Fab@Home:Packaging

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Model II Packaging for Shipping

Survived drop tests from 2 feet on all sides, successful ship from Cornell to University of Virginia. Measurements not absolutely critical, but diagrams will be produced of the following steps for clarification.

I. Materials:

  1. 1/2" Thick 1.7LB density Polyethylene Foam . QTY: 5 (54" x 24") sheets.
  2. Bubblewrap. QTY: varies, cut to wrap around machine in all three directions
  3. Box: standard/heavy duty cardboard 20” l, 20” w, 24” h that opens on a 20"x20" side.
  4. 1.5”x1.5”x~10.5” wood shim to fit between front x-axis tensioner plates.
  5. Masking tape – to wrap around stacks of foam sheets
  6. Clear packaging tape – for box, and anchoring z-axis
  7. Knife, scissors, wood saw.

II. Preparation

  1. Detach tool - will be placed into a slot within a foam block.
  2. Move z-axis to bottom, move bridge nearly all the way to the back of the machine such that y axis motor approximately flush with back.
  3. Loosen all structural screws slightly to minimize stress.
  4. Loosen belts with tensioners
  5. Unplug ethernet cables from motors and hub, secure with tape and label for simplicity. Can be secured approximately in location where they will be used, but make sure not to pinch them when packaging.
  6. Remove feet, place into a bag and wedge into tool/accessory slot when packing.

III. Interior:

1. Note: blocks of foam will be formed from multiple half-inch pieces held together with loops of masking tape.

2. Z-table

  1. Side supports: 2 blocks. One 9 sheets thick, other ~13. Each sheet 6”x4”. Insert these on either side of the z-table support structure between it and the inside of each side of the chassis. Will be a tight fit.
  2. Bottom supports: Narrow blocks to wedge the z support structure against the bottom of the chassis, fit between the triangular spars supporting the z-support. Each block made of 6 3”x10” sheets.
1.Carve out a notch in each block such that a space is made for the deposition tool and acessories.
  1. Tape z table to z support assembly. Tape z axis down to bottom of chassis, passing across the base of each side of the machine and also the front. Use clear packaging tape as masking tape does not appear strong enough.

3. Wood shim

  1. Cut to length such that the block snugly fits into the gap in the top of the front plate along with squares of foam taped on to each end. ~10.25” + 2 foam squares on each end.

4. Snap hub support block

  1. 3 sheets 10” long, 2.5” wide each with a notch cut for the snap hub. Place around hub.
  2. Stack strips above the hub such that top of stack flush with top of machine.

5. Secure Bridge

  1. Insert small foam shims between bridge and edge of top plate.Tape bridge to back of machine using masking tape.

6. Secure motors

  1. insert small foam shims into gaps between motors and chassis.

IV. Bubble wrap

  1. Wrap in three directions:
    1. Anchor at one of the handles, wrap across each side, bottom, and top. Cut a hole where the tool will reside on the bottom.
    2. Starting on a side, wrap across the sides, front, and back.
    3. Starting on the bottom, wrap across the front, top, back, and bottom. Cut a hole where the notch for the tool is. Will probably require two sheets for coverage
    4. Fold two strips lengthwise to get double thickness and half width. Wrap around edge of each side for additional cushioning.

V. Outer foam blocks.

1. Side support blocks:

  1. 2 long blocks will be on bottom of box. 20”x~5.5”, 5 sheets thick. Place these into the bottom on opposite edges with the large face down.
  2. 2 long blocks will be on top of box. Same dimensions, but 4 sheets thick. Place these aside for now.

2. Bottom support blocks:

  1. 2 long blocks between bottom of machine and side of box. 18.5"x~5.5". 6 sheets thick. Place these perpendicular to and on top of the blocks in V.1.1 such that two L-shapes are formed in the box along the bottom and one side.

3. Bottom shim blocks:

  1. These short blocks fit between the Bottom Support Blocks (V.2.1), pressing them against the sides of the box.
    1. 2 blocks 9"x6", 6 sheets thick. These go at the top and bottom of the box between the bottom support blocks.
    2. 1 block the same size as above, but hollowed out to fit tool(s) and accessories. This indentation in this block will face and be aligned with the hollow formed by the cuts in the Z-table bottom support blocks in III.2.2, making a secure place to store displacement tools and accessories.

4. Narrow support blocks

  1. 4 narrow blocks, each 17.5"x3", 4 sheets thick.
    1. 2 lie on top of the Side Support blocks on the bottom of the box (V.1.1). They are parallel with the Side Support blocks, and perpendicular to the Bottom Support blocks (V.2.1), butting up against them and the side of the box opposite them. The 17.5"x3" side of each faces the inside of the cardboard box.
    2. 2 lie in the same orientation but against the Side Support Blocks on the top of the box (V.2.2).

5. Top shim blocks:

  1. 2 blocks, same dimensions as bottom shim blocks but 4 sheets thick. Wedged between the tops of each of the handles and the side of the box opposite to the one with the bottom support blocks (V.2).

VI. Pack

  1. Lower machine into the box such that the bottom faces the Bottom Support Blocks (V.2.1), and that the snap hub side is downwards.
  2. Adjust packaging if necessary to make a better fit by adding shims or removing layers. The box should not excessively bulge, but the machine and the foam should fit tightly against the sides.
  3. Wedge the narrow support blocks (V.4) and the Top Shim blocks (V.5) into place between the machine and the outside of the box.
  4. Seal the box with packaging tape
  5. Liberally apply "Fragile" and "This side up" labels.
  6. Ship.

Reinforce Box with Wood

Used 4x of 1x2 wood (1.5" x .75") of length:

  • 18.5"
  • 20"
  • 21"

Staple wood framing generously to the box, making sure all parts interlock with eachother.

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