3D Printer Design Evolution

Table of Contents:

1. Requirements & Quality Control
1. Axis
1. Overall Requirements
2. Carriagem
3. Idler Side
4. Motor Side
2. Frame
3. Electronics
4. Wiring
5. Overall
2. BOM
• Single Axis - Carriage + Idler + Motor
• Basic 3D Printer
• Axes
• Extruder
• Heated Bed
3. Fabrication Diagram
• 1 Axis
• Frame
• Overall Mechanical
• Electronics
• Wiring
• Overall Assembly
4. Scaling Calculations
• Deflection limits
• Maximum allowable sizes
5. Design Evolution Concept
• Interface Concept Design
• Interface Technical Design
• Scalability
6. FreeCAD
7. Try 2

Table of Contents:

• Visual BOM

Systems Engineering Breakdown Diagram

Extruder

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Frame

Michel

Heated Bed System

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2D Fab Drawings

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BOM for Single Axis

Auto Bed Leveling

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Collaboration

Marcin

Dr. Helmi

Jonathan

Dorkmo

Jeshua

DE People

Moushira

Ian

• Cut off ⅓ on the idler side
• On motor side - cut off as much as possible to leave Nema 23 available

3DPCS December 16-18 Critical Path

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

First Axis Complete

Sep 9

Start

Aug 18

Enclosure

Complete

2x2’

Sep 18

Bas - Franklin Webinar

Aug 26

Complete Sourcing

Rambo Tested with Firmware

Franklin Including Bed Leveling + Scalable Controller

Sep 9

Publish Registration

Oct 25

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Full Machine with Controller + Bed Level

Oct 18

Dec 15

Workshop

Print All Participants Parts

Heated Bed + Surface + Springs

12x12”

Oct 2

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Extruder

October 2

USA

Build + Quality Control

Oct 3

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3D Part Printing

Nov 18

USA Build + Quality Control Nov 4

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Build Lulzbot Extruder DIY

Franklin Including Bed Leveling + Scalable Extruder

Sep 9

Sep

Oct

Nov

Dec

Sep. 9 - CNC Torch Table w/ 1” rods

Sep. 1 - Rambo and 1 Axis Motion tested with height controller

3D Printer Setup - athena setup instructions on Appropedia

December 16-18 Critical Path Checklist

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Calendar

Workshop

Print All Participants Parts

• Start Aug 18th
• Bas Franklin Webinar Aug 26
• Contact Bas
• Franklin Including Bed Leveling Sep. 9th
• Working meeting with Bas
• Scalable controller
• Rambo Test with Firmware
• Selected Franklin or Marlin
• Enclosure Complete Sept 18th
• Order Cut from Sweiger
• Order fasteners + Assemble Enclosure
• If works, get a cut done in Belgium
• Assemble
• First Complete Axis Sept 18th
• Iterations + review
• Fits both ½” and 12 mm version
• 3mm correction
• Print prototype axis
• Marcin (USA Replication + QC)
• Heated bed + Surface + Springs
• Source heated bed & secure parts
• Secure print surface + springs
• Review: PEI, BuildTak, Glass, Or Aluminum
• Order & Secure surface
• Full Machine with Controller + Bed Level Oct 18th

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Weekly Check-in Dates (Performance Review)

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• Week 16 Aug. 25th
• Week 15 Sept. 1st
• Week 14 Sept. 8th
• Week 13 Sept. 15th
• Week 12 Sept. 22nd
• Week 11 Sept. 29th
• Week 10 Oct. 6th
• Week 9 Oct.13th
• Week 8 Oct. 20th
• Week 7 Oct. 27th
• Week 6 Nov. 3rd
• Week 5 Nov. 10th
• Week 4 Nov. 17th
• Week 3 Nov. 24th
• Week 2 Dec. 1st
• Week 1 Dec. 8th
• Week 0 Dec. 15th
• Workshop Dec 16th-18th

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Production Machine

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Calendar

Workshop

Print All Participants Parts

• Example: MOST Delta 4-layer:

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• 4-head production machine: example http://www.thingiverse.com/thing:724999

Modules

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Calendar

Workshop

Print All Participants Parts

• Enclosure
• A
• B
• C
• D
• E
• F
• Axis
• X
• Y
• Z
• Electronics
• Controller
• Stepper Motors
• Heigth sensor
• Bed temp sensor
• ​

Visual BOM - Axis

1.247” thick double clam

0.3” indent

Screw should be 1” or ⅞”

[48] screws (4 per clam)

Hole needs to be large enough to countersink bolt head of motor

688 bearing

Zz is without rubber seal?

Visual BOM - Frame + Axes

[4]

[6]

[24]

Prototyping Diagram

[4]

[6]

[24]

[72]

[72]

Finished Product

Controller

Bolt Lengths

#8 screw:

11 ga steel (⅛”)

1/16” Bracket

1/16” Bracket

¼” lock nut

Total Length: 1/16”+⅛”+¼”+ = 7/16”

Thus, use ½” screw.

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ENCLOSURE (SYMMETRIC)

[24] Bracket - Zinc-Plated Steel, 1-1/2"

[72] #8 ½” screws or #8 ⅜” screws

[72] #8 hex lock nuts or #8 hex nuts

Overall Axis - Requirements

Axis Requirements -

• Starts with ½” or 12 mm rods as initial prototype
• 3D printed body and bushing fit together well
• Bushing can be either for 12 mm or ½”
• The bushing can be either 3D printed or stock. Stock bushing is interchangeable with 3D printed bushing
• BOM is optimized for minimum parts count and universal part sourcing
• Motor mount can accept nema 17-34 motors
• Carriage features optimized belt tensioning mechanism
• All mounting bolts have recessed bolt so no bolts protrude from 3D printed body
• For heavier duty applications of mounting to a panel frame, a steel plate can be used to stiffen the 3D printed body of Axis

Carriage Requirements

• OSE Patent-Pending LOL Quick Belt Tensioning System

Collaboration Ecology

For Distributive Enterprise

• Diversified Open Source Microfactory - MJ Piore’s Second Industrial Divide of flexible fabrication. Solution to ‘competition’ is diversification.
• Open Source Right Livelihood - metric of success - how many people un-job into regenerative livelihood

Core team

HR Team

3DP Construction Set Roadmap (Subset of Light Duty CNC CS)

Base Model -> full scalability -> multiple tool heads -> polycarb glazing, rubber tracks, aerial drones, cordless tool construction set, camera gear -> Enterprise Kit ->

Enterprise Construction Set

On Demand 3D Printing

Product Co-Creation

Online Ordering Platform

Online Useful Prints

Contributors:4 hour/week commitment

Web Platform: order, price, CNC files, viewing

HeroX Design Challenge: Crowd-funded Crowdsourced Design

Scribus Documentation

The Russians, Thomas Delvaux

Bas - Manual + ISO

Video Intro: Marcin

Renders - Michel

Workspace Creation

Blueprint3D

Documentation

Social Network: Minds

Jimmy Lin

(Rare Genomics Project)

PowerLolu

German RepRap

Edu Webinars

Includes Part Library, FreeCAD Instructional, Dedicated software - with automatic parametric design

Calendar

Print

Carriage + Bearing + Prototype with Rods

Deployment Plan:

1. Work with ½” for prototyping
2. Go to McMaster for Prototyping - 12 mm rods
1. Ultra machinable
2. O1 oil hardenable - $10
3. Menards hot rolled, 6’ - $9
3. Prototype Carriage with bushings and pegs
• Missing: possibly smooth ½” rod
• Missing: ¼” cap screws
4. Prototype End Pieces and full X Carriage assembly
5. Render on Sunday, Announce on Monday
6. Post event announcement by Aug 8 for July 8.

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Begin printing 1.5x7x10 cm pieces

Print

Motor and Idler, prototype full carriage

Publish on Kickstarter

Laser Cutting of frame begun

Sourcing Week

Publish Registration

Workshop in Belgium

Work on Enclosure

1. Router Render page 3
2. Contact Joshua for Franklin
3. Frame design

Priorities

Priority Plan

• Post Announcement - today.
• Send Michel $
• Print out XYZ axes - after determining any changes
• ½” linear bearing
• Source Bearings -
• Print Idler
• Design End Stop Holder
• Source Screws
• Design Frame - 2’ frame
• Rods are shorter than 2’
• Assemble working systems
• Consider heated build chamber

Begin printing 1.5x7x10 cm pieces

Laser Cutting of frame begun

Sourcing Week

Publish Registration

Sourcing Week

Work on Enclosure

Z Axis for Router

Front View

Z axis

Z axis

Router - attaches to end piece not carriage

X

axis

idler

X axis

X axis

idler

spacer

Z axis

Z axis

Z Axis

Z axis

router

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X

axis

Spacer

Front View

Z axis

Z axis

Router - attaches to end piece not carriage

X

axis

Z Axis for 3D Printer

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Carriage

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End piece

End piece

End piece

Platform

Carriage

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End piece

End piece

Platform

End piece

Platform

Z carriage

End piece

Print Surface - Spring Attachment

Front View

Top View

Structural Platform

- 3/16” aluminum

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Carriage

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End piece

End piece

End piece

Structural Platform - 3/16” aluminum

heater

PEI Surface

Springs used to

mount end pieces

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Carriage

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End piece

End piece

End piece

Structural Platform - 3/16” aluminum

heater

Adhesive surface

heater

heater

End piece

Need to select springs

[4] corner

bolts

Lucas Extruder?

http://www.thingiverse.com/thing:378330/#files

Router or Torch Application

Requirements for the Next Generation of Simplicity

After the French Revolution

Requirement: Change 3 3D Printed Pieces:

• Use 3 3D pieces inspired by x axis of Prusa i3
• Start with 12 mm rod
• 1 - Get rid of z rod mounting and threaded rod hole
• 2- belt mounting - next page
• Sourcing - for Belgium http://www.llamatech.be

1

2

3

Requirements for the Next Generation of Simplicity: Carriage Piece 2

After the French Revolution

Carriage Piece:

• Belt snaps in readily into place
• Uses completely repaceable bearings
• Use 4 bearings
• Bearing snap into a cylindrical hole
• They bottom out against each other
• Not Stackable sidewise
• Stackable back to back
• Stackable top to top upon using a sandwich interface metal plate
• Allows for tensioner clips
• Has square bolt pattern of 9 bolts

2

Pull belt to tighten, then instert plug from other side

Tension Data:

1. - 6 lb working strength for ¼” 2M Power Grip GT2
2. Second source - 6 lb working strength

Belt Mounting: Option 1. No go.

In place belt mounting

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Profile fit

Smooth fit

Peg

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pulley

Drive motor

Belt Mounting: Fixing Hole Only

There are 2 holes, one is fre

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Procedure:

• Fix end 1 as above (10 sec)
• For side 2, pull the blue belt through the hole in peg (thread it thru peg 1) (10 sec)
• Put in peg 2 (5 sec)
• Can’t move - belt teeth catch on 3D printed teeth of carriage

Slightly tapered peg with hole through it

‘Peg’ is part of hole

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1

2

Belt Mounting: Fixing Hole Only

There are 2 holes, one is fre

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Procedure: tension belt with 2 hands, then wrap belt around so you can hold with 1 hand, then set screw with other hand.

Smooth fit

‘Peg’ is part of hole

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peg

Pulleys, belts and bearing

Link to Pulley

RepRap Forum Review

Discussion of

Microstepping

Universal Motor Mount

Pulley Mount

System Integration

Y

Y

X

Y

Y

Idler Pulley

Strategy:

• Use a 3D printer running surface around a metal bearing
• 3D printed piece is 2-piece clamp around bearing

bearing

3D printed

Control Code

• Franklin - source paper
• Frankling - Appropedia
• And use open source controller, Nema 3A
• Proabably use RAMBO

Workshop Positioning

3D Printer Construction Set Workshop

• World’s first Construction Set for 3D printers
• Build your own 3D printer which can be built in different sizes and shapes by using a modular design
• Size of 3D printer can be anywhere from a few inches to 8’
• Stacking, elongation, and enlargement of common parts allow for a printer of any size to be built.
• Design accommodated sufficient robustness to build CNC torch tables, CNC laser cutters, and CNC routers based on the same part set

Basic Model

• Stationary build platform
• CNC cut metal frame

Small model

6”x6”

No frame

Basic model 1’x1’

No frame but stacked

Or frame no stack

Or no frame no stack

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Supersized, stacked version for 3D Printing

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4’x4’x8’

Definitely frame + stack

Torch table version

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4’x4’x8’

Laser cutter

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4’x4’x8’

Router Version (stiff)

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4’x4’x8’

Carriage Concept 1

No holes for belt yet

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Requirements for the Next Generation of Simplicity: Carriage Piece 3

After the French Revolution

Idler Piece:

• Pulley mounting
• Stackable back to back
• Stackable top to top via interface plate sandwich
• Rod hole captures the rot
• Clamp sandwich design to catch rods, and allows pulley to be mounted easily
• Nutcatcher on both sides, using a set screw, so you can tighten from either side

2

pulley

Rod hole

Rod hole

Assembly holes

Pulley

hole

X to Y Connection - Idler or Stepper to Carriage Connection

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Rod hole

Rod hole

Pulley

hole

Use ½” bolt hole

X idler

X idler

X

Y

Y

Universal NEMA Stepper Motor

Mount Piece

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Rod hole

Rod hole

Pulley

hole

1. 2-piece clamp design

Nema Stepper Motor Sizes - make this fit Nema 17, 23, 34, and 42

3”

3.5”

X to Y Mounting

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y carriage

X idler

rod

X idler

Y carriage

Use a shorter bolt with nut catcher.

Option for Attaching in More Complex Ways

After the French Revolution

Carriage Piece:

• ​

2

Pull belt to tighten, then instert plug from other side

Holes for assembly

Carriage + 2 End Pieces in One

Design Rationale:

• You can mount pieces on the face
• Infinitely stackable with longer bolts

Face

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2 piece

construction

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Y

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X

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Rigid Design

Design Rationale:

• dfad

Rigid Corner Bracket

Design Rationale:

• The Belgian Waffle

that saved the world

• Same can be done with corner

Bracket that uses rods.

3D Printer Design Iteration

• Starting from Folger Tech Prusa, we replace the frame with an enclosure
1. First iteration is used to test the frame
• Then we mount the print bed on 2 Z axes, and have all XY motion on print head
• Once the frame works - use the same z motors to carry the print bed
• Build x, x, and y axes to carry the extruder
• To reduce unique part count, convert the z axis to a belt drive just like the x + y axes

just like Scoovo

Folger Technologies

Prusa i3

OSE Version, Workshop 2

Original Build

Added Enclosure

Frame is removed from Prusa i3, and steel panels are added. Components attach to steel panels.

Stationary Print Bed

z

z

x

y

x

Why Enclosure and Stationary Print Bed?

• Enclosure advantages:
• Less time to heat up the bed, especially in cooler weather
• Higher quality prints due to more uniform temperature
• Less warping
• Contains fumes
• Enclosure Disadvantages:
• More materials
• Less access to parts
• Stationary Print Bed Advantages:
• Higher quality prints because bed does not move around
• Ability to print tall structures - structures shake on the platform if they are tall and thin
• Scalable to any 3D printer size - an object may otherwise become too heavy for the motion motors if it is being printed on a moving surface
• Stationary Print Bed Disadvantages:
• More complex 3D printer design

Interface Design

• 2 z motors
• 2 z rod holders
• 4 y rod holders
• Power Supply
• Y belt holder
• Y motor

To add the frame, need to interface components with the frame.

Interface Design 2

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• 2 z motors
• 2 z rod holders
• 4 y rod holders
• Power Supply
• Y belt holder
• Y motor
• Controller

Front Panel

Side Panel

Holes in steel panels are used to mount the various components.

Front Panel

5.45” (138.4 mm)

Elongate this 8 mm to make for robust fit.

0.31” diameter

(8 mm)

Bearing Holder

Z Rod

Z Rod

1.2” from center of z rod

Z motor mount

12.75”

Frame Width 15.15”

Frame Height - 12.15”

4.75”

2.6”

To belt

1.65”

2”

1”

1.5”

1.5”

12.15”

9.15”

Height drops to 1.75” after holes. Not. Reverse the thumb screws.

Menards.com

McMaster.com

Misumi

Front Panel

Updated Front

Panel

5.45” (138.4 mm)

Z Rod

Z Rod

12.75”

Frame Width 18.5”

Frame Height - 15.5”

4.75”

2.6”

To belt

1.65”

2”

1.5”

1.5”

1.5”

15.5”

12”

Z motor Bracket attached to back, not side, using a 1” standoff (due to 12” depth of frame)

1.25”

Side Panel

Side Panel

5.9”

Elongate this one to make for robust fit.

Controller

1.5”

1.15”

Z Motor

Power Supply

Motor & idler pulley

Part Substitution Strategy

Elongate this one to make for robust fit.

Bearing

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100 Skate Bearings

LM8UU linear bearing

3D Printer Scalability

• New Design allows for scaling the 3D printer to any size:

stacking or doubling of axes may be used

Design Evolution

Design Evolution: Extensive Scalability

By side to side addition - good for xy platform

These faces attach to the platform.

Put these side by side

D= separation between axis modules

D’=length of platform

For quadrupod If D’<<D we are not running into the 4 point problem

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For Tripod, can have D=D’

This is where you attach the additional axis, for unlimited scalability (biomimicry). This works for reasons of industrial ecology

Design Evolution: Extensive Scalability

By top to top addition

Side

Top (or back)

• Stack these back-to-back.
• Limit 2 if stepper motor is in the way
• Stagger them
• No limit - infinite scalability

Design Evolution: Intensive Scalability

Tripod Version

Tripod Version with stacked Z Axis on 1 tripod leg

Tripod Version, Scaled

Review Request:

Comment

Here.

Responses:

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(1) Trinus

(2) Ormerod

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Design Evolution: Scaled in x, y, z

3D Printed Bearings Bushings

Review: from Fab Academy

Carriages

Other Interesting Material

Carriage Requirement

• 3 Parts: Left, Right, Middle

• 2 holes for rods
• Bolt system for mounting to frame
• Bolt system for mounting to back-to-back
• Bolt system for mounting to side-to-side
• Hole for pulley and pulley mounting

• Same as left, except with additon of stepper motor mouting

Left

Right

Middle

Carriage Requirement

• 3 Parts: Left, Right, Middle

• 2 holes for rods
• Bolt system for mounting to frame
• Bolt system for mounting to back-to-back
• Bolt system for mounting to side-to-side
• Hole for pulley and pulley mounting

• Same as left, except with additon of stepper motor mouting

Left

Right

Middle

Initial Concept

Stepper Motor Mounting Types

• http://techref.massmind.org/techref/io/stepper/nemasizes.htm

Scalability Calculations

Start with GT2 belt - load limit

To draw frame in FreeCAD

1. See FreeCAD Sketcher instructional video
2. Draw frame in a separate document
3. Draw frame edge connectors in FreeCAD or import existing angle bracket
1. 3D printed corner bracket is preferred since it can be printed in house
2. Make it robust - using ½” bolt hole
4. Import bolts
5. Import frame
6. Scale parts accordingly -
7. Move and rotate them

Importing Parts into FreeCad

To import a part: Click File -> Import

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Then select from one of the many supported file formats

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Sketcher Script

Task description: Create a 2-3 minute instructional on one small part of the open source FreeCAD CAD software. This small part is the Sketcher Workbench (one of many toolsets available on FreeCAD). Extract and streamline content from existing instructional videos to create an excellent summary video. We are doing this because most videos are not tight and could be improved significantly so people can learn CAD from them faster. Further, we are creating a workflow where others could continue improving the video - collaboratively in the open source. To do this, there are 10 steps. Ask questions whenever you are not sure.

1. Find and view existing FreeCAD Sketcher Workbench instructionals on YouTube, etc, as well as read other instructionals on the Sketcher. See MJ Log for related work on the Sketcher Workbench.
2. Embed the videos on an OSE Wiki page that you create (you need to register on the wiki). Link to any other instructionals that you have read.
3. Select useful parts for each video - embed at a specific time that shows a useful part, and put a text transcript for the useful part below the video.
4. Download and install FreeCAD 0.16
5. Download Kdenlive.
6. Use screen capture to add any additional clips of you working within FreeCAD Sketcher, showing other useful instructions that may not have been covered in existing videos - perhaps on things that were not clear to you. If you feel that existing videos are not so valuable, use your own screen captures instead. Make sure you have sound (note how many of the existing videos don’t).
7. On your wiki page, list and link to all the clips you used in your video (including your own - for which purpose you will need to upload the video to your own YouTube channel), and if you used other images, upload them to the wiki or link to them. Use OSE Logo for branding.
8. Upload your Kdenlive source file to the wiki, so others can edit it collaboratively using your clips and images.
9. Post the video on your YouTube channel or in some other online location.
10. Keep track of all your progress on your Work Log. At the end, write down any comments and suggestions that you have for making this exercise more useful as a part of an application process for selecting motivated, inter-disciplinary candidates.

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Criteria for evaluation:

• Overall Task Completion is more important than quality of individual steps. Read the overall task first, and work on solving the entire task - as opposed to prioritizing completion of each step in a linear fashion.
• Collaborative effort used throughout the task - don’t go off into a corner to do this yourself, use as much help as possible. This demonstrates whether you can learn openly by becoming vulnerable to feedback when you don’t have all the answers.
• Ability to document results - a big part of the task is documenting your results for time-binding by others
• Entrepreneurial aspects - how enterprising are you when you do this task? That means, you approach the task strategically. For every step, you understand the intent of the step, so that you can meet its objectives more closely
• Actual product value - How good is the 2-3 minute instructional that was produced? This is the last question. The process to get there, and process to involve others and to allow further collaboration - are the main objectives of the task.

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Video Instructional for Sketcher - 2-3 Minutes

Questions to answer:

What can you draw with the sketcher? How do you set correct dimensions? How do you export to DXF?

Can you move things in sketcher? How do you get into edit mode within Sketcher? How do you select different items in Sketcher?

How do you extrude a sketch? How do you export to STL?

How do you draw a square? What navigation mode do you need to be in?

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Key Performance Indicator (JK Notes)

Outcomes:

• Fully functioning -
• High performing printer -
• Parallel
• Modularity
• Cost Per Print -
• Cost per axis - 6 Pieces per axis - 18 pieces - 8-10 hrs for one axis
• Total Cost of the printer -
• Evaluating cost of the R&D

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Modules

• Enclosure
• Electronics
• Axis’
• ​