The Speculist: RepRap Friday

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RepRap Friday

Adrian Bowyer has made some significant progress in his RepRap project:

This time-lapse video (courtesy of YouTube) shows Adrian Bowyer assembling all the mechanical parts of the first RepRap Version 1.0 "Darwin" machine from start to finish. It was shot at one frame every three seconds and represents an elapsed time of about four and a half hours.

The RepRap is a self-replicating rapid prototyper. It is a 3D copy machine that will be able to make all of its own parts - minus a few items that can be easily purchased at hardware stores worldwide. The software will also be free.

RepRap will make plastic, ceramic, or metal parts, and is itself made from plastic parts, so it will be able to make copies of itself. It is a three-axis robot that moves several material extruders. These extruders produce fine filaments of their working material with a paste-like consistency. If RepRap were making a plastic cone, it would use its plastic extruder to lay down a quickly-hardening 0.5mm filament of molten plastic, drawing a filled-in disc. It would then raise the plastic extrusion head and draw the next layer (a smaller filled disc) on top of the first, repeating the process until it completed the cone. To make an inverted cone it would also lay down a support material under the overhanging parts. The support would be removed when the cone was complete. Conductors can be intermixed with the plastic to form electronic circuits - in 3D even!

This process is called fused deposition modeling; machines that do this are called 3D printers, rapid prototypers, or fabbers. They are very useful. Unfortunately they are also very expensive - $20,000 US or more - and existing models don't self-replicate. The RepRap build cost will be less than $400 US for the bought-in materials, all of which have been selected to be as widely available everywhere in the world as possible. Also, the RepRap software will work on all computer platforms for free. Complete open-source instructions and plans are published on this website for zero cost and available to everyone so, if you want to make one yourself, you can.

We hope to announce self-replication in 2008.

Bowyer named this first RepRap prototype "Darwin" because he intends to study how the machine evolves for local needs as it spreads throughout the world. It is a remarkable project that could have a profound effect on the world.

And don't miss:

Comments

I wonder when the first machines get into the wild. I'll see if I can get sufficient interest to run a Foresight Exchange claim on the matter.

Karl:

Let us know if you do!

If Bowyer has already assembled a working prototype, I doubt that it will be 2008 before it gets loose "into the wild." It might get out before Bowyer is officially ready - which he hopes to be 2008.

Yeah, If I were a betting man I'd say some version of this will be out by late 2007.

Of course "the wild" will mostly be other university labs and perhaps the workshops of a few hard core engineer geeks.

Actually since the designs are published and open source, it appears that people are already working on them. Always the problem with stuff like this, the claim may already be true.

There's a lot of discussion going on in the Foresight Exchange mailing list over my still vague proposal.

One interesting point is that the lathe not only is a machine that with human labor can make its own parts, but is also "self-building". Ie, you need to start with a "pre-lathe" and add to its capabilities gradually. Even such things as screws are developed as you go. Yes, the original machine need not be held together with screws!

For example, here's an interesting reference, Dave Gingerly wrote a series of seven books (for sale in the link) not only describing how to build a lathe, but also how starting with a charcoal foundry, build (I gather that with a few hundred hours of work) a small machine shop including lathe, drill press, mill, and shaper. If I understand correctly, he describes a way to self-build the lathe given the charcoal foundry and possibly some other tools.

"It might get out before Bowyer is officially ready - which he hopes to be 2008."

The RepRap project already has several more or less working 3D printers operational. Vik Olivier's Zaphod down in Auckland has pride of place as the first. Vik coaxed Zaphod into making a printing a part of itself way back last September at a conference in Vienna. Recently, he printed out a parts set for the Mk 2 FDM extruder, THE critical part of the printer, assembled it and installed it on Zaphod.

Ed Sells', a graduate student of Adrian's, A.R.N.I.E was next to go hot just a few months ago while my own Tommelise went hot just a few weeks back.

Darwin is going to be pretty much the first standard release version of the RepRap project. A lot of people are taking bits and pieces out of the treasure trove of technology documented at the site and trying out different stuff of their own. For example, Vik will soon be trying to make Zaphod print with PLA, a bioplastic instead of the regular polycaprolactone. My own Tommelise prints HDPE and uses shaft-encoded gearmotors for it's positioning system instead of stepper motors.

A.R.N.I.E and Darwin use belt drives for the xy axes while Zaphod and Tommelise both use threaded screw drives. There is a lot of variation in the developer community. Technology development at RepRap is proceeding along a fairly wide front.

In between Gingery and RepRap there's a whole world of homebuilt machinery. Here's a good place to start. Public domain plans for CNC routers buildable for under $500; even less if you have as many scavenged stepper motors as I do.

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