Santa Clara University

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Mechanical Engineering Senior Theses Engineering Senior Theses

6-8-2015

AkaBot 2.0: pet 3D printing filament from waste

plastic
Jay Dubashi
Santa Clara University

Brian Grau
Santa Clara University

Alex McKernan
Santa Clara University

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Dubashi, Jay; Grau, Brian; and McKernan, Alex, "AkaBot 2.0: pet 3D printing filament from waste plastic" (2015). Mechanical
Engineering Senior Theses. 44.
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AKABOT 2.0: PET 3D PRINTING FILAMENT FROM
WASTE PLASTIC

By

Jay Dubashi, Brian Grau, Alex McKernan

SENIOR DESIGN PROJECT REPORT

Submitted to
the Department of Mechanical Engineering

of

SANTA CLARA UNIVERSITY

in Partial Fulfillment of the Requirements

for the degree of
Bachelor of Science in Mechanical Engineering

Santa Clara, California

2015
 Abstract

Extrusion is how 3D printing filament is created. Melted plastic is pushed through an

extrusion die and is shaped into a long thin strand of plastic. Extrusion machines are
usually sized for industrial use, capable of creating hundreds of feet of filament a day.
This filament is expensive to purchase, and many end-users would prefer to extrude
their own filament, from a virgin plastic input or plastic waste input. There are no home-
scale filament extruders on the market for Polyethylene Terephthalate (PET) plastic
waste. AkaBot was designed to allow end users to produce their own filament from a
PET plastic input. AkaBot was designed and manufactured to created filament that has
the required ductility for spooling and use in a 3D printer. It functioned well with PET
pellets as the plastic input, but it was not as successful when trying to use recycled
water bottles. The final filament product is dependent on the tension put on the filament
as it exits the machine. At present, a skilled human operator is required to consistently
produce acceptable filament. An automated spooling system for the filament would
greatly improve the consistency of the output and decrease the cost of using AkaBot.

iii
 Acknowledgements

We would like to thank The Miller Center for Social Entrepreneurship at Santa Clara
University for funding our project.

We would like to thank our faculty advisor, Dr. Panthea Sepehrband, for all of her
support and help to make this project become a reality.

We would like to thank Donald MacCubbin, Joe Soares, and Calvin Sellers for all of
their help with the design and manufacturing of our prototypes.

We would like to thank Dr. Hohyun Lee from the Mechanical Engineering Department
for his help with various tests.

Finally, we would like to thank our friends and family who collected water bottles for us
throughout the project.

iv
 Table of Contents
Abstract ........................................................................................................................... iii
Acknowledgements .........................................................................................................iv
Chapter 1: Introduction .................................................................................................... 1
1.1 Background .................................................................................................... 1
1.2 Review of Field ............................................................................................... 3
1.2.1 Plastic Extrusion Process ................................................................. 3
1.2.2 Differential Scanning Calorimetry...................................................... 5
1.3 Project Objectives........................................................................................... 6
Chapter 2: Systems-Level ............................................................................................... 7
2.1 Customer Needs............................................................................................. 7
2.2 Benchmarked Results .................................................................................... 7
2.3 System Level Requirements ........................................................................... 9
2.4 System-level Sketch ....................................................................................... 9
2.5 Functional Analysis ....................................................................................... 10
2.6 Design Process ............................................................................................ 11
2.7 Key System Level Issues.............................................................................. 12
2.8 Hardware Limitations/ Lead Time ................................................................. 12
2.9 Team and Project Management ................................................................... 13
2.10 Budget ........................................................................................................ 14
Chapter 3: Materials ...................................................................................................... 16
3.1 Material Testing ............................................................................................ 16
3.2 Preparation ................................................................................................... 18
Chapter 4: Machine Design ........................................................................................... 20
4.1 Machine Overview ........................................................................................ 20
4.2 Hopper .......................................................................................................... 21
4.3 Chamber and Heating .................................................................................. 22
4.3.1 Chamber and Heating Overview ..................................................... 22
4.3.2 Chamber ......................................................................................... 22
4.3.3 Band Heaters .................................................................................. 24

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 4.4 Extrusion....................................................................................................... 25
4.4.1 Extrusion Overview ......................................................................... 25
4.4.2 Custom Auger Design ..................................................................... 25
4.4.3 Commercial Augers ........................................................................ 26
4.5 Die ................................................................................................................ 27
4.5.1 Die Overview .................................................................................. 27
4.5.2 Die Design ...................................................................................... 27
4.6 Cooling ......................................................................................................... 29
4.6.1 Cooling System Overview ............................................................... 29
4.7 Controls ........................................................................................................ 30
4.7.1 Controls Overview........................................................................... 30
4.7.2 Heating System............................................................................... 30
4.7.3 Motor............................................................................................... 33
Chapter 5: System Integration ....................................................................................... 35
5.1 Assembly and Systems Testing.................................................................... 35
5.2 Extrusion Process ......................................................................................... 35
5.3 Extrusion Testing .......................................................................................... 37
Chapter 6: Cost Analysis ............................................................................................... 42
6.1 System Cost ................................................................................................. 42
6.2 Economic Analysis ....................................................................................... 43
Chapter 7: Business Plan .............................................................................................. 45
7.1 Executive Summary ...................................................................................... 45
7.2 Introduction ................................................................................................... 45
7.3 Goals and Objectives ................................................................................... 46
7.4 Description of Product .................................................................................. 47
7.5 Potential Markets .......................................................................................... 47
7.6 Competition .................................................................................................. 48
7.7 Sales & Marketing ........................................................................................ 50
7.8 Manufacturing ............................................................................................... 50
7.9 Product Cost and Price ................................................................................. 51

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 7.10 Service & Warranties .................................................................................. 51
7.11 Financial Plan ............................................................................................. 51
Chapter 8: Engineering Standards and Realistic Constraints........................................ 53
8.1 Economic ...................................................................................................... 53
8.2 Environmental............................................................................................... 53
8.3 Manufacturability .......................................................................................... 54
8.4 Health & Safety............................................................................................. 54
8.5 Social ............................................................................................................ 55
8.6 Santa Clara University Arts Requirement ..................................................... 56
Chapter 9: Conclusion ................................................................................................... 57
9.1 Summary ...................................................................................................... 57
9.2 Future Work .................................................................................................. 57
Appendix A: Bibliography .............................................................................................. 58
Appendix B: Calculations .............................................................................................. 60
Appendix C: Project Design Specifications (PDS) ......................................................... 62
Appendix D: Decision Matrix ......................................................................................... 63
Appendix E: Timeline .................................................................................................... 64
Appendix F: Budget ....................................................................................................... 65
Appendix G: Senior Design Presentation Slides ........................................................... 68
Appendix H: Tensile Test Graphs and Results.............................................................. 76
Appendix I: Detailed Drawings and Assembly Drawings ............................................... 77

vii
 List of Figures
Figure 1: Anudip training facility. Photo courtesy of Anudip [1] ....................................... 1
Figure 2: Plastic waste buildup in India. Photo courtesy of Anudip [1] ............................ 2
Figure 3: Example of a DSC test result graph ................................................................. 5
Figure 4: Semicrystalline polymer structure. Photo courtesy of Journal of Chemical &
Pharmaceutical Research [5] ................................................................................... 6
Figure 5: AkaBot 1.0 machine before modifications ........................................................ 8
Figure 6: System-level sketch of extrusion process ...................................................... 10
Figure 7: Example of a DSC test result graph ............................................................... 17
Figure 8: DSC results of Crystal Geyser water bottles .................................................. 18
Figure 9: PET water bottles after cleaning and shredding ............................................. 19
Figure 10: Main subsystems ......................................................................................... 20
Figure 11: AkaBot 2.0 final machine.............................................................................. 20
Figure 12: Sheet metal hopper ...................................................................................... 21
Figure 13: SolidWorks rendering of the chamber .......................................................... 23
Figure 14: Heating band ................................................................................................ 24
Figure 15: Sections to an auger design. Photo courtesy of Polymer Mixing and
Extrusion Technology [9] ........................................................................................ 25
Figure 16: SolidWorks rendering of the custom auger design ....................................... 26
Figure 17: Commercial ship bore auger ........................................................................ 27
Figure 18: Brass die ...................................................................................................... 28
Figure 19: Section view of a SolidWorks rendering of the die ....................................... 29
Figure 20: Acrylic trough to hold cooling fluid ................................................................ 30
Figure 21: Electrical schematic for the control of a single heating element ................... 31
Figure 22: Sestos DIS-VR-220 PID temperature control unit ........................................ 31
Figure 23: Fotek solid-state relay for switching high voltage and high current .............. 32
Figure 24: Chain drive connecting motor and auger ..................................................... 34
Figure 25: Trough to guide material through cooling system......................................... 36
Figure 26: DSC test results of AkaBot 2.0 1.75mm filament extruded into 20C oil bath 38

viii
Figure 27: Stress-strain curve of 86mm long samples of purchased filament with a 1.80
diameter and AkaBot 2.0 filament 1 with a 1.77mm diameter and AkaBot 2.0
filament 2 with a diameter of 1.70mm .................................................................... 40
Figure 28: Economic comparison between purchased filament and filament produced by
AkaBot 2.0 ............................................................................................................. 44
Figure 29: FEA model of heat propagation from heating bands .................................... 61
Figure 30: Prioritization matrix for the design specifications of the cooling system ....... 63
Figure 31: Concept score in relation to baseline to determine best cooling system to use
............................................................................................................................... 63
Figure 32: Session 1 tensile test of AkaBot 2.0 and purchased filament ....................... 76
Figure 33: Session 2 tensile test AkaBot 2.0 and purchased filament ........................... 76

ix
 List of Tables
Table 1: System requirements for AkaBot 2.0 ................................................................. 9
Table 2: Timeline ........................................................................................................... 14
Table 3: Initial budget .................................................................................................... 15
Table 4: Parameters for custom designed auger .......................................................... 26
Table 5: Sestos DIS-VR-220 temperature control unit specifications ............................ 32
Table 6: Summary of specifications for the Fotek SSR-40 DA ...................................... 33
Table 7: Tensile test comparison .................................................................................. 41
Table 8: Material cost of Akabot 2.0 .............................................................................. 42
Table 9: Comparison of existing extruders on the market ............................................. 49
Table 10: Team members arts contributions ................................................................. 56

x
Chapter 1: Introduction

1.1 Background

Lack of access to education and training puts workers in developing countries at a

disadvantage when they build a business. Their enterprises struggle to compete with
cheaper foreign goods and services. We have partnered with Anudip, a non-profit
organization in India that provides job training to disadvantaged people, especially
women, in rural areas. Anudip provides resources and training to level the playing field.
Anudip has set up offices and training centers, seen in Figure 1, in India to teach
vocational skills and train workers looking to jumpstart their careers. They focus on
supporting small enterprises in rural villages. Anudip has already mentored over 200
different groups, and they continue to expand their operations. They operate over 150
training centers across Eastern India.

Figure 1: Anudip training facility. Photo courtesy of Anudip [1]

3D printing technology gives entrepreneaurs access to advanced manufacturing

techniques at a fraction of the previous cost. The technology is scaled down, from
factory to garage. Companies who previously lacked resources to make their ideas
come to life now have the opportunity to try new avenues. Importing expensive
filaments is the sole barrier to entry.

1
Used plastic water bottles are a constant problem in developing countries. The plastic
waste litters the streets, or ends up in landfills, as seen in Figure 2.

Figure 2: Plastic waste buildup in India. Photo courtesy of Anudip [1]

Utilizing this waste to make 3D printing filament solves two problems at once. It gives
entrepreneurs a cheap resource, and removes a damaging element from the
environment. A common pitfall that developing countries face is the expensive nature of
“green industries.” 3D printing gives them a cheap option without the cost barriers
associated with other green technologies.

AkaBot is different from other filament production machines on the market.

Commercially available machines at this scale require virgin pellets of acrylonitrile
butadiene styrene (ABS) or polylactic acid (PLA) plastic. They do not work with recycled
or virgin polyethylene terephthalate (PET). Recycled plastic is cheaper and more
accessible than factory produced pellets. AkaBot allows workers to create their own
filaments at a much lower cost than what is currently available on the market. Anudip
has supported this project from the inception, and AkaBot’s design will be vetted in their

2
training facilities. Plastic waste is a common problem in developing countries, and
AkaBot could be used by social enterprise partners across the developing world.

Small business development is the key to improving the lives of people in developing
countries. 3D printing is a versatile process that simplifies existing manufacturing
methods. Its simplicity allows for developing countries to grow their own manufacturing
base, instead of relying on foreign countries. They can create local sustainable
businesses to increase prosperity. 3D printing is the key that unlocks opportunities for
workers and entrepreneurs in developing countries. AkaBot moves one step closer to
that goal by giving them new options at a low cost.

1.2 Review of Field

1.2.1 Plastic Extrusion Process

The 3D printing process came from the need to quickly manufacture prototypes. While
today the growing field is becoming more and more complex to include
stereolithography and metals, 3D printing originally began with the use of extruding
plastics to print small simple designs. Even in this fast growing field, small scale
hobbyist 3D printers are still using extruded plastic filament in a fused deposition
modeling (FDM) process. This process takes the filament input, a thick thread of plastic
typically 1.75 mm or 3 mm in diameter, and melts it to produce a liquid plastic that is
then pushed out of the tip of the printer nozzle. 3D designs are created on a computer
and converted into the desired file format for the printer program and then sent to the
printer. The printer program takes the model and converts the 3D model into small
slices that can be printed at a consistent thickness. As the printer nozzle moves across
the base of the printer, it deposits a thin layer of plastic that cools quickly and hardens.
The printer then returns the nozzle back over the hardened plastic to add another layer
to the print. As the plastic layers harden on top of one another, they fuse together. This
slowly builds up to create the desired 3D part. [2]

3
The filament used in these FDM machines is critical for the functionality of the printer.
Manufacturing of 3D printing filament is done through extrusion. This extrusion process
is done by inputting plastic to a hopper, which then feeds it to a chamber. This chamber
is heated, melting plastic in a barrel and slowly pushing it out using a rotating screw.
This screw slowly builds up pressure forcing the melted plastic out the end through a
small hole, or die, at the opposite end of the machine. [3]

There are many nuances and key components when designing a filament extruder, one
of which is the die. The design of a die is extremely important to an extruding system.
The shape of the die determines the characteristics of the final filament. It is hard to
predict the exact behavior of the material, and this is where a series of equations can
make a rough prediction. In order to get a better understanding of the design, computer
modeling must be used to analyze the fluid dynamics of the flow through the die. [4]

Another critical design parameter of an extrusion device is the clearance between the
auger and the barrel. The tolerance between these parts for most designs is less than
0.001in (0.0025 cm). These clearances are important, but are difficult to calculate. This
clearance needs to be maintained over the entire length of the auger, which requires
precise alignment. If a system is not accurately aligned and the proper tolerances are
not maintained, then the wear on the motor and the auger will be great, reducing the
lifespan of the product. 3D printing filament needs to meet a specific tolerance in order
to be utilized by a printer. [5]

This can be controlled easily in a large-scale factory system, but specific measures
need to be taken to improve precision in small scale, household production. Improving
precision and achieving a consistent output is critical to having a good finished product.
This study focuses on the variety of tools available for PET extrusion, and the relative
precision of each product. Based on the final precision desired, different types of tools
are needed. High precision jobs need more precise and expensive equipment such as
6- axis CNC machines. [5]

4
1.2.2 Differential Scanning Calorimetry

Differential scanning calorimetry (DSC) tests are a very useful tool when analyzing
material properties. The test uses small samples with a weight of 10-15 mg and heats
and cools them to determine different material properties. The heating profile can be
changed based on the desired test, as can the cooling rate. The test inputs a constant
heating profile and records the amount of heat flow at the progressing temperatures.
This results in a graph such as the one shown in Figure 3.

Figure 3: Example of a DSC test result graph

In this graph, Tg is the glass transition temperature, Tc is the cold crystallization

temperature, and Tm is the melting temperature. The glass transition temperature
indicates when the material transitions from elastic to brittle. The cold crystallization
temperature indicates when the crystals in the material are aligning. The melting
temperature is the temperature at which the material is completely melted. Using the
area under these curves as denoted by the red and blue in the graph, the percent
crystallinity can be determined. Both Hm and Hc are divided by the heat of melting of a
100% crystalline material to determine crystallinity. This is an important factor because
it determines the ductility of the material being tested. Materials such as PET are

5
considered semicrystalline materials, meaning they have both amorphous and
crystalline regions. Figure 4 below shows a semicrystalline structure.

Figure 4: Semicrystalline polymer structure. Photo courtesy of Journal of Chemical &

Pharmaceutical Research [5]

This percent crystallinity indicates the percentage of crystalline regions in the material.
The fewer crystalline regions in the material, the more amorphous the material, and the
more ductile the material. [6]

1.3 Project Objectives

The goal of this project was to design, build, and test an extruder that converts raw
material into 3D printing filament. The focus was specifically on creating 3D printing
filament made from PET, both from virgin pellets and from plastic waste. The produced
filament needs to have material properties that either meet or exceed commercially
available filament.

6
Chapter 2: Systems-Level

2.1 Customer Needs

The AkaBot team worked with Anudip to determine the requirements for the machine.
Anudip had primary and secondary goals.

Primary Goals:

• The filament quality was on par with commercially available filament.

• The input material for the machine is virgin PET pellets.
• Machine can be operated by unskilled workers.
• Machine was robust enough to operate in rural India.

Secondary Goals:

• Plastic waste as the input material.

• Automated with little human interaction.

2.2 Benchmarked Results

AkaBot 2.0 was built upon the research conducted by the AkaBot 1.0 team. Students
developed AkaBot 1.0 as a senior design project at Santa Clara University during the
2013-2014 school year. Their machine, seen in Figure 5, developed the initial concept
and design. They were able to produce filament, but had problems with consistency,
ductility, and filament diameter.

7
 Figure 5: AkaBot 1.0 machine before modifications

Testing with the AkaBot 1.0 machine led us to change many of the components during
our initial testing, including:

• Orientation of the machine – from horizontal orientation to vertical

orientation
• New chamber mounts – to keep the chamber from rotating due to motor
torque
• New die design – manufactured die for 1.75 mm filament vs. 3 mm
filament, and with a smaller cone angle
• New cooling system – liquid cooling system vs. air cooling system

These tests gave us insight as to what changes we needed to make to our AkaBot 2.0
design. By making new parts and using them with the old machine, we could specify our
design requirements. After conducting tests in the fall quarter on the existing machine,
we included four major changes in our design.

1. Extrude a 1.75 mm filament

2. Change the orientation to a vertical design

8
 3. Employ a liquid cooling system
4. Simplify the machine cleaning process

2.3 System Level Requirements

After working with AkaBot 1.0 as well as taking input from our customer, we set the
system requirements for AkaBot 2.0. A summary of these requirements can be seen in
Table 1, while the full list can be seen in the Project Design Specifications contained in
Appendix C.

Table 1: System requirements for AkaBot 2.0

Baseline Requirement

Filament Size 1.75 mm ± 0.1mm

Extrusion Speed 0.2-0.7 cm/s

Extrusion Temperature 250 °C

Time to Disassemble and Clean <10 min

Cooling Rate >34°C/min

Price $500-$750

2.4 System-level Sketch

The first step is to clean and prepare the material. The PET is cleaned, shredded and
dried, then the device is turned on, and the heating bands heat up the chamber to the
proper level. The motor is turned on, and any blockages are cleared. The shredded PET
is added to the system, and the filament is slowly pulled out by hand (automatic

9
spooling was not included at that time). A block diagram of the system can be seen in
Figure 6.

Figure 6: System-level sketch of extrusion process

2.5 Functional Analysis

1. Produce filament
a. Clean and shred plastic: removes impurities.
b. Melt plastic shards.
i. Create a viscous liquid form of the plastic.
c. Extrusion
i. Push mixture along chamber towards extrusion point.
ii. Create pressure in mixture to produce consistent extruded material.
d. Cooling
i. Lower temperature of filament as fast as possible: Fast
solidification reduces crystallinity, which increases ductility.
ii. Make filament safe to handle.
e. Spooling
i. Maintain constant tension on finished filament to reach desired
tensile properties.
ii. Collect filament for ease of use in 3D printer.

Inputs: Shredded plastic water bottles, raw PET pellets, heat, and auger rotation.

Output: 3D printer compatible PET filament, and waste heat.

Constraints: Cost, extrusion rate, heating rate, and cooling rate.

10
2.6 Design Process

We built on the work completed by the senior design team from last year. They were
able to create a working prototype of a plastic extruder that showed promising results.
We refined the design, made improvements, and created a new device that can be
implemented in rural India.

Our primary goal for this project was to design a machine that produces a consistent
filament output with the same properties as commercial 3D printing filament. The
previous team was able to produce a filament, but it was not ductile enough to be used
by a commercial 3D printer. We tested a variety of commercially available filaments to
set specifications and tolerances for our final product.

Originally we believed that the mixing chamber and auger must be designed specifically
for our purpose, in order to create an output of a consistent filament. The idea was that
this specific design would allow for mixing of the plastic shreds, and for specific
pressures and melting temperatures to be achieved, in order to create uniform material
properties. The previous team used commercially available drill bits, but we planned to
design a purpose-built auger from scratch that would exactly match our needs. After we
designed this auger and ran simulations on it, we concluded that the cost to machine
the hardware would outweigh the benefits. After testing AkaBot 1.0 with an off-the-shelf
auger and making a few modifications, we concluded that we could in fact use an off-
the-shelf auger and still improve the material properties by simply changing the
orientation of the machine and decreasing the clearance between the chamber and the
auger. The final step in creating a uniform filament was to design the die that the plastic
is pushed through and then is cooled from a liquid to a solid. This die determined the
final shape of the filament.

The next stage of our design was the cooling and spooling apparatus. The filament
needed to be “pulled” out of the machine at a certain rate to maintain tension. Keeping
the correct level of tension is critical to achieving the desired mechanical properties for
the filament. We researched how the filament is affected by various spooling rates in
order to determine the right one for our needs.

11
2.7 Key System Level Issues

There are two issues we had to solve for our iteration of the machine. First, we needed
to increase the pressure at the extrusion die. Having a high pressure ensures
consistency in the filament output, improving the yield of usable filament. There were
two ways to accomplish this. First, we planned to have an extrusion auger machined to
the exact specifications required to extrude PET. This is a complex and expensive
process that would have taken up the majority of our budget. The complexity of the
design requirements meant we would not be 100% confident in the auger until we had
tested the final design extensively. If there were flaws, we would have had to find more
money to construct a new auger, or find other ways to increase pressure. The
drawbacks associated with a custom auger forced us to look for different ways to
increase the pressure. We tested rotating AkaBot 1.0 into a vertical orientation, which
generated enough pressure at the extrusion die to generate a consistent filament
output. With a vertical orientation, we reached the required pressure levels without an
expensive auger.

Cooling was the second issue we needed to solve. Based on our material research, we
needed to reach a cooling rate of at least 34°C per minute in order to maximize ductility
of the filament. We tested an air-cooling system using AkaBot 1.0, which did not provide
the necessary cooling rate. A liquid cooling system was required, but we could not use
water. PET readily absorbs water when it is in a semi-liquid state, and water absorption
sharply decreases ductility. We decided to extrude into a bath of oil, which gave us the
cooling rate needed to achieve the required ductility.

2.8 Hardware Limitations/ Lead Time

There were a couple of constraints that set our hardware limitations. We wanted to be
able to do all of the machining of the components on campus, so this dictated some of
the material choices. We also wanted to make the assembly process as easy as
possible, so we did our best to select components that were off-the-shelf. This ensures

12
the device can be easily repaired, and sourcing replacement parts will not be a long,
drawn out, or expensive process. All parts and raw materials were sourced from
Pinecone Lumber, Home Depot, McMaster Carr, and other online sources. The
complete list of parts and where they were purchased from can be found in Appendix F.

2.9 Team and Project Management

There were three members on the AkaBot 2.0 team; Jay Dubashi, Brian Grau, and Alex
McKernan. There were three major sections of the project, in terms of developing
specialized knowledge: Finite Element Analysis (FEA) and business analysis; machine
design and Computer Aided Design (CAD); and material properties including Differential
Scanning Calorimetry (DSC). The leads for each part of the project were defined as
follows:

• Jay Dubashi - Finite Element Analysis (FEA) and business analysis

• Brian Grau - machine design and Computer Aided Design (CAD)
• Alex McKernan - material properties including Differential Scanning
Calorimetry (DSC)

Having a small team reduces the challenges of trying to arrange meeting times. While
each of us had specialized tasks, we all contributed to all aspects of the project.

This project was divided into three distinct phases. The first phase was the material
properties research, testing different prototype designs on AkaBot 1.0, and design of the
auger, which was later scrapped. The second phase of the project was the design of
AkaBot 2.0, construction, and testing of the machine. The final phase of the project was
testing our results, preparing our senior design presentation and thesis, and preparing
our machine for implementation in India. A summary of the project timeline can be seen
in Table 2 and a full Gantt chart can be found in Appendix E.

13
 Table 2: Timeline

Deliverable Oct. Nov. Dec. Jan. Feb. Mar. Apr. May June
‘14 ‘14 ‘14 ‘15 ‘15 ‘15 ‘15 ‘15 ‘15

Material Properties X X X X
Research

Design X X X

Construction X X X X

Filament Property X X
Testing

Senior Design X
Conference

Implementation X X

2.10 Budget

The funding from our project came from a Roelandts Grant from the Center for Science,
Technology, and Society at Santa Clara University. We received our full budget, seen in
Table 3, of $5,120. We were able to substantially reduce the cost of the machine and
using CAD to design and test the system, eliminate prototype costs. At the end of the
project we still had $3,400 remaining. This money is being used to continue testing with
AkaBot 2.0 during the summer of 2015.

14
 Table 3: Initial budget

Item Cost

Electronics $900

Auger $1,600

Spooling $700

Hardware $1,420

Raw Materials (PET) $500

$5,120

15
Chapter 3: Materials

3.1 Material Testing

The first step in this process is to analyze the input material, plastic water bottle shreds.
PET is an incredibly sensitive material to work with, so the cooling profile of the material
as it exits the machine is extremely important. Last year the team encountered
problems with the filaments ductility. If the filament is not ductile enough it will not be
able to be processed through a 3D printer. This problem last year was due to a slow
cooling rate. The slower a material cools, the more time crystals have to form. The
percent crystallinity can be found by Equation 1 below [7]. Higher crystallinity
corresponds to a less ductile material.

(eq. 1)

Hm is the heat of melting, Hc is the heat of cold crystallization and both are divided by
the heat of melting of a 100% crystalline PET. In order to determine the proper cooling
rate, the input material was run through a Differential Scanning Calorimetry (DSC) test.
This test provided the team with a graph similar to the one seen in Figure 7 below.

16
 Figure 7: Example of a DSC test result graph

Tg is the glass transition temperature, Tc is the cold crystallization temperature, and Tm

is the melting temperature. Using the area under these curves as denoted by the red
and blue regions in the graph, the percent crystallinity can be determined.

The DSC was run in two phases, one to simulate the material going through AkaBot,
and one to determine the resultant crystallinity. First the material was heated to 280°C
from room temperature at a rate of 10°C/min to mimic the material in the auger. Next it
was cooled with the initial cooling profile 34°C/min to mimic the cooling phase of the
material. The second phase was to heat the material again at 10°C/min in order to
obtain a graph similar to that seen in Figure 7. This determined the material’s final
crystallinity at the specific cooling rate.

This DSC profile was initially run to test the feasibility of using plastic water bottles. We
ran small water bottle samples through this double DSC test in order to characterize the
material we were working with. The results can be found below in Figure 8.

17
 Figure 8: DSC results of Crystal Geyser water bottles

Using Equation 1 the percent crystallinity was found to be 11.8%. With this data, we
determined that recycling plastic water bottles was, in fact, a feasible option for
extrusion.

3.2 Preparation

Preparation of the PET is a crucial step in the process. The water bottles must be
completely stripped of all labels and adhesives and thoroughly cleaned to ensure all
contaminates are removed from the polymer. This is done using soap and water and is
a labor-intensive process. The water bottles that are completely free of all labeling and
adhesives are then cut into strips and fed through a standard paper shredder. Once
cleaned and shredded, the PET must be completely dried. The material can then be
processed. Figure 9 shows what the prepared material will look like.

18
 Figure 9: PET water bottles after cleaning and shredding

Ultimately, the goal of AkaBot is to take this pure recycled PET and convert it into a
usable 3D printing filament. However, upon testing with AkaBot 1.0, it was clear that the
shreds captured too much air in the extrusion system. This led to a decrease in
pressure, and as a result the material was burned as it exited the machine. Upon
discussing our result with Anudip, we reached the conclusion that virgin PET pellets
could be used as a viable option for reducing the cost of the filament. While the PET
pellets are not made of recycled material, they are a cheaper option than purchasing
PET filament.

19
Chapter 4: Machine Design

4.1 Machine Overview

There are four main subsystems to our machine, as seen in Figure 10. In addition,
several auxiliary subsystems complement these.

Chamber & Heating Auger Extrusion Die Cooling

Figure 10: Main subsystems

AkaBot 2.0, the final machine, is 2 feet [60.96 cm] wide by 1 foot [30.48 cm] deep by 2
feet [60.96 cm] tall. Figure 11 shows the machine in its final form.

Figure 11: AkaBot 2.0 final machine

20
4.2 Hopper

Changing the machine to a vertical orientation necessitated a redesign of the hopper

from AkaBot 1.0. We chose a gravity-fed hopper design because of its simplicity. The
material is loaded at the top of the machine and then as the auger picks up material, the
pressure due to gravity keeps the material flowing to the input part. Figure 12 is a
computer rendering of the hopper.

Figure 12: Sheet metal hopper

We tested this hopper design, and the angle was not steep enough to keep a constant
feed of material into the machine. We hand fed the material into AkaBot 2.0 for all of our
tests because we did not have enough time to implement a new hopper design.

21
4.3 Chamber and Heating

4.3.1 Chamber and Heating Overview

As the material travels through the melting section of the chamber, band heaters melt
the solid plastic material to a liquid. We designed the chamber and selected the heating
bands for their ability to be customizable and movable. Flexibility was critical because
the theoretical calculations are extremely complex. We selected band heaters because
they could be positioned on the outside of the chamber to allow for them to be moved
along the length after construction is completed. These were also a proven design from
AkaBot 1.0.

4.3.2 Chamber

The chamber is the component that transfers the heat from the heating bands to the
material inside. It houses the auger and has to withstand temperatures of 260°C. The
material selection, the manufacturing technique, as well as the design, were all done in
parallel.

We evaluated three different materials for possible usability; 6061-T6 Aluminum,

Carbon Steel, 316 Stainless Steel. The first material we evaluated was 6061-T6
aluminum due to its low cost, ease of manufacturing, and availability. When looking at
the material properties of aluminum we concluded that it would deform over time,
making it an undesirable choice. The melting temperature is 660°C. [8] We are
operating at a temperature range between 250°C and 270°C, and this is greater than
1/3 the melting temperature, resulting in possible creep. The next material that we
looked into was carbon steel. While the melting temperature of 1,425°C is much greater
than our operating temperature, steel enters an embrittlement region right at 250°C,
which is where we are operating. [8] This can lead to failure of the machine. Ultimately,
we chose 316 stainless steel as the final material because it has a high melting
temperature (1,510°C), and will have a long life. [8] This material does require more
time to machine and more specialized tools.

22
The design of the chamber, seen in Figure 13, required a few different machining
operations to be performed. Because of the limitations of the tools on campus in the
machine shop, we bought a stock tube that has an outer diameter of 1.000 ± 0.005 in
(2.54 ± 0.013 cm) and inside diameter of 0.76 ± 0.005 in (1.930 ± 0.013 cm). This
meant that no work needed to be done on the inside of the tube for the auger of 0.75 in
(1.91 cm) to have a clearance fit. We selected an outside diameter of 1.000 in (2.54 cm)
because there was a commercially available heating band for this size.

Figure 13: SolidWorks rendering of the chamber

We used a mill to remove a section at the top for the hopper connection. Along the rest
of the length of the tube there is a groove so the thermocouples can be recessed into
the chamber for a more accurate reading, and to keep the heating bands from applying

23
pressure to the tip of the thermocouple, which could reduce its life span. At the bottom
there are four tapped holes 90° apart for 8-32 set screws to hold the die in place.

4.3.3 Band Heaters

There are three 250 Watt band heaters on the outside of the chamber. These band
heaters are 2.000 in (5.08 cm) in length and operate on 120 VAC. They are made by
Tempco and are in the same product line as those used on AkaBot 1.0. They have a
maximum temperature of 482°C (900°F), making them an ideal choice. At peak
operation they have a power draw of 2.08 Amps. These heating bands were chosen
because there are 220 V equivalent models, so that the entire system can be converted
over for use in India.

Figure 14: Heating band

24
4.4 Extrusion

4.4.1 Extrusion Overview

The material is forced through the length of the chamber by a screw auger. Initially, we
believed this to be the most important part of the system and much of our initial design
work was spent on this single component. As testing progressed, we determined the
importance of this part was less than anticipated and we could use a cheaper solution.

4.4.2 Custom Auger Design

There are three main sections in a screw auger: feed zone, metering and melting zone,
and the pumping zone. These are shown in Figure 15 below.

Figure 15: Sections to an auger design. Photo courtesy of Polymer Mixing and
Extrusion Technology [9]

In order to do a complete analysis of the design for an auger, there are multiple different
geometric parameters that must be taken into account including the pitch angle, the
helix angle, the length to diameter ratio, the channel depth, and the clearance between
the auger and the chamber. After research into all of these we determined that for our
needs the optimal design configuration would be as seen in Table 3. [9]

25
 Table 4: Parameters for custom designed auger

Parameter Value

Pitch Angle 17.61°

Helix Angle 17.61°

Length to diameter ratio 16:1 – 36:1

Channel depth Different for each section

Clearance between auger and chamber 0.001 in (0.0025 cm)

Using these parameters and other design recommendations we designed our auger
using SolidWorks. This auger, seen in Figure 16, is 22.00 in (55.88 cm) in length and
has a maximum diameter of 1.00 in (2.54 cm).

Figure 16: SolidWorks rendering of the custom auger design

While the pitch angle and the helix angle remain constant, the depth varies over the
length of the auger. The depth of the feed zone, where the material enters the chamber,
is a constant depth and relatively deep. The melting zone, between the feed zone and
the metering zone, has a depth that is decreasing as the material travels from left to
right. The metering zone has a constant depth, shallower than the feed zone. Finally,
the pumping zone has a constant shallow depth, where pressure is built up before
material exits through the die.

4.4.3 Commercial Augers

Based on our testing with AkaBot 1.0, we concluded that the auger could be simplified
greatly and still work adequately. With other design decisions that we made, including

26
rotating the machine to a vertical orientation and decreasing the filament size, we found
that a commercial auger would be able to build up enough pressure at the die. Looking
at different commercial augers, the design that matched our custom auger
specifications closest was a ship bore auger (see Figure 17). We selected a diameter of
0.75 in (1.905 cm) after the chamber was designed.

Figure 17: Commercial ship bore auger

4.5 Die

4.5.1 Die Overview

The die of the machine determines the final filament size. We designed the die to be
easily removed in order to clean it, and to switch it out for different filament types.

4.5.2 Die Design

The die is made from 360 Brass. We chose this material for a variety of reasons. The
temperature on the die needs to be controlled very precisely to make sure the material
does not begin to solidify in the die, but it also cannot be so hot that it takes a long time
to cool when it comes out the end. Brass has a melting temperature of 930°C, meaning
we did not have to worry about material deformation. [8] It also has a high thermal
conductivity so that it can transfer its heat. Finally, the linear thermal expansion
coefficient of brass is 18.7. [8] This needed to be greater than that of 316 stainless
steel, of 16.0. [8] The design of the interchangeable die uses 4 set screws. When the
machine is off and cold, there is a slight gap between the components, meaning it can
be swapped out. When the machine is brought up to temperature, the materials expand,

27
brass more than stainless steel, and this seals off the end of the tube so plastic will not
leak, as well as creating a friction surface so the pressure is distributed between this
friction interface as well as the set screws.

The design for the die was such that it can slide into the chamber and not protrude past
a 1.00 in (2.54 cm) diameter. This means the heating bands can be moved along the
entire length of the chamber, all the way to the end, because maintaining a set
temperature at the die is crucial to the material properties. Figure 18 shows the final die
after machining.

Figure 18: Brass die

Figure 19 shows a section view of the die. The inside cone angle of the die is 60°, which
was the smallest angle that we could machine on campus. The output diameter was
0.089 in (0.226 cm) and took into account the swelling of both the die as well as the
PET material. There are four circular pockets, all 90° apart around the outside, which
match up to the 8-32 tapped holes on the chamber.

28
 Figure 19: Section view of a SolidWorks rendering of the die

4.6 Cooling

4.6.1 Cooling System Overview

After the material exits the extrusion barrel through the die, it needs to be rapidly
cooled. This is completed by the cooling system, seen in Figure 20. Immediately after
the material exits the die it goes into a cooling bath of vegetable oil. We chose
vegetable oil because it is nontoxic and readily available. There are hubs on the side of
the chamber to allow for metal rods and pulleys to be put in place. These can guide the
filament out and onto a spooling system in the future. The oil bath allows for a rapid
decrease in temperature of 36°C/sec. The oil does heat up from room temperature of
20°C to 40°C, and then it needs to be replaced. We estimate that this change needs to
happen once every hour.

29
 Figure 20: Acrylic trough to hold cooling fluid

4.7 Controls

4.7.1 Controls Overview

There are two independent control systems, the heating system and the motor, that
control the various aspects of the machine and ensure that it is functioning properly in
order to create a uniform filament.

4.7.2 Heating System

The first of these systems are the control systems for the band heaters along the length
of the chamber, which melt the filament before mixing and extrusion. An electrical
schematic, shown in Figure 21, shows the control system for one of these heaters. The
only user input is the desired temperature, which is keyed into the temperature
controller.

30
 Figure 21: Electrical schematic for the control of a single heating element

The temperature controller we are using is made by Sestos and can be seen in Figure
22. This controller uses a PID control algorithm in order to maintain a precise steady
temperature.

Figure 22: Sestos DIS-VR-220 PID temperature control unit

31
A thermocouple embedded into the heating element is the feedback part of the control
loop. Table 5 summarizes the characteristics of this controller.

Table 5: Sestos DIS-VR-220 temperature control unit specifications

Parameter Value

Sensor Input K, S, Wre, T, E, J, B, N,CU50, PT100

Control Range 50-1300C (K sensor)

Control Accuracy 0.1°C

PID On/Off Modes

Power AC 110-240 °C

Output 12 V for SR

The temperature control unit provides a 12 V signal that is wired to a relay, which
switches the high voltage AC current that is fed to the band heater. The solid state relay
we are using is manufactured by Fotek and can handle the load. A picture of the relay
can be seen in Figure 23, and Table 6 summarizes the specifications.

Figure 23: Fotek solid-state relay for switching high voltage and high current

32
 Table 6: Summary of specifications for the Fotek SSR-40 DA

Parameter Value

Rated Load Current 40 A

Input Operating Voltge 3-32 VDC

Min On/Off Voltage ON > 2.4V, OFF < 10 V

Trigger Current 7.5 mA @ 12 V

Output Operating Voltage 24-380 VAC

Response Time ON <10 ms, OFF <10ms

Operating Temperature -20C to +80 °C

4.7.3 Motor

The motor for the system is a 10 RPM motor with a stall torque of 368 oz-in (26.5 kg-
cm). The motor is controlled by a Single Pole Single Throw switch. This switch is wired
in series with the power source from a 12 V supply and the motor. This was the simplest
control system. It is a single speed system with the revolutions per minute selected by
the speed of the motor and the gearing between the motor and the auger. The gear
ratio was selected to be 2.5:1, resulting in an auger speed of 4 RPM. This speed
transfer occurred using a chain drive.

33
Figure 24: Chain drive connecting motor and auger

34
Chapter 5: System Integration

5.1 Assembly and Systems Testing

Once AkaBot 2.0 was fully assembled, we tested each system to ensure that it was
operating properly. First, we turned on the heating bands and the control system to see
if our design would reach the required heating profile. We tested this by using a
thermocouple to measure the temperature on the outside of each heating band. We
also tuned the PID controllers by using the built-in automatic tuning function. This
eliminated the variability in the temperature of the heating bands that we had seen in
AkaBot 1.0. Once the controllers were tuned, the temperature of the heating bands only
varied by 1°C.

Next, we tested the mechanical power system. The rotational speed of the auger
slowed significantly as pellets were loaded into the chamber. If too many were loaded,
the auger stopped, and it required manual assistance to start again. We decided to limit
the pellet supply to 35ml at any given time, to assist the motor.

Our first major problem came from the hopper. We planned on a 30 degree angle from
the funnel to the chamber, but the pellets did not self-feed, and had to be pushed into
the chamber. We scrapped the initial hopper design for our first tests, and put filament
into the system by hand.

5.2 Extrusion Process

From viewing videos of other DIY extruders (small-scale devices designed for home
use), we knew that the extrusion and filament collection process was just as important
as the design of the machine. The consistency and final shape of the filament was
dependent on the tension applied as it left the die. Without applying tension, the filament
would collect in a pile within the oil bath. The internal structure of the filament was as
desired (clear), but it was wound too tightly to be used in a 3D printer. The filament had

35
to be guided out and away from the extrusion die to form the long straight pieces
needed for 3D printing. We assigned one team member to hold the filament and gently
pull it out of the machine. This tension had a significant impact on the variance of the
filament diameter.

While the tension created a straighter, more consistent filament, the filament
occasionally drifted or spun in the oil bath, which created inconsistencies in the
diameter and sharp kinks and corners in the filament. The more accustomed the user
becomes to these issues, the better the filament output.

In order to attempt to produce a more uniform filament without extensive user training,
we designed and manufactured a trough, seen in Figure 25. This trough allows the
filament to sit in it and keep the filament from drifting from side to side.

Figure 25: Trough to guide material through cooling system

36
5.3 Extrusion Testing

3D printing filament does not need to meet precise technical requirements. The only
requirement is that it can be used in a 3D printer. The ductility and diameter can have
some variation and still be usable. If the produced filament can be spooled and fed like
commercial filament, it is usable. Therefore, most of our testing was qualitative, and we
backed it up with two quantitative tests. We tried to spool our filament in the same
manner as the produced filament, and visually compared the internal properties. The
ideal filament is clear, almost transparent. Cloudy regions signify high crystallinity and
thus low ductility. We also sampled the diameter of the produced filament at fixed
intervals to determine the average diameter and tolerance.

Once we obtained a consistent filament, we initially tested it for ductility by winding it

into a 3 inch (7.62 cm) diameter circle. If the filament did not snap, we conducted further
tests to determine its characteristics.

First we conducted a DSC test on a segment of 1.75 mm filament. This was filament
extruded into a room temperature, 20°C, oil bath. The filament was found to be clear
and uncloudy, and could be tightly wound without snapping. The test we conducted was
a simple single DSC test. This meant that there was no preliminary heating and cooling
profile. The samples were simply heated to 280°C at a rate of 10°C/min to obtain the
data graph seen in Figure 26.

37
 Figure 26: DSC test results of AkaBot 2.0 1.75mm filament extruded into 20C oil bath

Using Equation 1, and the areas obtained from the DSC, the percent crystallinity of the
AkaBot 2.0 filament was found to be 5.85%. After comparing these results to those
found in the thesis from AkaBot 1.0, we found that they were actually quite similar.
AkaBot 1.0 was achieving similar crystallinity; however, the previous tests were
conducted with filament of a much smaller diameter of around 1 mm. This diameter
difference makes cooling AkaBot 1.0 filament much easier due to the thinner diameter.
Had the same cooling system been applied to AkaBot 2.0, the results would have been
drastically different. The cooling rate made all the difference in these results. AkaBot 1.0
simply had a fan blowing room temperature air over the filament as it came out of the
machine. While it worked better than stagnant air, this cooling rate was slow when
larger samples were extruded. The system worked to reduce crystals in the thin filament
because it had less to cool; however, it was less successful at lowering the ductility of a
larger sample because of the longer time it takes to cool the larger diameter samples.
AkaBot 2.0 extruded into room temperature vegetable oil. Due to oils thermodynamic

38
properties, it draws out heat much faster than air blowing over the filament. This means
that even in a larger diameter filament, the cooling rate remains high.

Once we concluded that the oil bath extrusion was successful, we conducted tests to
compare the effects of lowering the oil temperature. We placed vegetable oil in the
freezer, cooled it to 0°C, and then mixed it with room temperature oil. The resulting
temperature was 10°C. After numerous rounds of extruding, it was qualitatively
concluded that the cooler oil did not have a drastic effect on the ductility of the filament.
Each test from both the 10°C oil and 20°C oil (room temperature) was able to be wound
tightly into a spool with a 2 in (5.08 cm) diameter. We thus concluded that both samples
were ductile enough to be processed through a 3D printer. From here, we made the
decision to maintain the oil at room temperature, in order to keep the extruding process
more simple and reduce its energy input.

In order to verify quantitatively that the ductility of AkaBot 2.0 actually did surpass that of
its predecessor, we conducted tensile tests and compared the results to both AkaBot
1.0 and purchased filament. While conducting the tensile tests, we found that Akabot
2.0’s filament was actually far more ductile than both the purchased filament and last
year’s filament.

The most crucial comparison that was drawn, however, was between the Akabot 2.0
filament and the purchased filament. In order to obtain most consistent and true results,
all of our samples were prepared in the same manner. Samples of equal lengths were
cut and placed into the tensile tester. Clamps holding the sample at either end were 86
mm for every test. During each test the strain rate was 20 mm/min. We conducted tests
in two sessions. Session 1 tested two strands of AkaBot filament and one strand of
purchased filament. This round of testing produced results that were slightly
inconsistent, as the two samples of AkaBot filament produced different results. Session
2 was conducted in order to gather more data and confirm the team’s conclusions about
an increased ductility. Unfortunately, session 2 yielded mostly inconclusive data, as all
but one of the samples broke at the clamps. Once a sample fractures at the clamp, it
becomes unreliable data, as the pressure of the clamp may have compromised the

39
integrity of the sample. The one sample that fractured in the middle of the sample was
compared to the tests run during session 2. Similarities in ductility were found between
one of the tests in session 1 and one of the tests in session 2. These results were
compared to the successful test of purchased filament in session 1. A graphical
representation of a stress strain curve can be seen in Figure 27 to compare the two
samples that were tested.

AkaBot Filament 1 Purchased Filament Akabot Filament 2

40

35

30

25
Stress (MPa)

20

15

10

0
0 0.5 1 1.5 2 2.5 3 3.5 4
Strain

Figure 27: Stress-strain curve of 86mm long samples of purchased filament with a 1.80
diameter and AkaBot 2.0 filament 1 with a 1.77mm diameter and AkaBot 2.0 filament 2
with a diameter of 1.70mm

While some similarities can be seen, the data is still not conclusive. Table 7 further
examines these differences and compares this year’s results to the results from last
year.

40
 Table 7: Tensile test comparison

Purchased Akabot 1.0 AkaBot 2.0 AkaBot 2.0

Filament Filament 1 Filament 1 Filament 2
Diameter (mm) 1.80 1.04 1.77 1.70
Yield Strength (MPa) 34.48 29.5 35.98 24.04
Modulus of Elasticity (MPa) 909.76 366 731.60 758.25
Strain at Fracture (%) 35.6 4.35 405 317

As seen in the table above, both AkaBot 2.0 filaments had extremely large elongations,
as seen by their % strain at fracture. The modulus of elasticity was also very similar.
The yield strength varied more than anticipated between the samples. Future testing
must be done in order to come to any final conclusions about the filaments exact
properties.

For future testing, we recommend that short samples be prepared directly from
extrusion. One issue we found in retrieving samples was that when the filament was
spooled, kinks and inconsistencies in the diameter formed. If small sections are
extruded with greater precision specifically for a tensile test, this could yield more
consistent results. Also, while a total of 9 tensile tests were conducted, 3 for the
purchased filament and 6 for AkaBot 2.0 filament, only 3 tests were deemed to have
usable data. For this reason, many more tests must be conducted to gain more useful
data. In addition, a fixture to hold the filament without deforming it as the clamps do
would help the issue of fracturing at the clamps. Finally, the rate at which the machine
was pulling the samples should be slowed, as this could also affect where the samples
fracture. Future research will benefit greatly from these small changes to the design of
the experiment.

41
Chapter 6: Cost Analysis

6.1 System Cost

The material cost of AkaBot 2.0 is $637.96, as shown in Table 8. The complete cost
breakdown can be seen in Appendix F. This cost includes just the parts that it takes to
make the machine.

Table 8: Material cost of Akabot 2.0

Subassembly Cost

Frame $32.48

Hardware $21.32

Heating $99.75

Mechanical Power $85.18

Hopper $2.35

Auger, Chamber, and Die $66.69

Cooling $35.82

Electronics $234.79

Raw Material $59.58

Total $637.96

42
If the labor was outsourced to professionals it would be:

• Machining Time: 6 hours

• Laser Cutting: 1 hour
• Final Mechanical Assembly: 2 hours
• Electrical System: 2 hours

This is a total of 11 hours at $100/hour for a total labor cost of $1,100. This would bring
the entire machine to a cost of $1,737.96.

6.2 Economic Analysis

AkaBot needs to provide a cost savings over a short time period in order to be a viable
option for implementation in India. We constructed an economic analysis in order to see
where AkaBot becomes a cost-effective option when compared to purchasing filament.
This analysis is based on several assumptions. First, three workers are required to
operate the machine, and they will be paid the semi-skilled minimum wage for workers
in West Bengal State (65.94 USD per month). Second, we assumed that the input
prices of PET pellets and purchased filament remains constant. We also assumed that
this machine is operated by a large print shop, operating approximately five 3D printers,
and using nearly 20 kg of filament per month.

Figure 28 shows the cost progression over a one-year period. Based on this analysis,
AkaBot will start off with a higher cost than purchasing filament, but will produce cost
savings between the fifth and sixth months. After one year, the device will save
approximately $900. This shows how AkaBot can save money for a business, especially
with a high print volume. This is also assuming just four hours of extrusion per day, with
one machine. With more machines, there could be more savings and higher print
volumes.

43
 4500
4200
3900
Total Cost (US Dollars) 3600
3300
3000
2700
2400
2100 AkaBot
1800
1500 Purchased Filament
1200
900
600
300
0
1 2 3 4 5 6 7 8 9 10 11 12
Month

Figure 28: Economic comparison between purchased filament and filament produced by
AkaBot 2.0

44
Chapter 7: Business Plan

7.1 Executive Summary

Hobbyists and small groups at MakerSpaces primarily use plastic 3D printing. The
material limitations of PET plastic prevent its use in large-scale industrial processes.
PET recycling does exist at the industrial level, but those devices have not been scaled
down in a cost-effective manner. AkaBot will fill that market niche, allowing people to
produce their own PET filament at a lower cost than repeated commercial purchases.
3D printing has the potential to replace existing manufacturing processes in developing
countries. With low labor costs, companies can pay people to collect plastic water
bottles and increase their profits by taken advantage of free raw material.

7.2 Introduction

AkaBot is an extruder that creates 3D printing filament from a raw plastic input, either
PET pellets, or water bottles. It has the potential to produce filament at a low price point,
and help with the recycling of plastic PET waste. Throughout this project, we have been
working with the Anudip Foundation, a non-profit organization based in Eastern India.
They run vocational training centers for impoverished and marginalized women. This
plan is based on how they would run the business to achieve their goals.

The uses of 3D printing grow along with the technology. With its low startup costs and
ease-of-use, 3D printing is a viable option in many developing countries. Anudip wants
to teach the skills related to 3D printing and help young entrepreneurs grow their own
businesses. AkaBot is designed to offset the main drawback of 3D printing, the cost of
raw material. By producing filament at home, costs can be reduced significantly. There
are several filament extruders on the market that allow people to make filament from
their own substrate, like pellets or shredded plastic. However, these devices are limited
to PLA and ABS plastic, not PET. They cannot be adjusted to make PET filament either.

45
Plastic waste is a huge problem in India. The water infrastructure cannot deliver clean
drinking water to many locations. The poor make do with unsanitary water from wells or
rivers, while those with means rely almost entirely on bottled water. These bottles end
up in landfills or as litter; few are recycled. These bottles represent a wealth of raw
material. AkaBot is a way to repurpose this trash into a useful product.

7.3 Goals and Objectives

As AkaBot will be used by a non-profit organization, it has different goals than a

traditional business. Anudip wants to use this machine to produce large quantities of 3D
printing filament for use in training programs. It will not be a commercial product; the
filament will be used in training programs. They do not plan on commercializing AkaBot
at this time, either by selling filament or extruders. We have identified three separate
goals that will make this project a success for Anudip

1. Produce filament that is both materially and economically viable.

2. Provide a viable method for recycling plastic waste.
3. Encourage adoption of 3D printing technology in India.

As previously stated, importing filament is prohibitively expensive, especially for a non-

profit that relies on donations for operating income. Implementing 3D printing training is
dependent on reducing the cost of filament. By necessity, training uses and wastes a lot
of filament. If AkaBot can result in significant cost savings over purchased filament
within a reasonable time frame, it becomes a good choice for Anudip to use. Plastic
waste is a significant problem in eastern India, and other developing countries. Without
recycling infrastructure, the water bottles pile up on the side of the road. These water
bottles are usually made from PET, and provide a nearly limitless source of material for
filament. Existing PET recycling just turns old bottles into new bottles. AkaBot provides
a way to break out of this cycle, and turn the PET into something else. 3D printing
allows manufacturing firms to greatly reduce their startup costs in comparison to

46
traditional manufacturing methods. Right now, it is still a niche technology without
standardized training regimens, in either the US or India. By encouraging the use of this
new technology, entrepreneurs in India can start their own businesses at a much lower
cost than before.

7.4 Description of Product

AkaBot is a filament extruder. It takes in raw plastic material, melts it down, and pushes
it through an extrusion die to form a 3D printing filament. It allows the user to produce
filament on their own, and not rely on outside suppliers. It allows a business to control
their own supply chain for material and inputs. For Anudip, it lets them reduce costs,
and provide more employment and training opportunities for their clients. Businesses
and non-profits are constantly trying to find ways to reduce their costs, and increase
control over all aspects of the market. Vertical integration (owning the entire supply
chain) is the “Holy Grail” for many businesses, but nearly unattainable for most
industries. Any product that gives a business more control over its supply chain is going
to be attractive to executives.

7.5 Potential Markets

Our target consumer is Anudip, and we have designed AkaBot based on their
requirements. Filament extruders are generally used by hobbyists and MakerSpaces,
groups who have small operating margins. Small-scale extruders do exist, but for other
plastics like ABS and PLA. PET extruders do not exist on this scale. PET is uniquely
suited for Anudip because of the plastic waste prevalent in its operating area. By
extruding PET, they can take advantage of the resources surrounding their area. Once
Anudip has established their operations, AkaBot will be opened to other potential
markets and users. These users are the same hobbyists, MakerSpace users, and
entrepreneurs that other extruders are targeted towards. AkaBot could be sold in two

47
forms. First, it could be sold as a completely assembled machine that requires minimal
tinkering to begin extrusion. Second, it could be sold as a kit that contains all the parts
required for AkaBot, but with assembly and testing left to the user. This is the hobbyist
option, because it allows the end-user to make adjustments as they see fit. The largest
market for AkaBot would exist in the US and other countries that have seen mass
adoption of 3D printing, where hobbyists and entrepreneurs are more likely to try out
new technology. In India, AkaBot will have to prove its worth as a filament extruder by
reliably creating large amounts of filament over a long period of time, and as a recycling
machine by producing good filament from water bottles. Anudip’s training centers will be
the proving grounds for AkaBot. There will be more local interest once 3D printing and
local filament are shown to be viable options for Indian businesses.

7.6 Competition

As previously stated, AkaBot is a unique product. It is the only extruder for PET at the
hobbyist level. Numerous other products exist for extrusion, but not for PET plastic.
Some of these products can be seen in Table 9. Other extrusion devices are designed
around the plastic they extrude, and cannot be adjusted to extrude different plastics.
AkaBot has this ability, which makes it stand out from the competition. The heating
profile and cooling system can be changed to extrude ABS or PLA. This makes AkaBot
more useful as a ‘do-it-all’ extruder than other products.

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 Table 9: Comparison of existing extruders on the market

Image Price

$310
Filastruder
[10]

$649-$1,949
Filabot
[11]

$699
Protocycler
[12]

The above machines are all examples of ‘home-level’ extruders on the market.
Filastruder and Protocycler are available as fully constructed machines, or as kits.
However, none of these machines can extrude PET. They are all limited to ABS or PLA,
and cannot be switched between the two. AkaBot has more flexibility in usage.

49
7.7 Sales & Marketing

Anudip is planning to implement the machine in India this summer, to test and
determine the viability of using it to extrude filament for 3D printing. They will take
ownership of the machine and be responsible for making decisions on expansion. Any
marketing for AkaBot will focus on the savings potential and different uses for the
machine. It is cheaper than purchasing filament, and it gives the user more flexibility in
their choice of plastic than other extrusion devices. This machine could be packaged
with a simple 3D printer as a starter kit. It is not a consumer product with mass appeal; it
is an enterprise product that allows businesses to control more of their supply chain.
Marketing efforts would focus on this sector, and how businesses can reduce their costs
by taking advantage of readily available material, and by purchasing a machine that can
extrude three kinds of plastic instead of just one.

7.8 Manufacturing

AkaBot is designed for construction by hand. The majority of the parts are available off
the shelf. There are some parts that require basic machining; these parts will be
sourced in mass orders from a machine shop. Anudip will pay workers to assemble the
machines, and deliver them to the final training center. If they decide to commercialize
the design, Anudip can offer AkaBot as a fully assembled device, or in a kit. Machine
shops exist in India that can handle the machining of parts, eliminating shipping costs.
Labor wages for machining are much cheaper in India, which will greatly reduce the
cost.

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7.9 Product Cost and Price

The AkaBot 2.0 prototype cost approximately $1,737.96 to make in its current design.
However, there are several ways to reduce the cost of a final machine. Lower quality
plywood could be used for the frame, and the size of the interior could be reduced
significantly. Replacing the PID controllers with a microcontroller and a program would
reduce the cost of the control system from $95 to $25. The cooling system could be
replaced with a bowl filled with oil, instead of a custom acrylic box. The labor costs can
also be reduced by using different manufacturing techniques and by reducing the
number of machining operations that need to be performed.

7.10 Service & Warranties

Anudip will be running AkaBot as an internal program at first, and they will be
responsible for supporting and maintaining the devices during the initial testing and
production phases (if necessary). If they decide to commercialize the machine, a 30-day
return policy on assembled machines, and a 1-year parts and service agreement would
be implemented. This policy would only cover defective parts. The quality of filament is
entirely dependent on the operator pulling it out of the machine, so the end user would
have to train their people to produce filament.

7.11 Financial Plan

Anudip plans on using one machine this summer as a test case, to see if they can
produce enough filament to make AkaBot economically feasible. This initial test will be
funded entirely out of their own pocket. If they decide to proceed, they will seek funding
from outside sources in order to produce and staff the 150 machines they need to
operate for their training centers. As Anudip’s operation would be focused on training
and not production, they would need constant outside funding to maintain the product,
unless they decided to commercialize and sell the machine. Assuming they purchase

51
200 machines to operate in their training centers, they will need to hire 600 employees
to operate them. This would be funded with a combination of internal revenue and
outside donations. However, any future planning depends on the results of the feasibility
study to be conducted this summer.

52
Chapter 8: Engineering Standards and Realistic Constraints

8.1 Economic

Anudip has limited financial resources. They want to set up as many training centers as
they can, but the full 3D printing process has high start-up costs. AkaBot needs to be a
financially viable tool for Anudip. Sacrifices were made in the design to keep costs
down. AkaBot needs to produce filament, but there are areas where standards can be
relaxed and costs cut. Financial restraints exist in all phases of design. Designing the
perfect extrusion device requires tolerances down to 0.000254 cm (0.0001 in) This level
of precision could not be realistically achieved.

8.2 Environmental

AkaBot was designed to reduce plastic PET waste in its surrounding environment. PET
waste is extremely common in areas like India where most people drink water from
plastic bottles instead of the potentially harmful tap water. The extruder is designed to
use recycled PET. This means that once the PET is recycled, the extruder will be able
to process any scrap material again to ensure no material is wasted. The goal is to
create less waste, not more. The second environmental consideration is the
manufacturing of the device itself. Large-scale manufacturing for AkaBot will need to be
done in India in order to both create more jobs and reduce waste from sending the parts
all over the globe. When choosing manufacturing centers it is important to ensure that
the site also has high environmental standards.

53
8.3 Manufacturability

Our target market is developing countries. They will invest in AkaBot as a cost-saving
measure, and they must be able to assemble and source components locally. Having to
import expensive high-precision parts from overseas would not make economic sense.
AkaBot is designed for manufacturing in a simple machine shop. We used a mill and a
lathe in manufacturing these parts. Both machines are available for use in developing
countries. A laser cutter was used to make the manufacturing processing time of the
frame, cooling system, and electronics easier, but these can be made with a drill and
saw. The tolerances for the parts could be reached in a standard machine shop.
Assembly requires basic hand tools and mechanical knowledge.

The design of many of the components could be changed to allow for them to be made
on a 3D printer. These include the hopper, the mounts, and the trough.

8.4 Health & Safety

1. Manufacture
a. Commercially available parts: no safety concern
b. Machined parts: there is an inherent risk when operating heavy
machinery. All machine shop policies will be obeyed in order to maintain a
safe working environment.
2. Assembly
a. All parts can be assembled with simple hand tools. Electronics will be
soldered together and all wire connections will be done with proper
insulation. All machine shop and lab safety policies will be followed.
b. The electrical system will operate at a voltage of 120 VAC. There will be
shutoff switches.
c. When assembling the unit, safety glasses, long pants, and closed toed
shoes will be worn.
3. Test/Operation

54
 a. Heat risk: the chamber is heated to 260°C, which can cause severe burns.
The tube will have warning signs.
b. Rotating parts: the auger will be driven with an exposed chain. These
rotating parts can grab fingers or hair. Proper training will be used as well
as signs to warn of the danger.
c. Fumes: the device will only be tested under a fume hood. The hood will be
cleared of hazardous materials prior to testing.
d. Oil from the cooling system and water from the cleaning system will be
kept away from electrical components to reduce electrocution risks.
4. Display
a. The device will not be on during a display.
b. The device will be completely cool before being put on display.
5. Storage
a. The device will be turned off and be cool before it is stored.
6. Disposal
a. PET residue within the device will be removed by disassembling the
device and chipping out the auger.
b. The components are all made from standard materials that can be readily
disposed of.
c. Any chemicals or oils used for cleaning plastic will be disposed of as
hazardous waste.

8.5 Social

The social impacts of the device are taken into account during implementation. The
purpose of 3D printing is to aid the start of small businesses in rural India. However, the
main barrier for entry is the cost of the filament. AkaBot solves this problem, thus
helping small businesses grow. This growth will lead to more jobs, and eventually an
improvement in the living conditions for those employed.

55
8.6 Santa Clara University Arts Requirement

Each team member contributed to the project in an artistic way, shown in Table 10.

Table 10: Team members arts contributions

Team Member Description Location

Jay Dubashi FEA model of the chamber Figure 29

Brian Grau Final Assembly CAD Drawing A008

Alex McKernan Frame Assembly CAD Drawing A004

56
Chapter 9: Conclusion

9.1 Summary

In summary, the goal of this project is to create a PET filament from recycled plastic
water bottles that meets the same standards as commercially available spools for 3D
printing. Beginning with plastic water bottle shreds made of PET, the AkaBot design will
melt and extrude the filament through a cooling system, which will then be spooled and
ready for use. This process is important because it will give individuals in rural
communities access to a cheap filament, thus making 3D printing an accessible means
of advanced manufacturing. The importance of this project stretches beyond recycling,
to the need for grassroots entrepreneurship in many low-income areas. With access to
low cost manufacturing techniques, local enterprise and vocational training can help
improve the lives of many, leading to an increase in the number of small businesses
and jobs in rural communities.

9.2 Future Work

There are four main areas where we would like to see work done in the future.

1. Redesign the hopper so that the machine can have a constant feed to reduce the
number of people it takes to operate the machine.
2. Using guides, or another system, reduce the variation of filament diameter.
3. Build an automated spooling system, so the machine can be completely
autonomous after initially started.
4. Improve pre-processing of water bottles.

57
Appendix A: Bibliography

[1] "Gallery," Anudip, [Online]. Available: http://anudip.org/news/gallery/. [Accessed 15

March 2015].

[2] J. Griffey, "The Types of 3-D Printing," Library Technology Reports, pp. 1-30, 2014.

[3] E. Albi, K. Kozel, D. Ventoza and R. Wilmoth, "AkaBot: 3D Printing Filament

Extruder," Santa Clara University, Santa Clara, 2014.

[4] K. Kovalenko, V. Sivetskii and A. Sokol'skii, "Design of an Extrusion Die for Plastic
Profiles," Chemical and Petroleum Engineering, vol. 49, no. 9, pp. 675-678, 2014.

[5] Y. Yuefeng, "Study on the Precision Co-Extrusion Technology for PET Recycling,"
Journal of Chemical & Pharmaceutical Research, pp. 265-269, 2013.

[6] W. Sichina, "DSC as Problem Solving Tool: Measurement of Perfent Crystallinity of

Thermoplastics," PerkinElmer Instruments, Norwalk, CT, 2000.

[7] A. Haji and S. Rahbar, "Crystallinity and Orientation Development Upon Hot
Multistage Drawing of PET Multifilamnet Yarn," The Journal of the Textile Institute,
vol. 104, no. 3, pp. 231-238, 2013.

[8] "The Engineering Toolbox," The Engineering Toolbox, [Online]. Available:

http://www.engineeringtoolbox.com/. [Accessed 6 May 2015].

[9] N. Cheremisinoff, Polymer Mixing and Extrusion Technology, New York: Marcel
Dekker Inc., 1987.

[10] "Filastruder Kit," Filastruder, [Online]. Available:

http://www.filastruder.com/products/filastruder-kit. [Accessed 1 May 2015].

[11] "Filabot Filament Makers," Filabot, 2015. [Online]. Available:

58
 http://www.filabot.com/collections/filabot-core. [Accessed 1 May 2015].

[12] "ProtoCycler: Free, Sustainable 3D Printing Filament," Indiegogo, 31 January 2015.

[Online]. Available: https://www.indiegogo.com/projects/protocycler-free-
sustainable-3d-printer-filament#/story. [Accessed 1 May 2015].

[13] "Brittle and Ductile Materials," Aerpspace and Mechanical Engineering Department
at the University of Liege, [Online]. Available: http://www.ltas-
cm3.ulg.ac.be/FractureMechanics/overview_P3.html. [Accessed 3 November
2014].

59
Appendix B: Calculations

We wanted to create a Finite Element Analysis (FEA) model of the chamber and auger,
in order to see if our auger design would create adequate pressure at the extrusion die.
We also wanted to see if the heating bands would generate the temperature in the
chamber required for melting. Constructing this model proved to be more difficult than
we first believed. In order to find the temperature at the tip of the extrusion die, we
needed to show the heat flow through the chamber, in three dimensions. The third
dimension makes constructing the model much more difficult. The second part of the
analysis is the pressure model; we had to model the buildup of the plastic as a fluid. We
had to construct two models, a finite volume analysis thermal model, and a
computational fluid dynamics model of the plastic. The time and knowledge required to
build this model was beyond our abilities. We decided to limit our finite modeling to the
temperature distribution on the surface of the chamber. We could prove the other
properties via testing of the machine.

60
 Figure 29: FEA model of heat propagation from heating bands

This analysis shows that the surface of the pipe will only reach as high as the setting of
the heating bands. We used this analysis for our safety analysis, to show which parts of
the chamber are too dangerous to touch.

61
Appendix C: Project Design Specifications (PDS)

Design Project _______AkaBot_________

Team: _AkaBot______ Date: ____March 21, 2015_ Revision: _3_

Datum description: ______AkaBot Project 2014_______________________________

ELEMENTS/ PARAMETERS

REQUIREMENTS UNITS DATUM TARGET - RANGE

PERFORMANCE

Size m 0.6x0.3x0.6 0.7x0.7x0.7-1.2x1.2x1.2

Price US Dollars 485 500 -750

Speed cm/sec 0.5 0.2 -0.7

Tolerance +/- mm 0.1 0.1

Extrusion Temperature C 250 250

Filament Size mm 3 1.75

Power Volts 120 120

Lifetime years 5-7 5-7

Sound dB

Time to Disassemble and Clean minutes <10

Cooling Temperature C <20

Material Type PET PET

SAFETY

Chemical Fumes

Temperature of Outside C <50

Shutoff Time sec <5

62
Appendix D: Decision Matrix

This decision matrix uses two steps to compare designs. The first step is to assign the
priorities for each of the categories of the system. Each design was then assigned a
score in comparison to a baseline. This example analysis focuses on the cooling system
of the extruder. The baseline was the air cooling system that used a fan, implemented
by a group from Santa Clara University in 2014. The designs being considered were the
ones produced by team members.

Figure 30: Prioritization matrix for the design specifications of the cooling system

Figure 31: Concept score in relation to baseline to determine best cooling system to use

63
Appendix E: Timeline

64
Appendix F: Budget
Part Price Per Quantitiy Quantitiy Price Number AkaBot
Part Source Number Unit Per Unit Ordered Per Unit of Units Cost
Frame $32.48
Southern
Russian Birch Plywood 12mm (5' x 5') Lumber 12RB $42.79 25 1 $1.71 12 $20.54
Outside Corner-Reinforcing Bracket McMaster 15705A34 $2.22 1 2 $2.22 2 $4.44
Inside Corner-Reinforcing Bracket 2" Length of Sides McMaster 1088A31 $1.93 1 2 $1.93 2 $3.86
Bracket Zinc-Plated Steel, 2" Length of Sides McMaster 1556A54 $0.91 1 4 $0.91 4 $3.64

Hardware $21.32
Low-Strength Steel Hex Nut, Zinc Plated, 8-32 Thread
Size, 11/32" Wide, 1/8" High McMaster 90480A009 $1.49 100 1 $0.01 40 $0.60
Type 316 Stainless Steel Flat Washer, Number 8 Screw
Size, 0.174" ID, 0.375" OD McMaster 90107A010 $3.40 100 1 $0.03 100 $3.40
Type 316 Stainless Steel Button-Head Socket Cap
Screw, 8-32 Thread, 3/4" Length McMaster 98164A139 $7.98 25 1 $0.32 40 $12.77
18-8 Stainless Steel Button-Head Socket Cap Screw, 8-
32 Thread, 1-1/2" Length McMaster 92949A203 $11.36 100 1 $0.11 12 $1.36
Type 316 Stainless Steel Button-Head Socket Cap
Screw, 6-32 Thread, 1-1/2" Length McMaster 9816A445 $11.99 50 1 $0.24 4 $0.96
18-8 Stainless Steel Button-Head Socket Cap Screw, 8-
32 Thread, 2" Length McMaster 92949A207 $6.33 25 1 $0.25 4 $1.01
Steel Tee Nut for Wood, Zinc-Plated, 8-32 Interior
Thread, 1/4" Long Barrel, 1/2" Flange Diameter McMaster 90975A012 $8.54 100 1 $0.09 4 $0.34
Type 316 Stainless Steel Cup Point Set Screw, 8-32
Thread, 1/4" Long McMaster 92313A190 $2.79 25 1 $0.11 4 $0.45
18-8 Stainless Steel Button-Head Socket Cap Screw, 4-
40 Thread, 1-1/2" Length McMaster 92949A120 $10.72 50 1 $0.21 2 $0.43
Low-Strength Steel Hex Nut, Zinc Plated, 6-32 Thread
Size, 5/16" Wide, 7/64" High McMaster 90480A007 $1.16 100 1 $0.01 4 $0.05
Type 316 Stainless Steel Flat Washer, Number 6 Screw
Size, 0.156" ID, 0.312" OD McMaster 90107A007 $3.39 100 1 $0.03 4 $0.14

65
Heating $99.75
Band Heater, 900 Deg F, 1" Diameter, 2" Width Grainger 2VXZ4 $33.25 1 4 $33.25 3 $99.75

Mechanical Power $85.18

RZ12-300-
10 RPM Gear Motor ServoCity 10RPM $24.99 1 1 $24.99 1 $24.99
90 Degree Hub Mount bracket A ServoCity 585494 $5.99 1 1 $5.99 1 $5.99
Aluminum Motor Mount B ServoCity 555128 $4.99 1 1 $4.99 1 $4.99
Metal Chain (.250) 1 ft length ServoCity C250 $8.99 1 1 $8.99 1 $8.99
16 Tooth Sprocket ServoCity 615102 $3.99 1 2 $3.99 2 $7.98
6mm Bore Set Screw Hub ServoCity 545576 $4.99 1 1 $4.99 1 $4.99
0.5" Bore Set Screw Hub ServoCity 545560 $4.99 1 1 $4.99 1 $4.99
Type 316 Stainless Steel Button-Head Socket Cap
Screw, 6-32 Thread, 3/8" Length McMaster 98164A107 $10.00 100 1 $0.10 4 $0.40
Steel Ball Bearing-ABEC-1, Open Bearing No.R8 for
1/2" Shaft Diameter, 1-1/8" OD McMaster 60355K505 $6.04 1 1 $6.04 1 $6.04
Hinged One-Piece Clamp-on Shaft Collar, for 1/2"
Diameter, Black-Oxide Steel McMaster 57145K72 $15.82 1 2 $15.82 1 $15.82

Hopper $2.35
30 Gauge Sheet Metal McMaster 89015K111 $4.01 48 1 $0.08 28.13 $2.35

Auger & Chamber & Die $66.69

Southern
Weldtec Ship Auger 3/4" Lumber $32.99 1 1 $32.99 1 $32.99
Online
Seamless Stainless Tube 316 OD:1" ID:0.76" L:24" Metals $54.92 24 1 $2.29 13 $29.75
Ultra Machinable 360 Brass Rod Diameter:1-1/16" by
12" Length McMaster 8953K33 $42.05 12 1 $3.50 1 $3.50
Type 316 Stainless Steel Cup Point Set Screw, 8-32
Thread, 1/4" Long McMaster 92313A190 $2.79 25 1 $0.11 4 $0.45

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Cooling $35.82
18-8 Stainless Steel Sealing Pan Head Phillips Machine
Screw, Silicone O-Ring, 6-32 Thread, 0.5" Length McMaster 90825A717 $6.29 10 2 $0.63 12 $7.55
3/16 set screw hub ServoCity 545544 $4.99 1 4 $4.99 4 $19.96
Optically Clear Cast Acrylic Sheet McMaster 8560K261 $33.24 6 1 $5.54 1.5 $8.31

Electronics $234.79
COM-
Solid State Relay - 40A (3-32V DC Input) SparkFun 13015 $9.95 1 3 $9.95 3 $29.85
Thermocouple Type-K Glass Braid Insulated SparkFun SEN-00251 $13.95 1 3 $13.95 3 $41.85
Sestos Dual Digital PID Temperature Controller 2
Omron Relay Output Black D1s-vr-220 Amazon $28.99 1 3 $28.99 3 $86.97
COM-
Rocker Switch - SPST (round) SparkFun 11138 $0.50 1 4 $0.50 4 $2.00
6 Amp AC to 12V DC Power Adapter Amazon $11.98 1 1 $11.98 1 $11.98
22 - 16 AWG, #4 - 6 Stud Size Red Vinyl-Insulated Home
Spade Terminals Depot 410651 $6.97 75 3 $0.09 78 $7.25
Standard Wire, 300V AC, 20 Gauge, 50 ft, Black McMaster 8054T14 $7.57 50 1 $0.15 8 $1.21
Standard Wire, 300V AC, 20 Gauge, 50 ft, Red McMaster 8054T14 $7.57 50 1 $0.15 13 $1.97
Standard Wire, 300V AC, 20 Gauge, 50 ft, White McMaster 8054T14 $7.57 50 1 $0.15 18 $2.73
300 VAC/VDC Terminal Block, 10 Circuits, 3/8" Center-
to-Center, 20 Amps McMaster 7527K51 $4.51 1 3 $4.51 3 $13.53
Home 756847000
9' Power Tool Cord Depot 269 $13.97 1 1 $13.97 1 $13.97
Home 212004710
Mounting Tape Depot 25 $9.97 75 1 $0.13 24 $3.19
Red Acrylic Tap Plastic $73.20 12 12 $6.10 3 $18.30

Raw Material $59.58

Multipurpose 6061 Aluminum Rectangular Bar, 1-5/8" x
1-5/8" x 12" McMaster 9008K48 $19.60 12 1 $1.63 1.5 $2.45
Oversized Multipurpose 6061 Aluminum McMaster 89155K162 $91.41 24 1 $3.81 15 $57.13
Total $635.61

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Appendix G: Senior Design Presentation Slides

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Appendix H: Tensile Test Graphs and Results

AkaBot Filament 1 Purchased Filament

40

35

30

25
STRESS (MPA)

20

15

10

0
0 0.5 1 1.5 2
STRAIN 2.5 3 3.5 4

Figure 32: Session 1 tensile test of AkaBot 2.0 and purchased filament

Purchased Purchased AkaBot1 Akabot 2 AkaBot 3 AkaBot 4

40

35

30

25
STRES (MPA)

20

15

10

0
0 0.5 1 1.5 2 2.5 3
STRAIN

Figure 33: Session 2 tensile test AkaBot 2.0 and purchased filament

76
Appendix I: Detailed Drawings and Assembly Drawings

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