1. Name of applicant and organization:
Name: Agustín José Cruz Fernández, Laser-Metal E.I.R.L
2. Email address: 3dmetalprintingproject@gmail.com
3. What track are you applying to?: Established Project Track
4. Tell us about your project in one or two sentences
This project consists of an Open source, low-cost 3D Metal Printer for developing and low income countries, using an electron beam to sinter the metal powder. This project will spread the GOSH ethos in ways that would not be possible without this grant.
This printer uses an electron beam to selectively melt each layer of metal powder, causing the powder particles to fuse together. After one layer is complete, the build platform is moved down one layer in height. The re-coater comes in again with a fresh layer of powder, and the electron beam starts to induce the fusion of powder particles, causing the new layer to form. This process is repeated until the entire part is finished, making a solid metal part. Each layer height is around 0.05mm to 0.1mm thickness.
5. Describe your project goals and how you expect to achieve them
The goal is to make 3D Metal Printing more affordable to the general public, hospitals, small institutions, organizations and companies around the world. Specifically for developing and low income countries. This project fills a gap that no open hardware successfully fills.
3D Metal Printing is an impactful tool. Making it more accessible will democratize science, engineering and empower people. This low-cost hardware will be able to accelerate innovations in and lower barriers to scientific research.
The technical goal is to make a low cost 3D Metal Printer capable to work with titanium, stainless steel, aluminum, and other 3D metal printing powders. The electron beam focus point diameter is around 0.1mm, and the thickness of each layer of metal powder is 0.05mm to 0.1mm.
The initial work will take place in Chile. Then this project will continue to build and sustain collaboration with people around the world through it’s website wiki, collaborative websites like GitHub, GOSH Open Hardware website, social networks, YouTube and other channels.
This 3D Metal Printer will use already available open source 3D Printing software, like Cura, Slic3r and others. So there is no proprietary software and no black boxes.
6. Approximately how many people would be working on your project?
In Phase 1, there will be two people working in the following activities:
• CAD Design
• Electron beam optics: electron gun optimization
• Testing: Electron gun testing and powder sintering
• Project reporting on GOSH Open Hardware website
In Phase 2 there will be four people working in the following activities:
• Mechanics: Z Axis development
• Metal powder re-coater development
• 3D Metal Printing Testing/Operation
• Electronics: High voltage power supply optimizations
• Software programming
• Electron beam optics: electron gun optimization
• Website creation with the full documentation of the step-by-step instructions to build the 3D Metal Printer, hardware designs, the source code, videos, project reports, etc. GitHub project site creation, GOSH Open Hardware project site creation.
• Project reporting on GOSH Open Hardware website
Also, we’d expect to constantly increase the number of active volunteers over the next months, since this is a global project, and anyone can collaborate.
7. Describe how your organization will create and manage collaboration with others.
Our organization will stress the opportunities that are presented in pre-production, co-creation, customization, and collaboration through open processes of the 3D Metal Printer development. The final 3D Metal Printer can be created, modified, used, or distributed by anyone.
Specifically, the collaboration will be managed in two branches:
-Software collaboration: The 3D Metal Printer project will create a GitHub page, so anyone can browse and download software repositories but only registered users can contribute content to repositories. With a registered user account, users can have discussions, manage repositories, submit software contributions to others’ repositories, and review code changes.
-Hardware collaboration: The project will create a parent category for open science hardware project in GOSH Open Hardware website, where Hardware and operational tests will be fully documented, so anyone can browse and download the schematics, designs, etc. Only registered users can have discussions and submit hardware contributions to others.
8. Does your project have representation for a marginalized demographic due to factors such as race, ability, place of birth, gender, sexual orientation, socioeconomic class situation or other identification? If so, how?
We are open to including marginalized people in science and hardware and approach people actively to take part. We actively invite women, people of color, people of disability, people from varying social and economic backgrounds to take part in this project.
Our organization is registered in Chile, but our aim was always to connect a global network of individuals and groups from diverse cultures, low resource environments, as they also exist in Chile, America, Europe, as well as everywhere on the globe. We will use the GOSH guidelines for participation and collaboration.
The targets are professionals and amateurs, particularly in low incomes countries. Participation is not restricted to any particular background, country, race, sex, religion, etc. The use of 3D printing in a healthcare system for rural developing communities allows for a unique insight into product and technology adoptions processes in developing communities.
For hospitals located away from major cities, 3D Metal Printing will be practical when supplies run low. This is especially important in farming communities where patients from the nearby fields who come in with work-related injuries could be outfitted with custom splints that are 3D Metal Printed as needed.
We find that entrepreneurs will benefit from this project. Especially early stage entrepreneurs that are not yet financially secure enough to easily afford a 3D Metal Printer. Increasing access for these entrepreneurs ensures greater representation and impact, paving pathways to get these deep-tech innovations more efficiently into the market. Adopting open-source approaches play a key role in this process. The 3D Metal Printer design, plans, videos, schematics will be open and free for any person in the world.
9. What resources / infrastructure do you currently have to support your project?
Currently, the organization has a workshop in Chile, where the design, development and manufacturing of the equipment and parts are carried out. It has water, electricity and satellite internet to improve connectivity.
It has laboratory equipment, such as oscilloscopes, microscopes, different measurement instruments, high voltage power sources, vacuum pumps, digital vacuum gauges, cooling systems for vacuum pumps, among others.
Additionally, there are automated CNC machines, a laser machine, a mechanical lathe, welding machines, computers, work spaces, and various electrical tools, to manufacture the necessary parts for the project.
There are emergency generator systems to ensure the stability of electricity. There is also all the necessary space to expand the infrastructure, install new machines and increase the number of people to operate the equipment.
There are vehicles to transport cargo. The location is a safe place with controlled access.
10. What will you use the funds for? Describe your budget. List what you are going to spend it on and how.
Phase 1 budget: $5200 USD
Funds: $4600 USD. Own capital: $600 USD
1 April to 5 July 2022 (3 months)
Cost Category |
Details |
Estimated Cost in USD |
Why it’s needed |
Personnel |
Professional electric engineer, with experience in building CNC machines, Research & Development. Project leader. 4 months |
$3500.00 |
Needed to design and develop the hardware, operational testing |
Personnel |
External expert for electron gun design (consultant) |
$300.00 |
Needed as a consultant for general guidelines for the electron gun optimization and to achieve the smallest spot size possible |
Subcontracts |
CNC Machining: Laser Cutting of Steel and Stainless steel parts |
$100.00 |
Needed to cut the CAD design made of steel and stainless steel parts |
Subcontracts |
CNC Machining: CNC lathe of steel parts |
$200.00 |
Needed to manufacture the electron gun |
Subcontracts |
CNC Machining: waterjet cutting of ceramic parts |
$100.00 |
Needed to manufacture the electron gun |
Supplies |
Steel and Stainless Steel stocks |
$100.00 |
Needed for making the electron gun |
Supplies |
Ceramic materials |
$300.00 |
Needed to manufacture the electron gun |
Supplies |
1Kg of Metal powder for sintering testing |
$200.00 |
Needed for powder sintering testing with the electron beam |
Other expenses |
Shipping costs for ceramic parts |
$200.00 |
Needed to manufacture the electron gun |
Other expenses |
Project website domain registration (.org or .io) for 5 years |
$100.00 |
Needed to secure the project domain for a long time |
Other expenses |
Shipping costs for 1Kg of metal powder |
$100.00 |
Needed for powder sintering testing with the electron beam |
Phase 2 budget: $19100 USD
Funds: $18000 USD. Own capital: $1100 USD
30 June to 5 November 2022 (4 months)
Cost Category |
Details |
Estimated Cost in USD |
Why it’s needed |
Personnel |
Professional electric engineer, with experience in building CNC machines, Research & Development. Project leader. 4 months |
$6500.00 |
Needed to Z Axis development, powder re-coater development, electron gun optimizations, operational testing, reporting, etc |
Personnel |
External expert for high voltage power supply design (freelance, consultant, etc). Include circuit testing. 1 month |
$2000.00 |
Needed as a consultant for high voltage power source optimization to add feedback and better stability |
Personnel |
External expert for programming (freelance). 2 weeks |
$1000.00 |
Needed as a freelance for programming the needed code for translating the 3D software output to the printer instructions |
Personnel |
External expert for electron gun design (freelance, consultant, etc). 2 weeks |
$1000.00 |
Needed as a consultant for the electron gun optimization. To evaluate XY deflection systems |
Subcontracts |
CNC Machining: Laser Cutting of Steel and Stainless steel parts |
$1000.00 |
Needed to cut the CAD design made of steel and stainless steel parts |
Subcontracts |
CNC Machining: CNC lathe of steel parts |
$700.00 |
Needed to manufacture the electron gun |
Subcontracts |
CNC Machining: waterjet cutting of ceramic parts |
$300.00 |
Needed to manufacture the electron gun |
Supplies |
Steel and Stainless Steel stocks (pipes, bars, tubing, sheets) |
$500.00 |
Needed for making the Z Axis, powder re-coater, electron gun optimizations |
Supplies |
Ceramic materials |
$500.00 |
Needed to manufacture the electron gun |
Supplies |
20Kg of Metal powder for testing |
$500.00 |
Needed to make operational 3D Metal Printing tests |
Supplies |
Vacuum parts: vacuum sensor (gauge), vacuum fittings, vacuum bellows |
$800.00 |
Needed to manufacture the Z Axis and powder re-coater |
Supplies |
Electronics circuits: High voltage capacitors, high voltage diodes, high frequency ferrite cores, high voltage resistors, mineral oil |
$1500.00 |
High voltage power source optimizations |
Other expenses |
Shipping costs for ceramic parts |
$300.00 |
Needed to manufacture the electron gun |
Other expenses |
Shipping costs for 20Kg of metal powder |
$1000.00 |
Needed to make operational 3D Metal Printing tests |
Other expenses |
Project website hosting for 5 years |
$500.00 |
Needed to make the project website |
Other expenses |
Shipping costs for vacuum sensor, fitting, bellows |
$600.00 |
Needed to manufacture the Z Axis and powder re-coater |
Other expenses |
Shipping costs for high voltage supply developed by external consultant |
$200.00 |
Needed to optimize the high voltage supply |
Other expenses |
Shipping costs for Electronics circuits |
$200.00 |
Needed for different parts of the 3D Meal Printer |
The amounts described in both budgets are “before taxes”. Net amounts depend on applicable taxes. Costs are approximated.
11. How will you share the outcomes your project? What documentation will you provide so that it will benefit the community as a whole? (videos? photos? a how-to?)
The 3D Metal Printer Project will have a website wiki with the full documentation of the step-by-step instructions to build the 3D Metal Printer, hardware designs, the source code, videos, project reports, etc.
Also, this material will be permanently available in collaborative websites like GitHub, GOSH Open Hardware website, social networks, YouTube and other channels.
All these materials will be released under OSHWA-compatible licenses for hardware, free software licenses for software, and CC BY 4.0 or CC BY-SA 4.0 for others
12. How will your project address GOSH’s values of diversity and inclusion?
3D Metal Printer Project directly addresses GOSH’s values of diversity and inclusion. Enabling an exchange across different people in developing countries.
We invite free-lancers, creatives, hackers and artists, alongside researchers from established research institutions and professional hardware/software developers.
By explicitly using the GOSH guidelines to outline this project, we ensure that the issues of diversity, respect, inclusion and tolerance are foregrounded in all the processes.
13. Are there any conflicts of interest that you wish to declare?
Conflicts of interest: None
14. Describe your experimental plan, including any new technologies or tools to be developed.
Currently there is an advanced functional prototype, with more than 5 years of research and development with its own capital. This prototype is used to carry out initial tests and verify technical aspects before making larger investments.
The most important technical challenges are already 70% solved. The functional prototype is composed of a vacuum chamber made of stainless steel, a vacuum pump system, an electron gun, high voltage power sources, electrical connections, cooling systems, sensors, among others.
At this time the prototype is capable of generating a 0.5mm diameter electron beam, focusing it on a metal surface and moving it in XY axis. In this way, it is possible to heat a metal piece using the electron beam. Currently, optimization of the electron gun is being worked on, evaluating different configurations to reduce the size of the spot from 0.5mm to 0.1mm in diameter or less.
After that technical milestone is met, the next step will be to add the Z-axis and a metal powder re-coater. The Z axis will be composed of a stepper motor, guides, linear bearings and a controller.
The metal powder will be ordered and 3D printing tests will be carried out on different metals (titanium, stainless steel, aluminum, etc.)
You can see the video of the advanced prototype here:
3D Metal Printer - Electron gun tests
15. How will the work you describe be performed within the budget and time period allocated for the initial Phase I award? This should include project work time, ramp up and required reporting.
Phase 1 - Total Weeks: 12
Budget: 5200 USD
Funds: $4600 USD. Own capital: $600 USD
Time |
Details |
Estimated Cost in USD |
Week 1 |
Professional electrical engineer: Ordering metal powders used for 3D Metal Printing (titanium, stainless steel and aluminum powders). This activity includes quotations from different metal powder providers and manufacturers overseas. Cost includes shipping. Project reporting on GOSH Open Hardware website
|
M:$300 HR:$292 |
Week 1 |
Project website domain registration (.org or .io) for 5 years |
M:$100 |
Week 2-3 |
Professional electrical engineer: Electron gun CAD design and simulations using electron beam optics software. Project reporting on GOSH Open Hardware website
|
HR:$583 |
Week 2 |
An external expert will suggest the best electron gun design. Project reporting on GOSH Open Hardware website
|
HR:$300 |
Week 4-7 |
Subcontracts and Professional electrical engineer: Electron gun manufacturing. Steel parts are manufactured in a CNC lathe, then are polished and welded in our workshop. Ceramic parts are water cutted, then grinded in our workshop to have a smooth surface. Project reporting on GOSH Open Hardware website
|
M:$1000 HR:$1168 |
Week 8-9 |
Professional electrical engineer: Electron gun testing. Spot size diameter measurements. Testing on different metal surfaces. Project reporting on GOSH Open Hardware website
|
HR:$583 |
Week 10-11 |
Professional electrical engineer: Electron gun testing on a thin layer of metal powder. Powder sintering testing. Project reporting on GOSH Open Hardware website
|
HR:$583 |
Week 12 |
Professional electrical engineer: Final Project reporting on GOSH Open Hardware website. Phase 1 summary |
HR:$291 |
M: Material. HR: Human resource
16. What essential milestones will you generate during your Phase I award?
In Phase 1 the essential milestone is the focusing of the electron gun to a 0.1mm diameter spot. The current electron gun is capable of focusing to a 0.5mm diameter spot. This will offer the possibility in Phase 2 to 3D metal printing very fine details.
Also in Phase 1 will be carried out the first powder sintering tests. Every step will be documented on GOSH Open Hardware website
17. If Phase I is successfully completed, what are the next steps?
In Phase 2, the next step is integrating the Z axis and the powder coating system. Three external consultants will participate in this Phase, working in the programming, electronics and the electron gun design. The goal is to use common electronics components, so people from developing and low income countries can build, modify and repair easily.
Also in Phase 2 will take place the first operational 3D Metal Printing tests.
Every step will be documented on GOSH Open Hardware website
18. Please include a brief breakdown of allowable direct costs under the following categories: personnel, supplies, subcontracts, travel, and other expenses (equipment).
Breakdown of allowable direct costs for Phase 1:
• Personnel: $3800
- $3500: Agustín Cruz. Professional Electric Engineer, with experience in CNC projects, Research & Development
- $300: External consultant on electron optics
• Supplies: $400
- $100: Steel and stainless steel stocks (bars, pipes, tubing, sheets)
- $300: Ceramic parts (discs, plates, sheets)
- $200: 1Kg of Metal powder for sintering testing
• Subcontracts: $400
- $200: CNC lathe machining on steel and stainless steel parts
- $100: Laser cutting steel and stainless steel parts
- $100: Water jet cutting ceramic parts
• Other expenses: $400
- $200: Shipping costs for ceramic parts
- $100: Shipping costs for metal powder
- $100: Project website domain registration
Pictures and videos:
3D Metal Printer - Electron gun tests