BYRON LEE
BYRON LEE

 

 
M3-4-1.png

Carbon M3 Printer

Sr. Staff, Industrial Design Lead 2021-2023

  • Industrial Design

  • Project Management

  • UI.UX Research

  • HMI Design

Overview

Complete redesign of Carbon’s flagship printer to improve print quality/efficiency, scalability, HMI and alignment with business goals.

Lead the design and development of the Carbon M3 series printers, a high-impact, large-scale redesign with significant visibility across the organization. This project presented unique challenges, requiring solutions adaptable for diverse users, from small studio labs to high-volume manufacturing facilities.

In addition, the design had to accommodate the varying hardware configurations of the M3 and M3 Max within a shared chassis, including the M3 Max's double-sized print area and light engine. This required extensive cross-functional collaboration and strategic foresight.

Faster: Up to 2.5x Higher Throughput

Simpler: Built with You in Mind

Smarter: A Broader Design Space

Smoother: Consistency with a Fine Finish

 
 

001- INVESTIGATION Challenges

Data compiled from 6 yrs of customer data.

  • Small (DLP) light engine = small printable area

  • Cantilever print drive system = slow print time

  • Not scalable for automation

  • The cylindrical form factor- “It’s a tube”

  • Hard to access service panels

  • Poor display location and UX

  • Lack of status indication

  • Many (Overly) complex custom solutions

  • Poor facilities requirements

 

001- INVESTIGATION Product Requirements

  • Print performance increase

    • First print success

    • Speed & Quality

    • Increase annual resin sales

  • BOM cost reduction (always…)

  • Scalability for automation and lights out production

  • Single chassis design for 2 DLS engine sizes

  • Hardware serviceability and cleanability

  • Ease of install- HW and SW

 
 
 

 

IMG_6609.jpeg

001- CONCEPT PROTOTYPE

Engineering R&D: Z-Drive System Designs and Comparison

  • Single motor (center) drive system v.s. Dual motor (sym. and asym.) drive system, all developed as R&D units.

  • Print drive efficiency analysis + FEA

  • Initial BOM cost study (business case)

 

001- DESIGN SPACE EXPLORATION

Initial ID Concepts

  • On/Off-site UX & Ergonomics research and testing (customer sites) on developing concepts.

    • UX on user journey

  • Facilities requirement documentation

    • ADA and interior design requirements

    • Specific customer requirements- eg. J&J

    • Serviceability and accessibility

 

IMG_6589.jpeg

001- Key Learnings Decision Drivers

  • Customers wanted higher yield with more printable area, faster print speed. Cannot keep up with demand but committing to additional printers is challenging.

  • Higher quality prints with less layer lines. This requires less post-processing time.

  • Poor service experience of the light engine and other key components, such as the oxygen sensor and electronics. Currently, on the M2, all side panels must be removed for service, resulting in poor facility requirements.

  • Print deck accessibility is critical for cassette and platform UX.

  • Automation requirements- scalability for robots and other automated attachments.

  • Poor HMI experience with existing printer

Twin Drive System ->

  • The more robust and scalable system

  • Twin drive system allowed parts to print and pump at a higher rate while holding part accuracy

Twin drive R&D system

 

 
M3_Curve_006.182.jpg

 001- CONCEPT REFINEMENT

ME & ID Packaging Design

  • Finding the right balance between function and aesthetics while staying true to the Carbon brand identity

    • Single chassis design

    • Service and Facility requirements

  • Printer ergonomics and UX

    • Carefully work through touchpoints like Display, Cassette and Platform UX

  • HMI Design

    • Custom Touchscreen display

    • Visual status indication through an integrated LED status bar on top of device as well as interior lighting

    • Audible feedback

    • Mechanical v.s. digital switches

 
 
 
 
 
Sunrise 006- Beta, 4EDU.288.png

 002 DESIGN DEVELOPMENT

  • Lead the design and development of all ID and HMI features. Working cross-functionally with ME, EE, Print Dev. and SW teams.

    • Print arm, platform and cassette ID

    • Touch screen

    • LED status bar

    • Service access door

    • Custom notification sound design

    • Interior lighting

    • CMF

Alpha Builds

 
 

 002-003 DESIGN DEVELOPMENT | DFM

 

Cassettes & Platforms

  • M3 and M3 Max lightweight platform for better ergo

  • M3 Max lightweight cassette for better ergo

  • Cassette handle and pour spout for better handling and cleaning post pring

  • Cassette pour stand (legacy) for ease of cleaning and resin swap

  • Cassette lid for transport and storage

  • Ergo State for easy part removal

 

Custom Full-Touch Display

  • Designed and developed the display module

  • Defined and sourced the final touch sensor/LCD

  • EMC/EMI design and support

 

LED Status Indicator Bar

  • Integrated LED status lighting design

  • Defined and sourced the final LED strip

 
 

Service access door

  • Ease of service and access to all internal components

    • Oxygen, light engine, EE and power

  • Spill contamination solution on the main deck

  • Hands free access window design (yellow door)

 
 

Custom Sound Design

With Sanctus Audio

  • Sounds that work well various types of production settings

  • Sound designs for feedback and printer states

  • Carbon audio logo design

 
 
 
 
 

003 Design For Manufacturing

Beta Fab Design Review and QC

  • Developed a master Cosmetic Spec document for QC

  • Inspection and QC on all aspects of design

    • Part fitment

    • Paint quality, lot to lot color, color matching

    • Packaging

    • Quality of all parts

 

 
IMG_3888.png
 
 
 

 004 PRODUCTION AND FIRST INSTALLS

Carbon M3 & M3 Max

  • Build area doubled in size

  • 2.2x faster print speed

  • Higher accuracy and repeatability

  • Higher yield for first print success