Smart Manufacturing of Desktop Fiber Extrusion Devices (FrED): Design Optimization and Digital Factory Implementation

Abstract

This thesis presents the design and implementation of FrED Factory, a lab-scale, digitally integrated smart manufacturing environment developed to support scalable production and experiential learning in advanced manufacturing. Built around the Fiber Extrusion Device (FrED), a desktop analog to an industrial optical fiber draw tower. The project addresses both physical manufacturability and digital system coordination, aiming to simulate real-world Industry 4.0 practices in an educational setting. To ensure repeatable and efficient production, key design components were optimized through tolerance analysis of laser cut acrylic frames. Standard Operating Procedures (SOPs) were developed to guide consistent execution of processes including 3D printing, laser cutting, procurement, and assembly. A structured Bill of Materials (BOM) was implemented to manage subassemblies and support real-time inventory tracking. On the digital front, the FrED Factory leverages Tulip, a no code Manufacturing Execution System (MES), to deploy dynamic work instructions, manage work orders, and monitor shopfloor performance. Tulip’s EdgeMC hardware was used to integrate Internet of Things (IoT) devices for machine status tracking. MQTT protocols were applied to capture 3D printer activity via OctoPrint, and current sensors were deployed to automatically log Quality Control (QC) station usage. The result is a modular, scalable, and data-rich smart factory environment that enables students to gain hands-on experience with modern manufacturing systems. For educators, the FrED Factory provides a tangible platform for teaching digital manufacturing, while industry professionals can view it as a blueprint for applying lean, connected workflows in small-scale, high-mix production environments.