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FAB LAB IN A BOX

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Summary

During Machine Week, we designed and built FabLab in a Box—a compact, articulated robotic arm capable of plotting, laser engraving, and pick-and-place operations. Inspired by open-source projects like the “20 Square Feet Factory,” we extended the concept to develop a versatile robotic platform using articulated kinematics, salvaged components, and custom 3D-printed parts. The system was integrated using RAMPS 1.4 electronics, Marlin firmware, and multiple toolheads including a gripper, pen holder, and laser module. Through calibration, inverse kinematics programming, and practical testing, we were able to simulate real-world robotic tasks and prepare for future add-ons such as a 3D printing head and 4th-axis control.

Work Process Detail

1. Brainstorming & Project Selection

  • Initiated team discussion to choose a creative and technically challenging idea for Machine Week.
  • Considered three robotic kinematics: Articulated, SCARA, and Cartesian.
  • Selected Articulated kinematics for its mechanical advantages and unique motion profile.

2. Research & Reference Design

  • Studied the open-source project 20 Square Feet Factory.
  • Decided to build an enhanced version tailored for multifunctional use (plotting, engraving, gripping).
  • Named the system FabLab in a Box to reflect its modular, compact, all-in-one capability.

3. Design Finalization & Planning

  • Defined a 3 DoF articulated arm structure.
  • Planned multi-toolhead support: pen plotter, laser, gripper, and future 3D printer.
  • Delegated tasks across the team: mechanical, electronics, programming, and integration.

4. 3D Modeling & Printing

  • Modeled parts in Fusion 360.
  • Printed components in PLA with reinforced infill for stability.

5. Local Sourcing & Salvage

  • Purchased required mechanical parts locally: bearings, screws, nuts, washers.
  • Recycled motors and belts from unused 3D printer kits.

6. Mechanical Assembly

  • Labeled and organized all parts for efficient assembly.
  • Resolved bearing mismatch using tape shimming.
  • Fully assembled arm in 2 days.

7. Electronics Setup & Testing

  • Installed RAMPS 1.4 board with A4988 stepper drivers.
  • Used 12V power supply, verified voltage and current with a multimeter.
  • Pre-tested motors and limit switches separately.

8. Firmware & Serial Communication

  • Uploaded Arduino-based firmware.
  • Tested movement via Serial Monitor and YAT.

9. Calibration & Base Setup

  • Built a flat MDF base plate with coordinate grid.
  • Added aluminum rails for rigidity.
  • 3D printed calibration jigs to align joints.
  • Tuned joint positions and updated kinematic values in firmware.

10. Gripper Design & Pick-and-Place

  • Designed and printed a dual-finger gripper.
  • Controlled with stepper motor connected to RAMPS.
  • Stacked blocks labeled A, B, and C using YAT-based serial commands.

11. Frame Enclosure

  • Constructed aluminum cube frame to support future acrylic enclosure.

12. Plotting System Integration

  • Flashed Marlin firmware with robot-specific configuration.
  • Used Pronterface to control motion.
  • Converted SVGs to G-code using Inkscape Laser Tool plugin jtech laser gcode.
  • Successfully plotted images like the Fab Foundation logo.

13. G-Code Coordinate Adjustments

  • Used G92 commands to manually define origin.
  • Corrected homing offsets dynamically via G-code commands.

14. Laser Engraving Setup

  • Laser-cut a custom laser mount for the toolhead.
  • Calibrated Z-offset and tested laser focus.
  • Engraved logos on paper using Marlin + Pronterface.

15. Final Testing & Evaluation

  • Completed testing of gripper, plotting, and engraving functions.
  • Validated full motion and command precision.

16. Extension (Work-in-Progress)

  • Designed and prototyped a 4th axis rotary head using SolidWorks.
  • Exploring integration of 3D printing functionality.

Learning Outcome

This project gave us hands-on experience in full-cycle machine development—from mechanical design and fabrication to electronics integration, firmware customization, and motion control programming. We deepened our understanding of robot kinematics, serial communication,firmware behavior, and tool-path generation using open-source tools. The collaboration also enhanced our team dynamics, problem-solving, and prototyping skills. Most importantly, it proved that with resourcefulness and a clear vision, it’s possible to build a multi-functional robotic system within a short time using accessible materials.

Digital Files

Resources

Last update: April 23, 2025