Hey everyone,
These past two weeks have been really exciting. I first
tried to tackle the random fiber assortment problem by creating a tubesheet
design that could be made with the “Othermill” CNC Mill that we have on site at
my lab. What’s cool about this mill isn’t just the name, but the fact that the
smallest drill bit it accepts is 1/100 of an inch wide at the very tip. This is
about a quarter of a millimeter (or 254 microns if you want to sound fancy).
Eric, who works the shop, showed me how to set everything up
with the Othermill. I actually breezed through most of the CAD/CAM part, thanks
to my experience with Peddie Robotics. The entire machine is about the size of
a cubic foot, which is extremely small compared to the behemoth Haas mill that
we have back at Peddie. I first milled this cool honeycomb pattern of holes
into the back of a plastic petri dish. Ideally, the honeycomb pattern will keep
the fibers in an even order with a uniform diffusion radius between each hole,
which will hopefully help with the current design challenges.
Only after spending a couple days perfecting the plastic
tubesheet/fiber-holder, I realized that pushing 36 of the 200-micron wide
fibers through rigid plastic holes wouldn’t be the greatest idea for manufacturing
efficiency. Since the fibers are so small and fragile, I had to use tweezers to
push them through the tubesheet holes underneath a microscope, which turned out
to be both extremely tedious. Even worse, I found out after potting and
epoxying the fibers that the epoxy had climbed up the fibers towards the center
of the units, meaning that the tubesheet design was probably a wash.
Back to the drawing board, but hopefully with some better
results next week!
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