Improvement on the design of RapMan 3.1 3D printer using boothroyd dewhurst DFMA

This study focus on using Design For Manufacturing and Assembly (DFMA) to improve RapMan 3.1 3D printer. There are many methods of DFMA such as Hitachi Assembly Evaluation Method (AEM), Lucas-Hull and Boothroyd Dewhurst method; however this study uses Boothroyd Dewhurst method for improving Rap Man 3 .1. Using Boothroyd Dewhurst DFMA gives some advantages such as giving a methodical strategy to investigating a proposed plan from the perspective of assembly and fabricate. The outcome is less difficult to assembly which is less costly to collect and make it can give a pure resultant value of the time, cost measured before and after the developing process determining the best and the most efficient way to develop the unit and powering the theory. However, using DFMA has proved that the new developed design is more efficient, and saves cost and time. These advantages made it recommended to use this method in improving RapMan 3.1 which is one type of Reprap 3D printers. RapMan 3.1 has been noticed to be very difficult to assemble, due to the similarity between its pieces, whether it was by same orientation or symmetries. Also, during the assembly there are too many pieces which are hard to reach, so, in order to solve such a problem, redesigning the unit to be more suitable for regular user and also designing it more efficiently has made the unit easier to assemble, saving time, money and proving the principle of the Reprap upgrading ability. The RapMan 3.1 has a cubic shape constructed from the comers of the form. The process of redesigning included only the eight head corners as it includes most of the small parts, which are very easy to lose with no spare parts, as well as most of the similar parts, decreasing the number of parts from 15 parts to only one part. These adjustments will improve RapMan 3.1 3D printers. The new developed design will be more efficient, saves cost and time. Improving steps in this study starts with designing by handing sketches then solid work software, using DFMA Efficiency Table by making two tables one of them for the original parts and the other is for the new parts, Then making a comparison between the results of both of them to extract the design efficiency, using DFMA Equations such as effect of weight on handling time equation and effect of chamfer design equation, and using Pugh method by selecting one from three designs and the last step is parts fabrication by using Rap Man 3.1 3D printer and ABS material. The consequences of these steps will lead to reduce the total assembly steps from 429 steps to 349 steps, reduce the parts from 1502 parts to 1182 parts, and reduce the assembly time from 5197.24 Sec to 3999.26 Sec. It will make its assembly much easier by reducing the number of parts which will reduce the number of steps consequently. Hence, a lot of time and effort will be saved as well as encouraging fans of (DIY) 3D printers to start generating more creative ideas about some ways improve these type of printers. Also for those customers who prefer (DIY) 3D printers will be excited about the new version of Rap Man 3 .1 and looking forward to more enhancements in this field.