Design and Manufacturing of Educational Fiber Extrusion Device and Smart Factory

Abstract

Fiber Extrusion Device (FrED) is a desktop fiber extrusion system that mimics continuous fiber draw process for hands-on learning and/or laboratory experience on data acquisition, control system, and smart manufacturing. It allows learners to perform experiments, vary manufacturing parameters and control system, collect data, and perform analysis. Sucessful classroom activities have been conducted with FrED, however, the prior model is too costly to distribute to individual learners, given the rise of distant learning and MOOCs. A partnership with a university in Mexico, Tec de Monterrey, was formed to develop a low-cost FrED. This thesis covers the design, development and production of the low-cost variant in detail. Specifically discussing in depth the electronics system of FrED and the design for manufacturing and assembly (DfMA) process. An on-campus production and assembly facility, the FrED Factory, was made to mass produce FrEDs. The facility duals as a space for MIT students to learn about design and manufacturing. The FrED factory is undergoing digital transformation, aimed to streamline operations and to teach Industry 4.0 concepts. Three use cases are being developed: Machine Monitoring & Analytics, Smart Assembly Station and Digital Inventory Management. This thesis also covers the educational initiatives that has formed around the FrED ecosystem, both on-campus and with our partner university, Tecnologico de Monterrey, that has been conducted during the past academic year.