Distributed Rapid Manufacturing Using 3D Printers For Disaster Relief (Part3)

This will be just an overview of the main points of quality control for distributed rapid manufacturing using 3D printers that I have identified. I am sure that there are plenty more aspects to this subject, since this subject has never really been discussed.

The main points that aid in maintaining quality.

• Device Design
• Simplicity
• Ease of assembly 
• Intutitive to manufacture
• Use of standard materials
• Documentation of Manufacturing Process Parameters Used
• Printing process setup, general specs.
• Program printing parameters posted.
• Inspection(Duh!)
• Assure that the device or any of it's components is not out of spec
• Documented inspection procedures(SOPs)
• Operator
• Registered users akin to how HAM radio operators are licensed 
• Motivation

Design

1. Simplicity - Making  a device simplistic is a must for maintaining quality in distributed manufacturing It allows for more give in the system as whole. The system encompasses not only the actual device but manufacturing processes that must create the part and the operator that must assemble the device. This facet has a trickle down affect to other main points such as inspection, etc... Such as if the device is designed to be inspected with simple calipers,etc.. Also minimizing interfaces whether they are mechanical, electrical, fluid,etc.. or any combination of these. Interfaces are a point were failure can be introduced. For example, instead of using two pieces and joining them together, spend a little more time and make a design where a single piece can be used instead. Never settle on a design and constantly innovate to make that design more simple. 
2. Ease of assembly - By making the device easy or intuitive to assemble, errors can be minimized during the actual assembly process. 
3. Intuitive to manufacture -  If the device components impute the way they should be manufactured then errors can be reduced by an even experienced operator, since the system software(RepG, UP! V.1, etc...) often allow for 6 degrees of freedom(x, y, z, theta_x, theta_y, theta_z) set by the operator.
4. Use of standard materials - In order to create a more standardized version of device the materials must be readily available and fairly common. The most prominent material in the hobbyist, DIY 3D printing world is PLA, and ABS plastic. Preferably this material would be sourced from a single vendor if possible but other vendors could be used if needed. Also, if a design uses other materials the designer/operator must be conscientious of how operators in other parts of the world must obtain the materials.

Documentation of Manufacturing Process Parameters Used  

1. Printing process setup, general specs - This must be documented to help "standardize" setups between different machines and operators. This is needed because of the wide amount of differing hardware that exists today in the DIY, and hobby markets that may print "slightly" differently than another machine.  The biggest factor is that these machines are often assembled by the operators and can vary widely machine to machine. So, the more we know about a general setup the faster configurations from the setup can be shared to other operators
2. Program printing parameters posted -  This goes for any process, especially in the DIY and hobbyist since there is a wide variety of program tweaks that can be made in Slicer, SkienForge, etc... in order to repeat the process the settings(infills, feedrates, nozzle temp, etc..) must be documented and shared

Inspection(Duh!)

1. Assure that the device or any of it's components is not out of spec - Well, this is a given. However, it does tie in nicely with other main points such as simplicity and motivation.  If the device is made as simple as possible only the minimum amount a measuring equipment(hopefully the easiest, most available, and most intuitive to use) is needed. Motivation to do a good job is a must especially when dealing with inspection. The operator must want to put out a quality part, since after all they are doing this pro-bono, there is no wage involved.
2. Documented inspection procedures(SOPs) - Inspection SOPs are needed so that each operator is inspecting the device and device components in a consistent manner with proper inspection equipment.

Operator

1. Registered operators akin to how HAM radio operators are licensed - While I hate to register operators that make the devices, I think it is a necessary evil. To be registered, a operator would need to passing a test that encompasses the print, inspection, and assembly of a sample device. This would ensure that the operator is competent and the test would be given by an authorized registered operator.
2. Motivation - The operator must have the proper personal motivation to design, print, inspect, and assemble a device for emergency relief. After all, all of this work is being donated. This ensures that the operator does his or her best in each of those categories to make sure that a quality device is manufactured.  Because, the goal of this device is help  individuals or families in need, and may even save their lives.

Whoa, that was longer than expected. Again, like I said in the beginning of the post there are probably plenty of more. I am sure that in the very near future that this problem, maintaining quality in distributed rapid manufacturing 3D printing environments will rise to the general discussion in the DIY and hobbyist communities.