Mon 9 May 2011
Posted by Marcin
Sparks are flying in the workshop, and the Torch Table is ready for computer-aided manufacturing (CAM). Will is producing CAD and CAM files for the Tractor, from across the ocean, so we can cut tractor parts automatically:
Fri 22 Apr 2011
Posted by Marcin
Last year, we didn’t use any automation in our fabrication procedures. For example, check out the LifeTrac II build. We’re moving to digital fabrication this year. Our work this year will be a test case for optimizing production – to determine whether even your grandma can build industrial-grade tractors in her garage. To do this, we need your help. Read on.
We are taking the open source tractor, now in Prototype II phase, as the first test case. To create Prototype III, the first task is to take the existing LifeTrac design – full CAD in Blender (18 inch shorter version) by Will – and export it into CAM tool path files for every component - to be cut out on our computer controller (CNC) torch table. We are using LinuxCNC as the open source control software. As we go along, we are documenting the status and needs of the open source solution for providing a robust platform for digital fabrication of economically-significant products. Our first contribution to this is the torch table, which if we develop the open source stepper motor controller, will cost $800 in parts for a 4′x8′ working area, not counting the computer and plasma cutter. (more…)
Fri 23 Jul 2010
Posted by Marcin
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.
Open Source Metal Hole Puncher – Prototype I from Marcin Jakubowski on Vimeo.
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.
Wed 10 Feb 2010
Posted by Marcin
We’re now in production of the open source, Compressed Earth Block (CEB) press. Here we document the fabrication ergonomics for the first steps in the build. This is for those of you considering replication.
It took 11.5 hours to cut the steel for The Liberator Beta v2.0 CEB press according to this cut list. This involved punching some of the holes, shearing, and bending – care of the local fab shop.
It took me 2 hours to build the press foot:
It took 2 hours to build the grate. Here is the grate with spacers between rebar prior to welding:
So far, the total is 15.5 hours of fabrication. If we had a hole puncher, we could probably save ourselves 2 hours of outsourced labor. So here’s our design of the hole puncher, to be built – as part of an ironworker machine:
The dxf files are here, so you can download them and continue the design if you want to get involved. This is an invitation to collaboration, starting with the wiki. First part of the ironworker is a hole puncher, and second step is metal shears for up to 12 inch wide metal, 1″ thick. The shears could save us a few more hours of outsourced labor.
There are holes on the u-channel that don’t lend themselves to hole punching, so these will be drilled using the FeF Multimachine in-the-making.
Hey, look, I found two, scrap six cylinder, in-line, 300 cubic inch Ford engine blocks in the back of the pickup.
That will be the start of the next version of the Multimachine.
Cutting out the hopper took about an hour.
If we had RepTab, the open source torch table up and running already – we could cut the 1/8″ sheet in about 5 minutes at the rated cutting speed of our 60 amp plasma cutter. So here’s a case for spending 2 dedicated weeks to get RepTab shaken down into full running condition.
In the meantime, William has been learning MIG welding in preparation for his arrival in May. Here’s a video:
He is also learning QCad, so we’ll hit the ground running on design and build of a new civilization.
