Mechanical
Support Department 3D Printing
The
introduction of 3D printing to the Mechanical Support Department has changed
how our engineers approach problems. Because our inexpensive 3D printers allow
plastic parts of great complexity to be produced rapidly at almost no cost,
there is no longer an economic or time barrier to using iterative design
methods. Instead of trying to get a design 100% correct on the first try, 3D
printing enables our engineers to quickly make a 1st pass prototype,
test it out for fit and function, and use their observations to inform the next
iteration of a part. In a matter of a few days or sometimes hours, an engineer
can perform several iterations of a design and arrive at an optimized part in
far less time, and for far less cost, than conventional methods would allow.
The proliferation of iterative design methods is the future of engineering, and
Mechanical Support is embracing this methodology to improve efficiency and
deliver better designs.
To aid in our efforts, we have two 3D printers. The first is our Ultimaker 2+ Extended. It can print parts in a variety of plastics, with excellent detail resolution and a maximum print size of 8.7" x 8.7" x 12". Most parts made on this machine cost a few dollars to produce. The printer is mounted on a mobile cart using custom 3D printed brackets, has a 3D printed tool holder, and a 3D printed large spool holder as well.
The second
printer we have is a Fusion3 F400-HFR. This machine excels are producing large
parts quickly, with a maximum part size of 14" x 14" x 12.6". We recently created
a custom 25kg spool holder so that extremely large prints can be made without
worrying about running out of filament.
Below is
just a fraction of the things that have been printed on our machines in the
past few years. The printers are constantly in use, and so this list will be
updated over time to reflect new projects that have been completed.
Mu2e
Target Prototype
This
full-scale 3D printed assembly of the Mu2e target was used to aid physicists
and engineers in spotting potential design issues. This assembly was also used
to test and calibrate the target retrieval system until the real Mu2e target
was completed.
Electrospinning
Device
Electrospinning
offers a promising method of producing exotic materials. One research project
at Fermilab is investigating the use of
electrospinning to make targets. A custom electrospinning device is needed to
carry out this research, so one was designed and 3D
printed using the Form 2 resin printer that Target Systems owns. Extremely
detailed and with a novel recirculating reservoir in the base, this project is
a perfect fit for 3D printing, as conventional fabrication methods would be
cost prohibitive or impossible to use on a device like this.
Pelican
Case Organizers
Organization
and easy transport of parts is crucial to the efficiency of tunnel operations.
Custom 3D printed case separators were designed to fit many vacuum parts into a
Pelican case in an organized manner. This saves our technicians time and
reduces errors in the tunnel.
3 Point
Magnet Stand Model
Outreach and
education are important missions of the lab. To this effect, a basic 3-point
magnet stand model was designed and fabricated. It has been used in several
outreach events both at the lab and with local cub scout organizations. In
addition to this use, the magnet stand has been fiducialized
and used to practice & train personnel in the methods of machine alignment.
Recycler
Gradient Magnet Beam Tube Adjuster Assembly
The existing
beam tube adjusters at the end of the Recycler gradient magnets aren’t designed
to impart large loads on the beam tube. In at least one location, a significant
beam tube position adjustment was necessary. This was the prototype for that
design. This item was printed and installed on a Recycler gradient during an
access to ensure that the design fit the magnet, was easy to assemble and
disassemble with the beam tube in place, cleared all obstructions, and allowed
for adequate adjustment. Feedback from this plastic prototype informed a few
minor design changes in the final product. This particular
design was well received by the alignment crew, and so a modular and
universal beam tube adjustment stand system has been designed around it. This
system is now in use in the Main Injector, Recycler, and Muon Campus.
Stackable
Hardware & Tool Trays
When working
in the tunnel, ready access to organized hardware and tools improves efficiency
and reduces worker fatigue. These prototype tray designs can be customized to
fit a variety of hardware or tools and are stackable to permit easy transport.
Injection
and Extraction C-Magnet Vacuum Link Brackets
During
construction of the Muon Campus, a large potential vacuum thrust load was
identified on two magnets. To handle this load, an adjustable linkage was
designed that would tie the magnet to the ground. The linkage had to attach at
two brackets, one on the magnet and one near the ground. The engineering
drawings of the existing magnet and stand didn’t include every obstruction
present in the real-life installation. To ensure that the brackets were
designed in a way that would clear all obstructions, prototypes were printed
and installed. Once the final design was achieved, it was fabricated in steel.
Sextuple
Stand Installation Fitment Gauge
During the
2017 summer shutdown, 19 sextuple magnet stands were replaced with stands of a
new design. The existing wall mounted stand supports were reused.
Unfortunately, it was noted during an access day during spring that the wall
mount stands were not exactly built to print, calling into question the fitment
of the new sextuple stands. To ensure no clearance issues, a go/no-go gauge was
3D printed and tested on all 19 wall stands before attempting the new installation.
Luckily, the gauge showed at least a very small clearance in every case,
assuaging fears that there would be problems when installation occurred.
O2 Air
Monitor Test Cap
The
interlocks group requested a custom adapter for testing oxygen filters. They
attach this 3D printed cap to the air monitors and plug a hose into the other
side of the cap. Different grades of oxygen are then flowed into the cap to
test if the monitor trips or not. This print was made with a flexible filament
called nGen because it makes the cap easier to
install and remove with a consistent leakproof seal.
D3Q3 Pipe
Welding Plugs
Because of
the extremely strange shape of the D3Q3 vacuum pipe in the Muon campus, it had
to be fabricated out of cut strips of CNC-bent stainless steel. Jigging these
strips so that they would line up perfectly during welding was crucial, and no
conventional welding jigs or tools would give a satisfactory alignment.
Instead, custom 3D printed plugs were made, around which the sheetmetal was c-clamped. This solution turned a difficult
welding job into a simple and quick one.
CRT Wall
Prototype
An early
proposal for the SBN Near Detector CRT wall was a simple mechanically-locking
frame structure that could be pre-jigged without any tools before welding. This
design makes fabrication very simple, but explaining
how it goes together is difficult without any visual aids. This prototype
allowed the project leaders to examine the design and try it out for themselves, and was also used to get feedback from welders
and machinists involved with the project.
Borated
Polyethylene Shield Wall Prototype Model
To protect
the cable trays from damaging radiation, the Main Injector Department requested
that a removable shield wall be made around the collimators in the Main
Injector. One proposal for this design was 3D printed so that the installation
and removal procedures could be demonstrated at meetings and logistics
challenges could be solved visually.
80/20
Micro Switch Mounts
Two different
laser labs at Fermilab use micro limit switches in
their experiments. Aluminum 80/20 extrusion allows for easy design and setup of
experimental hardware, but no commercial solutions exist to mount the micro
limit switches to 80/20. Custom 3D printed mounts were designed and used to
solve this problem. These mounts are now in use at the MC1 and MP8 laser labs.
The printed black piece on the back allows remote adjustments to be made
without disturbing the experiment, saving time and making the experiment safer
for the operators.
Magnetometer
Testing Shelf
A custom
shelf was needed for holding a power supply and magnetometer that would be
lowered into the MINOS pit while taking measurements. 3D printing was a perfect
fit for this project.
SHV Connector
Cover
The
interlocks group is responsible for building and maintaining many electronics
enclosures at Fermilab, including the TLM (Total Loss
Monitor) chassis. One of the connectors inside of this chassis needed a custom
plastic cover, and 3D printing was a great fit. Several iterations of the
design were tested until the perfect fit was found. Roughly 30 of these covers
are currently in service.
Air
Velocity Sensor Mount
The
interlocks group needed to mount a proprietary air velocity sensor on the
periphery of a 24” metal pipe at HAB. This sensor used a very specific,
nonstandard thread pitch in its design, and taps or mounts for this particular thread were not available. Instead, a custom
mount was designed in NX, including the custom thread, and the entire thing was
3D printed. The printed thread fit the sensor excellently without cleanup
required.
Turbo
Pump Balancing Adapter
Because
turbo pumps have extremely high RPM components inside them, they must be in
nearly perfect balance to operate. At Fermilab, we
can balance several turbo pump styles, but the smaller Varian turbo pumps do
not fit on our balancing rig. This 3D printed adapter assembly allows us to use
the existing balancing machine with the small Varian turbo pumps.
Vacuum
Cart Bellows Protector
One
vulnerability of the vacuum carts at MI-60 is the connector bellows. If the
vacuum cart is not stored under vacuum when disconnected from the system, these
bellows hang off the end of the cart and sag. To prevent this scenario, a
custom bellows protector/slider was designed and 3D
printed as a co-op project.
Platform
Jack
https://www.thingiverse.com/thing:925556
This is a great example of leveraging open source designs. The design was made and published by a Thingiverse user named Intentional3D. The jack assembly prints in a single piece, meaning no assembly work is necessary. We only have so many metal platform jacks on hand, and they are helpful for all kinds of work here at Fermilab. This design could easily be modified to have custom contours at the top platform, such as a v-groove.
Fermilab Keychain
Originally
designed as a free 3D printed giveaway for DASTOW 2017, this keychain was a
popular choice among the attendees. Since then, we have printed several more
and used them on lab keychains.
Solenoid
Shield
The MI-60
vacuum carts all have a vulnerable solenoid mounted at an exposed corner of the
cart. This shield protects that solenoid. It is used on all 4 carts in service
and has performed its intended insurance function at least once, preventing a
solenoid from being damaged.
Nylon
Test Samples
Nylon is a
high-performance thermoplastic that can be 3D printed. These parts are test
pieces showcasing the capability of Taulman 3D’s new
Alloy 910 3D printing Nylon filament. With a tensile strength of 8100 PSI and
an elongation of 31% at tensile failure, this material offers exceptional
strength and toughness for functional objects such as tooling, alignment jigs,
and prototypes, as well as end use items.
Ultimaker Calibration Parts
These are
the calibration prints used to set up Ultimaker
printers. These parts are roughly the size of a nickel. They showcase the
detail capability of our Ultimaker 2+ Extended 3D
Printer.
D3Q3 Beam
Pipe Spacer
The D3Q3
magnet in the Muon Campus needed a very complex-shaped beam tube to go through
it. A custom spacer was required to locate the tube the correct distance off
the bottom pole tips of the magnet. To help design this spacer for a perfect
fit, several plastic 3D printed prototypes were made and tested in a span of
only a few days. The final iteration produced a perfect fit, and that design
was sent to the machine shop to make out of G10 plastic.
Expanding
Pipe Plug
Swabbing out
long beam tubes requires some sort of an expanding plug with an AlphaSorb wipe attached to the surface. This pipe plug
expands in diameter when a nut is tightened, allowing for an adjustable fit. It
also accommodates mechanical retention of an AlphaSorb
wipe.
Bellows
Retention Bracket
In addition
to having a vulnerable solenoid, the vacuum carts at MI60 also have a joint
that needs support against vacuum loads to prevent a bellows from contracting.
To design this bracket, a piece of card stock was traced over the existing
holes on the chassis. This trace was used to design a few iterations of
brackets, which were then 3D printed in plastic. During this process, a fitment
flaw was discovered that changed the design. The final version was sent to the
machine shop to be made in aluminum.
D3Q3 Beam
Pipe Vacuum Load Retainer
Due to
having different size flanges on each end, the D3Q3 beam pipe is subject to a
significant vacuum thrust load. A 2-piece collar had to be made to secure the
beam pipe. A few 3D printed prototypes were made and tested to ensure a perfect
fit. It took a few iterations to clear every obstruction, but the final design
met all the requirements and was sent to the machine shop to be made in
aluminum.
Main
Injector Dipole Model
A great use
of 3D printing is to make models for use in logistics planning. This Main
Injector Dipole can be used with a scale tunnel model to help plan out magnet
installation & removal.
Main
Injector 232 Cross Section
In the
future there may be a few new girders installed in the Main Injector 232 area.
This section of the tunnel has a non-standard cable tray, and so removal and
installation of components is slightly more difficult. To understand the
challenges, in-tunnel measurements were made and a
cross section of the tunnel was 3D printed, along with a gradient magnet cross
section. This model can be used to intuitively understand which motions are
needed to remove and install future magnets in this area.
Iro3D
Test Print
Metal 3D printing equipment has conventionally been very expensive. A small startup company in Washington, iro3d, aims to change that. They have introduced a metal 3D printer that only costs $5000. I was offered the chance to make a test part on one of their machines, so I designed a multi-functional torture test part. Included on this test part are material test samples which can be sawed off and then tensile tested.
Lattice
Generation Sample Parts
SLA printing
allows for extremely complex geometries to be printed, but there are a few
process limitations. Parts with large cross-sectional areas are difficult to
print. Designing a lattice structure into a part reduces the cross-sectional
area, increasing printability, while also generally retaining a great deal of
strength. Lightweight, strong parts can be printed using lattice structures.
These test parts demonstrate this capability and are the culmination of
developing new modeling processes here at Fermilab.
Fine
Detail Sample Part
SLA printers
are capable of extremely fine detail resolution. This open source model of the
Eiffel Tower is an excellent showcase of that capability. Printed at only a
25-micron layer height, every fine detail is present and sharp.
Prototype
Quick Seal
The current
quick seal design is very sensitive to assembly practices and flange
tolerances. A new design incorporating several improvements was made and
prototyped in plastic. The prototype helped confirm that the new folding tab
feature would not interfere with the Marman clamps
used to secure the seal.
Tensile
Test Samples
One of the
challenges of using 3D printed parts is the fact that the material properties
can vary greatly based on process parameters, part geometry, and print
orientation. Almost all 3D printed parts display non-isotropic materials
properties, and it is important to characterize this non-isotropy so that parts
will perform as intended. To aid in this testing, many ASTM D638 “Dogbone” samples have been printed with a variety of
process parameters and print orientations, and some of them will also be
irradiated. Thorough testing and analysis of these parts should give us the
knowledge we need to confidently produce more end-use printed parts in the
future.
Fast
Printing Sample
Our Fusion
F400-HFR printer is one of the fastest printers on the market, allowing large
models to be fabricated rapidly. One of the calibration prints for the printer
is a bottle with a screw on cap. This model can be printed in under 30 minutes.
USPAS Lab
Magnet Screws
The USPAS
lab program uses unique equipment to teach students about various accelerator
topics. Some of the equipment is old and failing. 3D printing offers an
excellent method of maintaining this equipment going forward. These small
screws were 3D printed to replace failing plastic screws in the dipole magnets
used for one of the lab sessions.
DUNE/LBNF
Photo Detector Prototype Molds
The design
of the DUNE/LBNF photodetectors is going to be iterative. One promising
material to make the lenses out of is cyclic olefin copolymer. This material is
readily available as beads, which can then be melted into a mold. Target
Systems’ Formlabs Form 2 printer offers a special
high temperature resin material for printing that can withstand temperatures
over 290° C. This makes it ideal for producing custom molds. This particular
mold has not been used to melt plastic yet, but has
been baked for 4 hours at 250° C to demonstrate its heat resistance.
Turbo
Pump Model
A technician
group at the lab needed a custom contoured case to hold an expensive turbo pump
for transport. The company that builds the cases wanted to borrow a turbo pump
for a few months to make the case, which is not feasible as all the pumps are
needed here at the lab. To circumvent this problem, the pump company was
contacted and provided us with a CAD model of the pump. This model was 3D
printed in plastic for use in producing the custom case.
Modified
SEY Station Samples
The current
SEY Station samples need to be modified for future experimentation. Very fine
welding, either TIG or laser, will need to be employed to attach the new
samples to the modified original sample holders. To understand the fit and
logistics involved in making this weld, a detailed plastic version was made on
the Form 2 resin printer.
Q106
Magnet Moving Vehicle Horn
During the
2016 shutdown a new rolling stand was designed for the Q106 magnet. To move
this rolling stand into and out of installed position, an aircraft tugger was modified with a custom “rhino horn” attachment.
To get the attachment dimensions exactly right, several plastic versions were
3D printed and trial fit until the exact right geometry was achieved.
Linac Cavity Displays
We were approached
by the directorate office to design three custom displays for various Linac cavities. These are currently on display in the Linac for public tours to enjoy. Each display is of a
different design to accommodate the different features of each cavity.
Large
Quad Lifting Mount Prototypes
The large
quads in the final focus of the M4 line in the Muon Campus were unable to be
lifted by the crane located in the area because the lifting fixture was too
large. A solution to weld on lifting points to attach swivel hoists was developed,
and 3D printing was used to make pieces for fit testing and to see if welding
was possible.
Oxygen Monitor
Mounts
These were used
by the interlocks group to hang oxygen monitors in various locations. The circular
feature is for easy placement on hooks and retrieval with long pole.
Blind
Bolt Mitigation Prototype Adjuster
This 3D
printed assembly for a prototype adjuster was used to explore ways of increasing
the safety of magnet stand adjusters and prevent the possibility of
unthreading. This prototype was not chosen because it was found that the
prototype had a fatal flaw. If you were to continue to extend it, it would lift
itself off the platform. This design test helped the team rapidly iterate to a
design that did mitigate the blind bolt issue in a satisfactory manner.
STEM Outreach
Marble Blaster
The Lederman
Science Center requested a marble blaster for use in its outreach programs.
This 3D printed mechanism shoots little metallic marbles so that students can
learn how magnets affect the trajectory of a moving object. The name of the
exhibit is Shape Shooter.
Prototype
Lambertson Model
To help
explain the unique geometry and assembly methods on a new lambertson
design, a 3D printed scale model was made. This model makes it much easier to
explain design features to all of the project
personnel without having to resort to verbose descriptions or confusing
drawings.