEngine 3D Scanner HD laser scanner was acquired to reverse engineer components and generate solid models for reference. The machine facilitates single and multi-pass scanning for objects up to 23 x 17. The built-in software generates points, NURBS, or solid model files. The multi-drive accessory allows scanning of small objects without repositioning. The scanner is interfaced with one of the Pro Fab Studio workstations. Page 4 of 12

5 NextEngine Laser Scanner (left) and Multi-Drive Table (right) To complete Phase I and maximize the ProFab Studio s capabilities for fabrication of physical prototypes, additional equipment will be acquired. The additional equipment includes: Manual vertical milling machine. Gap bed lathe. Bandsaw. Manual Vertical Milling Machine. A Grizzly 8 x 30 variable speed milling machine will be used for fabricating metal and plastic parts. The machine is complimentary to the CNC mill and is suitable for manual machining of simple medium or large parts when setup is quicker than generating CNC code. Page 5 of 12

6 Grizzly 8 x 30 Variable Speed Milling Machine Gap Bed Lathe A Grizzly 12 x 24 gap bed lathe will be used for fabricating metal and plastic parts. The machine is complimentary to the mills and will allow the ProFab Studio to do stand-alone fabrication of a wide variety of parts. Metal/Wood Cutting Bandsaw Grizzly 12 x 24 Gap Bed Lathe (stand not shown) A Grizzly 17 metal/wood cutting bandsaw will be used for sizing raw stock. The machine is complimentary to the mills and lathe and will allow the ProFab Studio to do stand-alone fabrication of a wide variety of parts. Page 6 of 12

7 Grizzly 17 Metal/Wood Cutting Bandsaw Page 7 of 12

8 Expenditures Phase I: 4-axis CNC Milling Machine $63,000 Haas DT-1 4 th Axis Drive & Wiring 4 th Axis Rotary Table Ethernet Interface Toolholder Tooling Package Water Jet Cutter $66,000 Maxiem HP 50,000 psi Pump Toolbox Nozzle & Pump Spares Kit 3D Printer $35,000 Stratasys uprint SE Plus 3D printer Support Material Removal System Startup Kit 3-Year Comprehensive Pack Laser Scanner $ 7,500 Next Engine 3D Scanner HD MultiDrive Rotary Table HD Pro Software CAD Tools Software Workstations $ 7,000 CAMWorks License $ 1,000 Tooling/Fixturing $ 10,000 +/- Measuring Tools, Hand Tools, Safety $ 5,000 +/- Facilities $ 9,000 +/- Space outfitting for equipment. Wiring/power for water jet and mill. Hard water line for water jet. Movable barrier for water jet. Page 8 of 12

9 Continuation of Phase I Manual Milling Machine $ 7,000 Grizzly 8 x 30 variable speed milling machine Lathe $ 6,500 Grizzly 12 x 24 gap bed lathe Bandsaw $ 1,900 Grizzly 17 metal/wood cutting bandsaw Phase II In Phase II, the Pro Fab Studio will be equipped with several key pieces of equipment for electronic prototyping and instrumentation development and testing. Key equipment will include: Counter-top printed circuit board prototyping system. High speed digital data acquisition systems. Digital oscilloscopes. Power supplies. Function generators. Solder and de-solder stations. Detailed specs for these key pieces of equipment are described below. In addition to the major equipment, the Pro Fab Studio will house three workstations for interfacing with the data acquisition systems and the necessary electronic prototyping components to support fabrication. Major Equipment Phase II: Rapid PCB Prototyping System A LPKF Laser & Electronics ProtoMat PCB Prototyper will be used to fabricate prototype printed circuit boards. The ProtoMat is used to mill single or double sided copper clad boards to form traces and recesses for custom PCBs. The boards are prepared to be populated with electronic components which can be soldered directly to the board. A through-hole plating system is used for fabricating two sided boards. The through-hole electroplating system is a stand-alone unit which processes boards after they are fabricated with the ProtoMat system. Page 9 of 12

10 LPKF S63 ProtoMat PCB Prototyper (left) and Through-Hole Electroplating System (right) High Speed DAQs Two National Instruments PXI 16 channel high speed digital data acquisition systems and four USB 4 channel basic DAQs will be used to interface workstations and student laptops with a variety of signal conditioning systems. The PXI systems sample at rates of 2 MS/s and buffer data for transfer to a PC via a USB connection. Interface cards to interface with a variety of electrical signals will be included with the systems. Three National Instruments USB DAQ 4 channel digital data acquisition systems will be used to interface workstations with a variety of signal conditioning systems. The systems are small and simple to interface for instrumentation prototyping purposes. The PC interface with the DAQ systems is LabView which is available to all RPI students via a campus license. Students use LabView in several courses and in many labs at RPI. National Instruments PXI 16 Channel High Speed Digital Data Acquisition System Digital Oscilloscope Two Tektronix TDS2024C digital storage oscilloscopes will be used to test and debug prototype electronic systems. The scopes are 4 channel with a bandwidth of 200 MHz and sample Page 10 of 12

11 rate of 2 GS/s. The scopes interface with a PC via a USB connection and data can be captured in LabView. Tektronix TDS2024C Digital Storage Oscilloscope Power Supplies Two BK Precision two channel programmable dual range DC power supplies will be used to test prototype electronic systems. The supplies are regulated linear DC power supplies which can be setup manually or using a USB interface with LabView on a PC. Function Generator BK Precision 9174 Programmable Two Channel Linear DC Power Supply A Tektronix AFG3101 C arbitrary function generator will be used to test prototype electronic systems. The function generator is capable of generating up to 100 MHz wave forms with a vertical resolution of 14 bits and a sample rate of 250 MS/s. Tektronix AFG3101 C Function Generator Page 11 of 12

12 Microprocessors Multiple microprocessors (Arduino Uno, Arduino Mega, Arduino MKR1000, Arduino Gemma) will be acquired for prototyping. Appropriate breadboards and circuit prototyping components will also be acquired to interface with the microprocessors for prototyping purposes. Proposed Expenditures Phase II: PCB Prototype System $35,000 LPKF S63 ProtoMat PCB Prototyper Through-Hole Electroplating System Starter Package Data Acquisition $9,000 (2) National Instruments PXI 16 channel DAQs including signal conditioning cards. (3) National Instruments USB 4 channel DAQs including signal conditioning cards. Digital Oscilloscope $ 5,000 (2) Tektronix TDS2024C 4 channel 200 MHz 2 GS/s digital storage oscilloscopes. Power Supplies $ 3,000 (2) BK Precision 9174 Programmable 2 channel DC power supplies. Function Generator $ 4,300 Tektronix AFG3101 C arbitrary function generator. Workstations $ 6,000 (3) Workstations for prototyping, testing, DAQ interface. Microprocessors, Equipment, & Supplies $ 5,000 +/- Multi-meters, probes, protoboards, wires, ICs, analog components, wire, solder, etc. PCB prototype supplies. Tables, stools, storage. Facilities $ 5,000 +/- Page 12 of 12