Heated Metal Powder Blender
Problem: Desktop Metal needed a diverse powder blender to be able to collect data of powdered metal properties given various powder processing techniques.
Action: Devised and built a testing rig that blends metal powder in a rotating vessel, while simultaneously heating the powder, and incorporating the option for gas flow or to pull a vacuum.
Action: Conducted an in-depth heat transfer analysis to determine the total number of heating elements necessary and the thickness of the insulation required to bring the metal powder to a predetermined temperature.
Action: Created a P&ID and selected the proper components for the gas and electrical systems.
Action: Fabricated an acrylic mounting panel and 3D printed various fixturing devices from CAD to support all components.
Result: Metal powder was successfully heated to the necessary temperature while the blender was turning. The P&ID design was tested and confirmed that process gas could flow through powder or vacuum could be pulled through the system. Performed initial powder testing using the fully functional blender and analyzed the powder samples for each test.
Safety Control Box
Problem: Desktop Metal needed a safety control box that monitored an autonomous system. The control box needed to turn off the system safely if either temperature or pressure strayed from the acceptable range.
Action: Selected programmable pressure and temperature transducers monitor the system. If the sensors detect a problem, they send an electric signal to the respective relay found in the safety control box to safely shut down the system.
Action: Designed a wiring schematic with a relay logic diagram that had the capability to perform all requested actions.
Action: Ordered necessary materials, designed the layout of the box on Solidworks, modified the control box from the design, installed din rail to attach components, and wired the components.
Result: Tested and implemented the fully functional safety control box into the autonomous system, which allows Desktop Metal to safely run the system unmonitored.
