We have recently shown the initial test drive of LifeTrac Prototype II. The 3D model in Blender corresponds exactly to the machine built – the point being that the models in Blender are useful as actual design drawings from which others can replicate a build. The design may be scaled – meaning that the same components may be used on a machine of a different size. This implies that a MicroTrac may be based on the same design. See our previous work on MicroTrac – which is based on one driving wheel.
We are proposing MicroTrac Prototype II to be a small version of LifeTrac, as opposed to the one-wheel drive version. Stability and traction issues need to be resolved on the one-wheel design, so a good solution may be to do another simple box with wheels, like LifeTrac Prototype II. If we use the same or similar components, that means that parts will be interchangeable between the two machines – consistent with our principles of radical modularity.
This is our MicroTrac Challenge – for you to design the best, smallest implementation for MicroTrac Prototype II, built around the components of LifeTrac Prototype II. If you have no skill or experience in building a working tractor, this could be your start in your career as a design-builder of open source tractors. We have a design that works – and it may be modified easily – so our Blender drawing may constitute an Open Source Tractor Construction Set. (more…)
Our infrastructure for flexible fabrication along the lines of the Open Source Fab Lab, RepLab, is evolving nicely. We reported recently on Prototype I the heavy duty, open source, drill press, and here we are reporting on Prototype I deployment of our 150 ton hole puncher. Both of these are critical to fabrication ergonomics optimization for resilient communities in general, and, in particular – for Factor e Farm’s present fabrication of The Liberator open source CEB press and the LifeTrac open source tractor. For comparison, see earlier notes about our off-grid flex fab facility in a blog post from 2 years ago.
Here is a video on the hole puncher, with explanations.
The implementation required a high level of attention to the extreme heavy build and die positioning precision requirements – much more than anything we’ve done with the open source tractor, automated CEB press, or other devices. This is our first device that required at least some consideration of structural engineering – beyond brute-force overbuild. The local fab shop helped on the design. You can download the dxf design file at our design repository.
The CEB automation for the Liberator Beta 2.0 open source CEB press builds on other open source projects. We are using: (1), power drivers from the RepRap project for driving the solenoid valves; (2), Arduino as the controller-brain for the brick-pressing logic; and (3), a Ubuntu 8.04 Linux laptop for programming the logic. The advantage of this approach is that utilizing existing modules builds on mountains of prior work and documentation. In the limit of an open source economy – one would in principle be able to take well-documented and available parts, components, and modules to become a Maker of all the surrounding world. This is a deep part of autonomy and of evolution to freedom.
Here is a video on how the different modules are used in the prototype 2 electronics for the CEB press. You can buy the Arduino and the driver from Makerbot Industries. We use Hall effect sensors to detect the position of the hydraulic cylinders.
These electronics are then packaged in a waterproof electrical box:
The drivers are red, and the Arduino is attached below the green breakout board. The design is transparent and modular, and allows for easy access and disconnection of components for trouble-shooting. We will test this in the field shortly, so that our first CEB press product can move out the door.
Kevin Carson, Research Asociate at the Center for a Stateless Society, just published a book called The Homebrew Industrial Revolution: A Low Overhead Manifesto. This is a progressive review of industrial history, culminating in the present option of post-scarcity economics. Open Source Ecology is featured as one of the Case Studies in the Coordination of Networked Fabrication and Open Design in the Appendix of Chapter 5. If you are interested in a comprehensive overview and of the technological ecology that we’re pursuing at Factor e Farm, this is a worthwhile read. It’s an insightful and quite accurate third-party analysis of our work, and the chapter provides a more in-depth understanding of the relationship between access to cheap, modern tools and collaborative design repositories – and how these combine for radical democratization of industry. Thumbs up for this important work. It is one of the cultural creative writings of the times, aimed at breaking through society’s limited consciousness on technology and production as a means of evolving to freedom. Read more about it on Kevin’s blog.
William Cleaver will be joining us at Factor e Farm on May 1 for a Dedicated Project Visit. He’s coming from across the big pond – from the United Kingdom – and we are planning for a 3 month stay.
William is not a novice to creative dexterity – he’s involved in repair and demolition of industrial chimney stacks and natural draught cooling towers – at heights. See for yourself:
He has experience with various tools, welding brickwork, ropework, woodwork, and general shop. He’s traveled the world, studied Romance languages, taught English in Chile, and is certified to teach high ropes courses. He is now showing great interest in the deeper message of post-scarcity, resilient community creation.
We discussed the following tentative plan, with both of us working in the shop and as needed:
May – Work on finishing or building Sawmill/LifeTrac II/MicroTrac II/ anciliary implements for construction – all in preparation for building.
June – begin building autonomous, zero energy housing with solar space. Experiment with CEB floors, CEB masonry stove and chimney, stabilized bricks, stabilized reject lime bricks, stabilized brick walkway and driveway, stabilized retaining walls, and others. We plan on winter food garden and sprouting in the solar space. If progress on the steam engine goes well, we’ll aim to install combined heat and power on the masonry stove.
July – continue building until comfortable accommodations for the winter are ready for several people.
We’re looking at building zero energy homes that look tentatively like this:
Other than this, William is learning Kdenlive on Linux for movie editing, as well as and QCad for CAD work. These are staple tools now at Factor e Farm. William will begin preparing some of the technical drawings for the sawmill, so we can collaborate on making that happen over distance until his arrival.
We do want to consider bringing in additional help from the CEB general contractor, Floyd (see last blog post). We will consider hosting a CEB workshop if progress is good. If the CEB fabrication is going well – there could be resources generated to really get things moving forward, and continue to build more structures. I think now is the beginning of really settling into the land – and getting the place to look half-way presentable. We’re open to all kinds of ideas, such as the proposed CEB vault construction and others – but we’d need other people to get involved to push those projects forward. Otherwise, we’re sticking to basics and all types of experiments in the process.
It turns out that there’s a CEB contractor by Lathrop, Missouri – which is within 30 miles from us. Meet Floyd Hagerman, who has built a couple of very interesting CEB houses. The first one shown here is a hybrid – or a combination of CEB and standard construction. It has a Trombe wall – meaning a South-facing CEB wall, painted black, and glazed over. The wall serves as a thermal collector – and its performance is impressive. Last winter, before anyone moved in, the house remained above 40 degrees Fahrenheit all winter – Zone 5 continental climate – with no supplemental heating! Here’s a look.
Here is an example of DIY concrete blocks that Floyd pressed with his machine, by adding about 2% cement. Floyd used reject lime from the quarry, mixed in the stabilizer – and made an external retaining wall:
This was only 3 shovels of cement for over 1000 pounds of reject lime. So we are seeing the feasibility of stabilized blocks for outside use, especially if we add more stabilizer. Sealing the surface with stone sealer or similar cover would finish the job for complete stabilization from the elements.
With LifeTrac, we could throw a bag of cement in front of the soil pulverizer as we work the soil (80 lb for a 1000 lb load of soil, for 8% stabilization), and we would mix and load the soil in one step – ready to be used in The Liberator. We plan on using stabilized brick for walkways, base courses in buildings, and we are considering the possibility for building a driveway paved with brick.
Here is Floyd’s machine – a Powell and Sons version at $15k for up to 6 brick per minute pressing rates:
Here Floyd discusses the feasibility of building with CEB as a contractor – based on his experience. The big question is, does it work? How much would a CEB house end up costing? Here are some interesting insights:
On the open enterprise front, the field is rich for incubating a number of open source CEB entrepreneurs. Anybody out there considering CEB contracting?
Here are the initial CAD drawings for the CEB press, The Liberator Beta v2.0. You can download these drawing interchange format (dxf) files at the Open+Pario project repository. You can view dxf files with QCad, AutoCAD, Lx-Viewer, or many other applications. Note that this is work in progress, and the drawings will be updated as time goes on. New files will appear at the repository as soon as they are available.
Lawrence has finalized the open source torch table design, after 11 days at Factor e Farm. Today, we are preparing the workshop space and he’s putting together the frame. Our goal is to complete the prototype in the stated 30 day period.
We now have the completed and documented design for an open source, GPL license or compatible, CNC torch table. You can download the Blender design file, which is dimensionally correct and contains the entire design. This design is now up for review, so please comment if you have experience with building CNC machines, or if you can direct other qualified individuals to this work.
We challenge, once again, anybody to propose any further simplification that does not reduce performance. The design uses stock steel throughout, with consistency of parts in the x, y, and z directions. The only fabrication requirement is bolting, after all the steel is cut. This lends itself well to selling CNC torch table kits at competitive cost, especially because the torch table is designed to be self-replicating. With a plasma torch head, one can cut out all the metal parts required to build another torch table!
In this sense, RepRap is our brother, and in fact, we will join the happy family of Arduino controller and RepRap motor drivers to reduce the electronics costs of future torch tables by about 75% below the present $460. The dream of open source fabrication infrastructure is coming alive – at Factor e Farm.
We have a complete bill of materials (BOM). Complete sourcing information is provided in the BOM. The summary BOM is shown here for reference, including parts we bought and outstanding parts:
The torch table features designed into the Prototype 1 build include:
Full industrial duty torch table, capable of cutting up to 4×8 foot slabs of 1″ steel
Cost of DIY production is 5-10 times lower than purchasing commercial equivalents
Fully consistent with GVCS pattern language for open source technology infrastructure
Self-replicability of torch table, and direct link to optimized CEB press and tractor fabrication
Ready adaptability to router or other cutting heads
Control via laptop is so far proving effective
These are the technical merits. We must add on the organizational milestones. Lawrence is presently succeeding in doubling Factor e Farm’s technical development capacity under his Dedicated Project Visit (DPV) – by demonstrating capacity to succeed in his stated goals. This has encouraging implications for scaling the project in general – as Lawrence is well on his way to demonstrating the power of well-thought out DPVs in terms of their ability to move design and build efforts forward. Personally, I am inspired – because we’re seeing that aligned effort can accomplish a great deal.
The above should be compelling reason for supporting our first torch table prototype build – as a part of a greater process towards optimized, open source product release. We’re equipped with a robust design, initial review is complete, we invite any further comments, and we are ready to move. Our outstanding costs are $800 for the Everlast plasma cutter , and under $600 for remaining gantry parts – for a total outstanding cost of $1358 including shipping. See BOM above. And then, ChipIn:
Power Cube is our open source, self-contained, modular, interchangeable, hydraulic power unit for all kinds of power eguipment. It has an 18 hp gasoline engine coupled to a hydraulic pump, and it will later be be powered by a flexible-fuel steam engine. Power Cube will be used to power MicroTrac (under construction) and it is the power source for the forthcoming CEB Press Prototype 2 adventures. It is designed as a general power unit for all devices at Factor e Farm, from the CEB press, power take-off (PTO) generator, heavy-duty workshop tools, even to the LifeTrac tractor itself. Power Cube will have a quick attachment, so it can be mounted readily on the quick attach plate of LifeTrac. As such, it can serve as a backup power source if the LifeTrac engine goes out. See the construction of Power Cube, and demonstration of it powering the PTO generator:
The noteworthy features are modularity, hydraulic quick-couplers, lifetime design, and design-for-disassembly. Any device can be plugged in readily through the quick couplers. It can be maintained easily because of its transparency of design, ready access to parts, and design for disassembly. It is a major step towards realizing the true, life-size Erector Set or Lego Set of heavy-duty, industrial machinery in the style of Industrial Swadeshi. Via open source, it is now becoming accessible to everybody. With the addition of local biofuel (pyrolysis oil) and steam engines, we await the time where local production is a reality.
I just got back from The Crucible in Oakland, CA where I spoke to Nick DiPhillipo. Nick constructed their foundry and has designed and built foundry equipment such as kilns and cupola furnaces at The Crucible, UC Santa Cruz, Artworks in Berkeley, and elsewhere.   We talked about setting up a basic foundry, electric induction furnaces, and appropriate technology.
Nick recommended some great sources of further information I want to pass on: Steve Hurst’s book Metal Casting: Appropriate Technology in the Small Foundry and the publishing houses Development Publications and Lindsay Publications.  Steve Hurst’s book talks about doing lost wax with bee’s wax and using cow dung mortar in mold making. I’m really excited.
According to Nick, Factor E should get started by building a training setup: A gas-fired crucible in the 10-30lb range plus the infrastructure for lost wax casting- A ceramic slurry batch mixer and a system for melting the wax out. Building an induction furnace is by all means possible, but the crucible furnace is a great system for small casting and is simple to build and operate. It’s something that will continue to get use even with an induction furnace around.
Induction is definitely the only way to go if we want to do serious work with iron and steel. The Crucible used someone else’s home-made induction furnace to cast the stainless steel funnels in the kiln (I’m going to try to contact the individual who designed and built this induction furnace).
Ok, well I’m headed back to the East Coast. Thanks for all the help, California.
We are farmer scientists - working to develop a world class research center for decentralization technologies using open source permaculture and technology to work together for providing basic needs and self replicating the entire operation at the cost of scrap metal. We seek societal transformation through interconnected self-sufficient villages and homes. This is a stepping stone to transcending survival and evolving to freedom. Factor e Farm is the land-based facility where we put this theory, Open Source Ecology, into practice. More
[Open Source Ecology] is yet another example of the many efforts underway to accelerate DIY technology development for Resilient Communities (The RC). As personal fabrication improves, these tinkering efforts will become MUCH more sophisticated at an ever decreasing cost. We (collectively, those of us engaged in decentralized thinking/action) are in the process of reinventing how the global economy is structured at a root level — good thing we didn’t ask permission. — John Robb, Global Guerrillas
Today, we are preparing the workshop space and he’s putting together the 
The project is part of our flexible fabrication workshop infrastructure,
which we discussed initially in an 
It can be maintained easily because of its transparency of design, ready access to parts, and design for disassembly. It is a major step towards realizing the true, life-size Erector Set or Lego Set of heavy-duty, industrial machinery in the style of 
