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Welcome to EDSGN 497J Open-Source 3D Printing course. We cover the topic of creating physical objects by converting a part-data file to machine language G-Code, then using a self REPlicating RAPid prototyping machine - REPRAP - to extrude melted polylactic acid through a nozzle, the movement of which is controlled by the G-code instructions. The source of the part-data for this course is mainly the internet, where related sites list part files to be downloaded free of charge. Users obtain the part files, inspect for errors, convert the .stl (standard tessellation language) file to G-code and create their part on the REPRAP machine. .stl files are those which are divided into slices representing the layers that the parts are built up from. The following is a presentation of a general introduction to Additive Manufacturing:

File:Https:\\\amg104\Direct Metal Deposition Presentation.pptx

]]Here is a presentation on the method of Powder-Bed Fusion:

File:Direct metal deposition presentation.ppt

A presentation on the method of Electron-Beam mnf'g

Presentation on the method of Direct Metal Deposition:


I will post continuing information as the course proceeds. Thanks.

2 Oct 14

Still working on being able to post the additive mnf'g presentation on this site - powerpoint files too large, looking for suitable link function.

A nicely detailed 3-D print of the Nittany Lion is in the print-club area of the room. Gives a good idea of the detail capability of Rep Rap machines.

Machines "Big Red", "Beta" and "Gold" are up and running. After adjusting operating parameters, they will be available to print parts for others and then objects for the class printing service to EDSGN 100 class teams. End.

9 Oct 14

Class continuing well although attendance is roughly 1/2. Those people are simply missing out for experience with these machines and background theory. Those here are continuing quite well and I'm surprised at how many up & running machines we have already. Our print service should be ready for the EDSGN classes. Still working on a method to get my Additive Mnf'g presentations posted on this site. Else, all good for now.

15 Oct 14: Attendance is a little sketchy but those here are doing really good work. Class could use more tools and equipment such as a vice or machine tools but there's no place to put them. Weblogs are quite sparse so far - there's one that's really good, full of explanation and enthusiasm. As for this one, still trying to find a way to include my powerpoint presentations on various Add'v Mnf'g methods. Else - good so far. >>>>>>>

28 Oct 14: Here's a few sites with information on Additive Manufacturing:

The Penn State research lab for metallic additive mnf'g: Center for Innovative Materials Processing Through Direct Digital Deposition

National organization for advance mnf’g methods – America Makes:

Site for Society of Manufacturing Engineers, additive mnf'g certification program:

30 Oct 14: Great! My inputs can be seen by the class now. I'll add everything I think is useful and of interest for the class in the complete area of Additive Manufacturing, so keep visiting my entries for updates. For example, Go to for good information on the subject of designing for weight reduction of mechanical assemblies and parts. Watch out for corporate buzzwordology such as "Lightweighting", which means weight reduction. Also, when a company is pontificating sweetly about their systems, they always add the word Technology to the name of the system that they describe, to make it sound more important or official. Of course, everyone is familiar with words that have been bludgeoned into the ground with overuse such as Awesome, Specific and -Centric. I believe this is done to make the user sound more important. Ironically the statement sounds silly, not important, with such overuse. Feel free to slice through the corporate gobbledygook and read about truly substantial advances being made for additive mnf'g. More soon >>>>>>>

4 Nov 14:

Quizzes returned. There were only 10 questions, explaining the grade jumps by 10 from one grade to the next. Thursday, we will review the class grading system so that we are all on solid ground with efforts and work results.

I will bring in a hand-held scanner as soon as it is available with instructions. I want to see the class make use of this item to demonstrate the process of reverse engineering and part production using our capabilities with the RepRap systems. This is a real-world process that is used to maintain operation of mechanical systems with, for example, the U.S. Navy heavily interested for use on ships for immediate maintenance of vital systems.

The printing service of EDSGN497J will support project II of EDSGN100 classes through the Printerverse system. We will create models as submitted and if there are fewer requests than needed for our points earnings, we will find additional requests from other classes.

11 Nov 14 Vets Day

Among other items mentioned in our class was subjects for weblog commentary. Some subjects are: > Printed clothing, including military clothing with embedded sensors > Printed food (what 'stuff' is used as feedstock?) > Paste extrusion > The comparison between proprietary and open-source Selective Inhibition Sintering. Here's a technical article on potential metal additive mnf'g:

13 Nov 14:

More information on Add'v Mnf'g from ASME - American Society of Mechanical Engineers:

18 Nov 14:

It's like 20 deg outside. Talk about heat transfer... Grade status done today. Most are in good shape, others to do make-up work and will be good. New RAMPS boards arrived, awaiting Arduino boards for other maintenance. PLA feedstock plugging problems were reviewed with one of the class, possibly clearing up that problem for him so that team cancontinue progress. Else, good for now.

25 Nov 14: Going through weblog entries - some are really good, with detail and photo images. Others barely exist. I encourage the class to enter all the information that you find interesting, which oughtta be a lot!

Will look at Wiki-edits soon.

Nice write-up in the Penn State Today online periodical about the 3-D print club that Taylor Horning runs:

I wonder if anyone in the class would like to join me in diving into the deep math of direct metal deposition, which involves partial differential equations in all directions for thermodynamics, heat & mass transfer and fluid flow? I have a few nice technical reports that we could work on : )

Source for part-printing capability:

More soon >>>>>>>>>>>>>>>>