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1 Fab Lab Kerala Guidelines Kerala Start-Up Mission 2015
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Fab Lab Kerala
Guidelines
Kerala Start-Up Mission
2015
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General Information
Govt. of Kerala has setup two Fablabs each at Technopark, Thiruvananthapuram and Kerala
Technology Innovation Zone, Kochi.
Fablab Thiruvananthapuram is located at the ground floor of Indian Institute of Information
Technology Management (IIITM-K), Technopark Phase I Campus, Trivandrum. This has a
builtup area of 18,00 sq.ft, the machine layout of which is attached as Annexure I
Fablab Kochi is located in the ground floor of Water Tank Building, Kerala Technology
Innovation Zone, KINFRA Hitch Park, Kochi. The lab is set up in a builtup space of approx.1,600
sq.ft. Annexure I
Objective:
The objective of Kerala Fablabs is to encourage the innovation, technology development,
product prototyping, maker learning, and commerciziable product development. This will
empower the maker-entrepreneurial culture, which at present is confined to ICT/ electronics
domain. The Fablab programme will lead to a cross learning culture among multiple technology
sectors and create a robust platform for the upcoming entrepreneurs to create indigenous
technology products.
Scope:
The Kerala fablabs are a support facility for the maker community comprising of startups,
entrepreneurs, corporates, individual makers, research groups, academic institutions and
universities across India.
The Kerala Fablabs has a vibrant ecosystem for creating a maker culture among the young
techno-entrepreneurs, who want to develop their innovative technology idea into a product
prototypes with fine design functionalities.
This fablab is open to all the ‗Members‘, who wish to become more familiar with digital
fabrication and to network with international Fablabs communities.
Target Group:
The target group for Kerala Fablabs are divided into three:
a. Corporates
b. Institutions (R & D Institutions/ Academic Institutions-schools, colleges, universities)
c. Individuals (SME‘s, Startup entrepreneurs, Makers, Maker & Startup Communities)
Sector: General Engineering
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Fablab People:
Each Fablab is operated and manged by 1 Fablab Co-ordinator, 2 Project Assistants (KSUM TIP
Fellows), 2 support staffs (each from IIITMK/ Startup Village) and 1 trainee.
fab lab coordinator roles and responsibilities
Duties will include establishing protocols for safe and effective use of the lab, monitoring of safety
conditions, equipment maintenance, supplies inventory, record keeping, budget management, develop
programs, and maintain schedule.
DUTIES: The Fab Lab Coordinator will be responsible for managing the use of the space, the
maintenance and support of the equipment, and maintaining partnerships with external organizations. This
position will work closely with faculty, staff and students to support the development and operation of
programs that serve the Museum's school, community, and public audiences.
This person will be responsible for:
Managing all aspects of the daily operation and use of the Fab Lab.
Timing from 9am to 7pm
This person shall manage the daily lab activities and also regularly manage the
inventory of the lab.
To work alongside staff at FabLab in Enginuity , to deliver an efficient and
welcoming service.
To meet and greet individuals/groups and get them set up at the workstations
To help troubleshoot and problem solve if visitors experience
difficulties, and to seek the assistance of the FabLab manager if you
get stuck
To make sure all booked slots run to time and gently usher out any member
who overstays if others are waiting to use the equipment
To train yourself on the various equipment between booked visits, and to take part
in additional update training given by the fab academy/foundation.
Collaborating with and supporting program teams in the development of new Fab Lab pr
To guide startups and individuals by providing necessary advices and guidance. Also provide
research assistance,
Managing the delivery of Fab Lab programs, including learning experiences for school,
community and public groups in the Fab Lab.
To conduct exclusive workshops and awareness programmes on various verticals related to
fablabs. Will be responsible for conducting the annual fab academy program
Managing the training and certification of all staff, volunteers, interns, and guests on the use
of the Fab Lab software, computers and manufacturing equipment.
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Lead staff, volunteers, and interns working in the Fab Lab.
Providing technical support for Fab Lab hardware and software.
Serving as a liaison with internal staff, external program partners and members of the global
Fab Lab network.
Participating as team member in assigned working groups and project teams as assigned.
Creating awareness programs and conducting workshops and training programs.
Maintain departmental responsibilities (report preparation, meetings, email, phone, etc.).
Other duties as assigned.
He shall be the contact point to the Global Fabalb Network and shall be the representative for
the fablabs in Kerala
Machines & Equipments:
Kerala Fablabs are equipped with machines and equipments like Laser Cutter, Large Scale CNC
Mill: Shopbot, 3D printers: Dimension SST 3D printer and Ultimaker 2, High Resolution Mini NC
Mill: Modela, Vinyl Plotter, Sand Blaster, Electronic Components and Tools, Molding and Casting
equipments, Electronics Test Equipments and Computers.
Policies and Procedures
The safety of the people using Fab lab is a principal consideration.
It is essential that Lab coordinator, Technical engineer and Technology Innovation fellows take
an active part in initiating preventive measures to control hazards associated with activities
under their direction.
Safety is an integral part of all programs in which there is a risk of injury or health in the
academic, research and service areas.
The rules and guidelines in this document apply to the entire fab lab area including the patio
accessed by the garage doors and any other lab related work environment.
All tools must remain in the Fabrication Lab at all times and may NOT be checked out. At no
point will tools will be allowed outside of the lab and its adjacent support areas.
The general fablab guidelines will be applicable to every person using the fablab
Special Attention/Personal Needs
The fab lab requires any user with a medical condition to consult with their personal physician
prior to using the fab lab.
Please inform the Fab-Lab co-ordinator or in-charge immediately if you are sensitive to the
following or have issues with any of the following. It will be your responsibility to inform the
Fab-Lab co-ordinator or in-charge, on duty each time you enter the lab.
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1. Dust allergies.
2. Latex allergies
3. Any other allergies that may be present.
4. Physical contact with your Fab-Lab Co-ordinator and/ or in-charge. (If they notice you
working improperly, they may physically move you for guidance or safety purposes.)
5. Loud background noises and/or commotion caused by machines.
6. Any other need that may require special attention.
General Fablab Guidelines
General Guidelines for the Fablabs are given below, the details of which are covered under each
section:
Registration & Online Booking: The applicant have to first login into www.fablabkerala.in and
register an online-application before 24 hours of accessing the facility. After logging in, the
applicant has to create a profile and upload proofs of Identity (Identity Proofs-
Organisational/Instititutional/Employee Identitity/Student Identity/ Personal Identity in case of a
maker or entrepreneur).
Purpose - Visit & Usage: While login, the applicant can select the purpose of accessing the
Fablab like ‗Visit‘ or ‗Usage‘. They will be provided with a Fablab Calender, where they can mark
their dates upon availability and Membership offerings. (Detailed under Membership).
Request for visit to fab lab may be made online at least a week in advance and shall be subject
to availability of free time.
If the applicant is looking for Using a particular machine or equipment, then the machine(s)/
equipment (s) has to be specified, while making online booking/registration. The applicant
should also mention on any technical support needed during operating the machines indicating
the level of expertise.The website has an incorporated payment gateway, where the applicant
can transfer the usage charges or payments through internet banking.
Request for machine usage should be made atleast 24 hrs before accessing the facility.
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Fablab Access: The registered applicants have to submit the receipt of online registration at
concerened Fablabs for accessing the Fablab facility and they will be provided with individual
access cards. The users can only enter the facility by swiping their own access cards, and no tail
gating is allowed.
Membership: KSUM will issue MEMBERSHIP cards for the users (Corporates/ Institutions/
Individuals) for availing the Membership Offerings. One has to apply online for availing the
membership card and the MEMBER will be given preferences, while blocking the time slots.
Machine Usage: The machines will be allotted on availability basis and the users will be charged
on machine usage on an hourly basis. Any overrun in work from the time slot allocated will be
charged extra. The usage charge is fixed by Kerala Start Up Mission from time to time.
Consumables: The applicant/member should communicate KSUM, about the consumables
required from the store at the time of registration.The consumables will be provided by KSUM
on availability and it will be charged on consumption basis. KSUM allows the applicant to bring
in additional consumable, and it should be properly informed to KSUM for verification.
Working Hours: The fablab working hours will be 10 hours a day starting from 9.00 Am to 7.00
Pm (Monday to Saturday). The time slot and working days is flexible based on request.
Workshops: Workshops will be conducted twice a month on pre published dates for creating
awareness among students, makers and enthusiasts. The applicants can block their time slot by
online.
Safety: The users of fab lab should strictly abide with the guidelines/ safety measures instructed
by the Fablab Co-ordinator and shall be responsible for the causalities that may arise.
KSUM will not be liable for any accidents /incidents occurred out of ignorance about
the machines negligence or non-compliance to safety guidelines.
All users must attend a Safety Training session, pass the safety test and perform
and pass skills tests on selected woodworking tools, will be only allowed to access
those machines.
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Outbound Activities
1. Registration
1. Registration
The applicant has to first login into http://fablabkerala.in/ and register an online - application
before 24 hours of accessing the facility. One can create his/ her own login and password.
After logging in, the applicant has to create a profile and upload proof of Identity. This can
be Employee Identity Cards, Institutional Identity cards (Faculty, Student, Fellows) or
Personal Identity card in case of a maker or entrepreneur.
If the applicant is registering on behalf of an Organisation/ Institution, he/ she should also
upload or produce a formal letter from the authorities, authorising the person to access the
Fablab.
The above activities complete the registration procedure.
Online Booking
Once registration is done, he/ she will be directed to the links of Online booking, where he
can check for the availability of fablab facility and block the required time slots. One can
easily do online bookings at any time using the registration id provided to them.
Purpose
While doing online booking, the applicant can select the purpose of accessing the Fablab i.e,
‗Visit‘ or ‗Usage‘. They will be provided with a Fablab Calender, where they can mark and
block the dates upon availability.
Visit
Any person, an institution, a maker, startup community or public can make visits to
Fablab, to see and understand, what is happening in a Fablab, get introduce to
machines, innovative project ideas done in Fablab etc.
Online request for visiting fab lab has to be made at least a week in advance and shall
be subject to availability of free time. The ‗Members‘ of the fablab shall be given
preferences while booking.
Lab Guests and Visitors
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Any individual who has completed the requirements for access may accompany Lab
guests and visitors. He or she is responsible for that guest and that person is the ‗group
leader‘.
Guests and visitors are not permitted to use any machines or tools and are not allowed
in the machine use areas.
Visits should be as brief as possible. The visitors have to enter their name/profession
and area of interest in the logbook provided.
Fab Lab Occupancy Limit
In order to maintain a safe work environment, strict user limits will be enforced.
Faculty need to be aware of this limit when planning Lab use and should utilize some
type of rotation or other strategy to avoid exceeding the occupancy limit.
The maximum number of individuals allowed to work in the Lab at any given time is 10.
The number can be increased based on the availability of machines.
Usage
The machines or equipments in the Fablab can be used with prior online booking, at
least before 24 hrs of accessing the facility.
If the applicant is looking for using a particular machine or equipment, then he/she has
to specify the machine(s)/ equipment (s), while making online booking. The applicant
should also mention about the level technical support needed for him/ her during
operating the machines. The level of expertise can be ‗Complete hands on support‘, ‗
Partial Support‘ or ‗Only Instruction‘. He/ She can also specify the time duration of using
selected machines and the usage is restricted within the time booked. In any case, the
user is in requirement of extra hours, he shall be allowed to continue his work, subject
to the availability of machines and free slots.
Usage Charges
The usage charges is calculated as below:
Usage charges have two components: a) Machine Charges b) Overhead Charges.
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Machine usage charges includes a small percentage of recovey cost for the machine,
usage duration, consumables used and utility charges (electricity charges,internet,
firefighting, water on actuals)
The overhead charges include manpower cost, technical assistance, common facility
charges and utility charges (lights, fan, house keeping, DG, building maintenence etc).
Based on the above, KSUM fixes the usage charges. The charges are subject to vary as
per the fablab operational cost. KSUM has right to revise the charges from time to time.
Payment of usage charges
The payment has to made in advance and it depends upon machines and time duration.
Payment for the extra hours will be directly settled with the Fablab, subject to the
availability of machines.
The website has an incorporated payment gateway, where the applicant can transfer the
usage charges or payments through internet banking. KSUM shall generate receipts for
the payments (online as well as direct, if any) made.
2. Fablab Access:
Fablabs can be accessed for the following THREE activities:
i. Visit to Fablab facility
ii. To use machines or equipments for prototyping/ digital fabrication
iii. To participate in Maker Workshops, certification courses.
For accessing the Fablabs, the registered applicants (Visit-Group Leader, Usage-User or
Workshops-individual particiant) have to submit the receipt of online booking pass to the
Fablab co-ordinator or in-charge, who will verify your ID proofs and authorisation letter,
if any, and issue individual access cards. The visitors/users/ participants can only enter
into the facility by swiping their own access cards.
Lab access may be limited during peak times. Any member who access the Fab Lab
must fill out a record/ logbook to mark the usage timings.The duration of using fablab
shall be noted and considered for Membership benefits.
Under no circumstances, anyone will be allowed to have extended usage outside of
standard operating hours.
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Renewing access cards:
Card swipe access will remain valid only for requested period of time, after which it
automatically expires. One can renew the access card upon its expiry by applying online.
If one doesn‘t want to renew the card, it should be prior intimated to Fablab co-
ordinator and surrender it to the Fablab.
3. Membership
Memberships are of THREE types
i. Corporates (Companies)
ii. Institutions (R & D Centres/ Academic Institutions)
iii. Individuals (Startup entrepreneurs, Innovators, Makers)
Corporate Membership (Companies)
The membership fee for Corporates are Rs 10,000.00 for an year, Rs.6,000.00 for 6
months and Rs.4,000.00 for 3 months.
Benefits under corporate membership are:
Access:
The corporates are provided with FIVE numbers of access cards. The cards shall be
issued to those employees prescribed by the company and the company should inform
the Fablab Co-ordinator regarding any change in users. The validity of card is 1 year.
The Member is eligible for making ONE guest(s) visits in a month on behalf of their
organisation. The member shall initimate guest visit to Fablab co-ordinator, before one
week in advance.
The Member shall be given an opportunity to demonstrate their protypes, or work done
for 1 event in an year.
Capacity building:
The member is eligible for participating in TWO free workshops/ machine training
sessons free of cost in an year, which is limited to 4 participants per workshop.
The member is eligible for participating in one certification course free of cost, which is
limited to 2 participants per course.
The Member can conduct/ host one Maker Workshop in an year in the facility.
Machine Usage:
The Member shall be given preferences, while doing online booking. The member will be
provided with free time slots for the first 24 hrs of booking.
The Member shall be offered free machine usage for 10 hrs per year.
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Only additional charges for consumables and machine usage (based on power
consumption) shall be taken.
Institutional Membership: (Research & Development Centres and Academic Institututions)
The membership fee for Institutions are Rs 5,000 for an year, Rs.3,000.00 for 6 months
and Rs.2,000.00 for 3 months. The students/ fellows from member institutions shall not be
charged for any membership.
The nodal officers of respective bootcamps have to take the institutional membership and
students shall not charged for any membership.For school children (upto 12th standard),
Fablab do not charge any membership fee, but shall be performed under the guidelines of a
trained member.
Benefits under Institutional membership are:
Acces:
The institutions are provided with TWO numbers of access cards. The cards shall be
issued to those students/ research fellows prescribed by the institutions and the
institution should inform the Fablab Co-ordinator regarding any change in users. The
validity of card is 1 year.
The Member is eligible for making ONE guest(s) visit in three months, on behalf of their
institutions. The member shall initimate guest visit to Fablab co-ordinator, before one
week in advance.
The Member shall be given an opportunity to demonstrate their protypes, or work done
for 1 event in an year.
The R & D and Educational Institutions are permitted to bring their institutional project
guides, upon prior approval of the Fablab co-ordinator.
Capacity building:
The member is eligible for participating in ONE workshop/ machine training sessons in
an year free of cost, which is limited to 2 participants per workshop.
The member is eligible for participating in one certification course with 50% discount on
course fee, which is limited to 2 participants per course.
The Member can conduct/ host one Maker Workshop in an year in the facility.
Machine Usage:
The Member shall be given preferences, while doing online booking. The member will be
provided with free time slots for the first 24 hrs of booking.
The Member shall be offered free machine usage for 6 hrs per year.
Only the additional cost for consumables and machine usage (based on power
consumption) shall be charged.
Individual Membership (Startup entrepreneurs, Innovators, Makers)
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The membership fee for individuals is Rs.3000 for an year, Rs.2,000.00 for 3 months and
Rs.1,000.00 for 3 months.
Individual memberships are offered to startup entrepreneurs, innovators and makers. Any
community can also be considered under this category.
Benefits under Individual membership are:
Acces:
Each individual is provided with only ONE access card and the validity of card is 1 year.
The Member is eligible for making ONE guest(s) visit in six months, related to his/ her
project work. The member shall initimate guest visit to Fablab co-ordinator, before one
week in advance.
The Member shall be given an opportunity to demonstrate their protypes, or work done
for 1 event in an year.
Capacity building:
The member is eligible for participating in ONE workshop/ machine training sesson in
an year free of cost.
The member is eligible for participating in one certification course free of cost.
Machine Usage:
The Member shall be given preferences, while doing online booking. The member will be
provided with free time slots for the first 24 hrs of booking.
The Member shall be offered free machine usage for 2 hrs per year.
Only the additional cost for consumables and machine usage (based on power
consumption) shall be charged.
Membership Validity:
Membership cards will remain valid only for requested period of time, i.e, 3 months, 6 months
and 12 months, after which it automatically expires. The current rates and validity of cards are
as follows:
Membership Category 3 months (Rs.) 6 months (Rs.) 12 months (Rs.)
Corporate
4,000.00 6,000.00 10,000.00
Instituitional
2,000.00 3,000.00 5,000.00
Individual
1,000.00 2,000.00 3,000.00
The rates are subjected to change based on the decisions by Kerala Stat Up Mission.
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Renewal of Membership
One can renew the access card upon its expiry by applying online. If one doesn‘t want to renew
the card, it should be prior intimated to Fablab co-ordinator and surrender it to the Fablab.
4. Programmes/ Activities
Fablab will conduct marker workshops, certification programmes, machine trainings, project
works, pre-fab trainings, community meets, confereneces, delegation visits etc This will be
updated in the Fablab Calender as well as Kerala Start Up Mission Event Calender.
Applicants for training and certification courses will be invited through various media and
selection of participants shall be done in a transparent manner. The training packages will be
designed by Kerala Start Up Mission.
Fablab will also invite proposals for projects execution or Fablab initiatives.
Fablab Facility
1. Machines
Currently, Kerala Fablabs are equipped with the following machines and equipments:
1. Shopbot PRSAlpha-96-48-6 Full Size PRSalpha CNC
2. Weller WES51 Analog Soldering Station
3. Ultimaker 2
4. Modela
5. Laser cutter
6. Digital Storage Oscilloscope
7. 3D printer. Dimensions sst 12000es
8. Scroll Saw
9. Band Saw
Machine details are covered under Fablab Machine Overview (Annexure III)
2. Consumables
The machines and equipments at Fablab are using various consumables in fabrication and
prototyping. The list of consumables are given in Annexure IV. The consumables required for
each machine is given under Fablab Machine Overview.
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3. People
Kerala Start Up Mission is the implementing agency of MIT Fablabs in Thiruvananthapuram and
Kochi. A Fablab co-ordinator assigned by KSUM has the charge of two labs. The Fablab Co-
ordinator is assisted by 2 Fablab supervisor (KSUM Technology Innovation Programme Fellows),
2 partner representative (each from IIITMK/ Startup Village) and 1 trainee.
The Fablab co-ordinator shall be responsible for following:
Any assistance/complaints/ grievence can be communicated to the Fablab Co-ordinator.
4. Safety Measures
The users of fab lab should strictly abide with the guidelines/ safety measures instructed by the
Fablab Co-ordinator and shall be responsible for the causalities that may arise.
Safety
Safety in the Fabrication Lab is the highest priority. Accidents may result in serious bodily harm
or death.
Following proper safety procedures and conforming to the Fabrication Lab policies outline
hereunder will greatly reduce any chance of injury.
Do not experiment with the tools or try to figure out how to use a machine on your own. If you
do not use a tool or machine exactly how you have been shown or neglect to follow all safety
rules, severe injury could result.
Fab Lab Use and Safety Training
In order to use the fabrication lab, userd must attend Safety Use and Orientation Training
which will be delivered by the Fab lab coordinator/ Project Assistant.
Any user entering the fabrication lab will be required to verify they have completed all required
safety training.
General Lab Safety Rules
The hazards associated with fabrication work require special safety considerations. Whether you
work in a metal lab, wood lab, or any other lab, the potential hazards for injury can be
numerous.
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All users entering the fab lab must acquire the appropriate safety gear prior to operating any
machine or tool.
All users must clean up after themselves; userd who do not clean up after themselves will lose
all lab privileges for a minimum of 1 week.
First -aid Box
The lab should keep first aid boxes with general items like cloth bandages, cotton, bandages,
sterilizers, spirit, reliefing sprays or oinments, creams or oinments for injury and burning. This
would help one to take immediate medication or before rushing to a medical centre.
Personal Protection
It is advised that the user should strictly wear respective Personal Protection Equipments
recommended for each machine. There are several measures you must take to protect yourself
from work hazards.
1. Do not wear loose fitting clothing
2. Do not wear neckties
3. No jewelry should be worn in the fabrication lab, which could interfere with the working in
the lab. (Including earrings, watches and rings)
4. Snug fitting clothing is essential to your safety
5. Make certain that long hair is not loose, but is pulled back away from equipment.
6. Always wear safety glasses when working with any lab equipment. Additional protection
using goggles or face shields may be necessary for work such as grinding, chiseling or chipping.
7. Notify your supervisor/professor if you notice any unsafe work conditions.
8. Inform other staffs if you see an unsafe work practice; however, be careful not to distract a
person who is working with power tools.
Safety Guidelines
Follow these guidelines for general work safety:
1. Never work alone. There must always be at least one Fablab –in charge officer to be present
in the fabrication lab.
2. Always wear appropriate safety gear and protective clothing, including closed toed shoes.
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3. Eye protection is required while operating any machine.
4. Know where the fire extinguishers are located and how to use them.
5. Never work impaired. This also does not simply mean impaired from drugs or alcohol, but
also from sleep deprivation.
6. Know the hazards associated with your work. Be sure you are fully educated on the proper
use and operation of any tool before beginning a job. If you cannot do a job safely in the
fabrication lab, don‘t do it. Think through the entire job before starting.
7. If you are unsure about how to safely execute the operation of a tool, ask for help. Have the
fabrication lab in-charge assist, demonstrate, and observe to help you become familiar and
comfortable.
8. If you have not worked with a specific material before, consult the fabrication lab in-charge
for precautions, methods and instruction prior to beginning work.
9. Do not work in the lab if you are in a hurry, this almost always ruins the work and often
results in injury.
10. Leave tool and equipment guards in place. This is especially true with the table saw. The
guard with the anti-kickback device should always be on the saw unless the operation is not
possible with it in place.
11. Before starting any machine be sure to check that it is set up correctly and fully operational.
12. Check power cords and plugs on portable tools before using them.
13. Use a brush, or special tool for the removal of chips, shavings and debris. Do not use your
hands to clean shavings or cuttings – they can be sharp and cause injury.
14. When doing heavy sanding face masks or respirators should always be worn.
15. Keep your fingers clear from the point of operation of machines by using special tools and
devices such as push sticks and paddles. Never use a rag near moving machinery.
16. Keep the work area free from debris, clean spills immediately and remove all sawdust and
wood chips. Do not bring food or drink in to the fabrication lab.
17. Clean up after yourself. Before you leave the lab be sure all tools are returned to their
appropriate position and all the machines are clean and the floor is swept. Allow a minimum of
10-15 minutes for your clean up procedure.
18. Earphones, cell phone use and texting are not allowed in the Lab. We need to be able to
get your attention and you need to hear what‘s going on around you.
Eye Protection
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1. Eye protection must be worn at all times while working in the Lab - Safety glasses are
provided.
2. Consistent failure to wear eye protection will result in loss of access.
Non-Injury Accidents
In the event of accidents resulting in machine damage, material ―kick-back‖ or other unsafe
events, the following procedure must be followed:
1. If gross negligence is determined to be involved in the course of a non-injury accident a
meeting is required between the user(s) and the Lab coordinator before Lab access may
resume.
2. If an individual is consistently working in an unsafe manner, Lab privileges will be revoked.
Injury-Causing Accidents
In the event of an injury-causing accident, the following procedures must be followed: Notify
the Lab supervisor or monitor on duty immediately.
1. Lab personnel will follow established first-aid procedures.
2. All injury-causing accidents requiring outside medical attention requires a meeting with the
Lab coordinator to determine the cause of the accident and as a preventive measure against
similar accidents in the future before Lab access may resume.
Hand tool Safety
These tools, while they do not involve the same dangers as power machinery, should be used
cautiously.
The type of injury sustained while misusing these tools are small cuts and lacerations -
sometimes requiring stitches.
Please observe the following guidelines while using hand tools.
Hand tools are non-powered tools. They include wrenches, hammers, chisels, screw drivers,
and other hand-operated mechanisms. Even though hand tool injuries tend to be less severe
than power tool injuries, hand tool injuries are more common. Because people take everyday
hand tools for granted, simple precautions for safety are easily forgotten.
Hand tools must remain in the Fabrication Lab at all times and may NOT be checked out. At no
point will tools will be allowed outside of the lab and its adjacent support areas.
The most common hand tool accidents are caused by the following:
1. Failure to use the right tool
2. Failure to use a tool correctly
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3. Failure to keep edged tools sharp
4. Failure to replace or repair a defective tool
5. Failure to safely store tools
IMPORTANT: Use the right tool for the job to complete a job safely, quickly, and efficiently.
Follow these guidelines for general hand tool safety:
1. Wear safety glasses whenever you hammer or cut, especially when working with surfaces
that chip or splinter.
2. Do not use a screwdriver as a chisel. The tool can slip and cause a deep puncture wound.
3. Do not use a chisel as a screwdriver. The tip of the chisel may break and cause an injury.
4. Do not use a knife as a screwdriver. The blade can snap and cause an injury.
5. Never carry a screwdriver or chisel in your pocket. If you fall, the tool could cause a serious
injury. Instead, use a tool belt.
6. Use the proper wrench to tighten or loosen nuts. Pliers can chew the corners off a nut and
the pliers can become damaged.
7. When using a chisel, always chip or cut away from yourself.
8. Do not use a wrench if the jaws are sprung.
9. Direct saw blades, knives, and other tools away from aisle areas, students and employees.
10. Keep knives and scissors sharp. Dull tools are more dangerous than sharp tools.
Improper tool storage is responsible for many fab lab accidents. Return each tool to its marked
location for proper tool storage.
Never use a dull tool - it is actually much more dangerous than a sharp one. Think about the
direction your energy is going while performing an operation. If you are holding material in your
hands, be sure the action if going away from your body. Better yet, clamp the material in a vise
or to the surface of a workbench.
Like power tools, think through a procedure before you attempt it. Many times, we become
complacent or are rushing through a job - that is when accidents are most likely to occur.
Hand-held Power Tools
Hand held power tools comprise of change blades, bits, etc., when the tool is off and
unplugged. It is very easy to accidentally turn the tool on.
1. Know what direction it moves and be prepared to compensate for the torque of the motor.
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2. Wear eye protection at all times - some tools such as the lathe may also require the use of
a face shield.
3. Always keep your hands a safe distance from cutters and blades.
4. Make sure all guards and safety devices are in place.
5. Do not use a machine without the proper guards. Keep the machine clean.
6. Know the physics of the machine and where the cutting force wants to throw the material.
7. Make sure to turn all power tools off before unplugging, and always check that it is turned
off before plugging in.
8. All hand held power tools must remain in the lab and may NOT be checked out. At no point
will tools will be allowed outside of the lab and its adjacent support areas.
Understanding Power Tools
The most dangerous parts of power tools are the moving parts. All of the machinery in this Lab
is powered by electric motors, and the radial forces produced by spinning shafts, pulleys, blades
and belts can be particularly dangerous. This danger arises from two effects of spinning parts:
(1) Outward forces—wood and debris can become violent projectiles when thrown by spinning
blades, and (2) inward forces—loose clothing, jewellery, hair, and fingers can be grabbed,
wound up, and pulled in and mangled by any spinning machinery. Always be aware of the
danger of these radial forces. Always wear eye protection, never stand in line with circular
blades, and always maintain a safe distance from spinning parts when the tool is operating.
Power tools can be extremely dangerous if they are used improperly. Common accidents
associated with power tools include abrasions, cuts, lacerations, amputations, burns,
electrocution, and broken bones.
These accidents are often caused by the following:
1. Touching the cutting, drilling, or grinding components
2. Getting caught in moving parts
3. Suffering electrical shock due to improper grounding, equipment defects, or operator misuse
4. Being struck by particles that normally eject during operation
5. Touching hot tools or work-pieces
6. Falling in the work area
7. Being struck by falling tools
When working around power tools, you must wear personal protective equipment and avoid
wearing loose clothing or jewellery that could catch in moving machinery.
In addition to general lab guidelines, follow these guidelines for working with power tools:
20
1. University employees or students shall not turn on, use, repair, or operate any machine, tool,
equipment unless authorized by a fabrication lab supervisor.
2. Use the correct tool for the job. Do not use a tool or an attachment for something it was not
designed to do.
3. Select the correct bit, blade, cutter, or grinder wheel for the material at hand. This
precaution will reduce the chance for an accident and improve the quality of your work.
4. Keep all guards in place. Cover exposed belts, pulleys, gears, and shafts that could cause
injury.
5. Always operate tools at the correct speed for the job at hand. Working too slowly can cause
an accident just as easily as working too fast.
6. Watch your work when operating power tools. Stop working if something distracts you.
7. Do not rely on strength to perform an operation. The correct tool, blade, and method should
not require excessive force. If undue force is necessary, you may be using the wrong tool or
have a dull blade.
8. Before clearing jams or blockages on power tools, disconnect from power source. Do not use
your hand to clear jams or blockages, use an appropriate tool.
9. Never reach over equipment while it is running.
10. Never disable or tamper with safety releases or other automatic switches.
11. When the chance for operator injury is great, use a push stick to move material through a
machine.
12. Disconnect power tools before performing maintenance or changing components.
13. Keep a firm grip on portable power tools. These tools tend to "get away" from operators
and can be difficult to control.
14. Never leave chuck key in chuck.
15. Keep bystanders away from moving machinery.
16. Do not operate power tools when you are sick, fatigued, or taking strong medication.
17. When possible, secure work pieces with a clamp or vise to free the hands and minimize the
chance of injury. Use a jig for pieces that are unstable or do not lie flat.
18. Always work in a clean environment. A unkempt work place can result in injury, especially
when sawdust accumulates on concrete floors. You must always be responsible for cleaning up
after yourself.
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Machine Safety
To operate a machine safely, you must know more than just how to turn it on and off. You
must know how to perform the basic operations and how to make simple adjustments. Always
maintain a healthy respect for the tool‘s capabilities and limits. Never use a machine for a job it
was not designed for and never experiment - if you are unsure about how to perform a certain
operation, ask for help. The more you know about a machine, the safer you will be. Don‘t
become over confident - that leads to carelessness, which causes accidents. The following are
general guidelines for stationary machines.
1. Wear eye protection at all times - some tools may also require the use of a face shield.
2. Always keep your hands a safe distance from cutters and blades.
3. Make sure all guards and safety devices are in place and in perfect operating order. Do
not use a machine without the proper guards.
4. Know the physics of the machine and where the cutting force wants to throw the
material.
5. When feeding material through a machine with the hands, be aware of the direction you
are pushing (away from blade or cutter).
6. Never operate a power tool when alone in the Lab.
7. Defects in material can be dangerous. Check the stock carefully for knots, splits, and
other defects.
8. Keep the machine clean. Remove all tools, lumber, and unnecessary materials. Objects
left on the machine can vibrate into revolving cutters. They can then be thrown from the
machine with great force. Never clean a machine while it is running.
9. Always work with a plan of procedure. Consider and think through each step ahead of
time.
10. Never make an adjustment unless the power is off. The tool must come to a complete
stop.
11. Your stance is also important - stand in a comfortable, balanced (defensive) position
when working with power tools. Both feet should be firmly on the floor. If something
doesn‘t sound right, or feel right - turn off the machine and inform the supervisor or
monitor.
12. Above all, think before you perform any task. Know the tool‘s capabilities and the work it
is intended for.
13. If you feel unsure, STOP and ask for assistance.
5. Procedures
Kerala Start Up Mission has created the ‗Operational Guidelines‘ for the Fablabs, which
should be followed for the operation and maintenanace of the facility. Any additions to the
guidelines may be reviewed and corrected/ updated from KSUM from time to time.
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Inbound Activities
Inbound activities involves the following:
1. Setting up of Fablab
Kerala Start Up Mission set up the Fabrication Labs by executing agreement with Centre
for Bits and Atoms (CBA), Massachuttus Institute of Technology (MIT), Boston, USA.
The centre provide machies, tools, equipments, consumables, raw materials, reading
books with basic fablab accessories.
A team from MIT Fablab including Fab Gurus and KSUM Fablab shall set up the lab with
machies, equipments, software installation and test run. They also build a few
prototypes to ensure the functioning of machines and equipments. The Fablab resources
shall also provide training for the Fablab co-ordinator and technical engineers and
suggest models for the successful operations of the Facility.
2. Procurement of Machines & Consumables
The machines and consumables can be intially procured from MIT, USA as part of the
Fablab agreement. In that case, KSUM has to manage the customs and taxes part of the
consignments for delivering it to respective locations.
The procurement of machines/ equipments/consumables depends on factors like type
of material make, processing quality, ease of procurement procedures, availability of
machines in local market, quantity required, logistics involved, pricing, delivery period
and process complexity.
If all the above factors recommend for a local purchase, then KSUM shall go for it, and
KSUM will choose MIT if the above factors endorse a purchase from them.Fablab co-
ordinator will handle all the procurement procedures.
The Fablab co-ordinator shall keep an asset register listing the existing machines,
equipments, tools and addons. He should update it regularly, when a new purchase is
done. It is also recommend that KSUM should keep a Machine/ Consumable issue
register mentioning name, duration, quantity,self cleaning etc
Machine addition:
Fablab may need of additional machines and equipments for various reasons such as
a) A New Machine to be brought like ‗Pick and Place‘, which is not in the package of
MIT Fablab
b) Replacement of an existing machine with a new one, due to its poor performance
and poor working condition
c) Addons to the existing Machines and equiments.
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In all the above cases, KSUM shall initially contact MIT, for their suggestions. If they are
available with them and MIT recommends for purchasing from them, then KSUM will
look for the above mentioned factors to initiate a procurement process with MIT. In case
if the particular machine is not available with them, or if the above mentioned factors
recommends for a local purchase, then KSUM will initiate the local procurement process
as per the tendering rules by the Government.
Procurement of local tools & equipments, raw materials and consumables
KSUM shall perform the procurement of Local tools & equipment,Consumables and
rawmaterials by itself. KSUM shall contact MIT for their procurement, unless and
otherwise they are not available within the local market.
The selection of the consumables/ rawmaterials/ equipments depend on the type
material of which it is made, its local availability, price
3. Store Management –Consumables/ Other Inventories
Fablab co-ordinator should monitor the stock pattern of consumables and other
inventories like raw materials, fabrication materials and miscellaneous items.
A stock register to be maintained for tracking the consumables and other
inventories.The store must always maintain a safety stock for 60 days and place orders
before that.
KSUM may analyse the factors for procurement before placing an order with MIT or local
vendors. KSUM can primarily look for procuring the inventories from local market, if they
are easily available. In that case, the quality of the materials has to be verified.
4. Maintenance of Machines –Annual Maintenance Contract, Insurance,
Replacements
Following activities to be done by KSUM under maintence of machines.
a) Repair for a fault
b) Annual Maintenance Contract
c) Replacements of machines
d) Managing spare parts
e) Insurance
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Preventive Maintenance Schedule
The Fablab Co-ordiante should manage and keep the Preventive Maintenance Schedule
for updating performance and the functionalities of machines and equipments. This
schedule has to be updated every week with out default.
The Preventive Maintenance Shedule measures the performance such as speed,
efficiency, power consumption, quality of deliverables, time of task completion etc
Corrective Maintenance Schedule
The Fablab co-ordinator should maintain a corrective maintenance schedule, once any of
the activities like repair, replacements, spare parts fittings/ removals, or any maintence
work are performed.
Work Procedure
Each machine/ equipment to be provided with a display board comprising Machine
Name, Specifications, Consumables, Usage purpose and work procedure.
Work Procedures should be supplied to users and the Fablab co-ordinator/ Fablab in-
charge should demonstrate the working of each machines to them, before they access it
for first time.
Each users should follow the work procedure provided by the Fablab people for safe and
outcome based operations. The Fablab in-charge should also monitor whether the users
are following the work procedure, serving its purpose.
5. Managing the supply chain
KSUM manages the supply chain primarily for procurement activities. KSUM will execute
agreement with vendors and do not involve with third parties for procuring, transporting
or delivering the Bill of Materials.
In case of direct purchase from MIT, no other vendors will be involved and the
consignement will be delivered by the vendors/ agencies entrusted by them.
Others
1. Registers
Fablab should manage the following registers
1. List of Machines & Consumables
2. Machine Usage Register
3. Consumables Usage Register
4. Asset Register
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5. Maintenance Register-Preventive Maintenance Register, Corrective Maintenance
Register, AMC & Insuranc
6. Stock Register
7. Membership Register
2. Storage of Materials/ Cleaning of Work area
Users should follow the below guidelines for storing projects/ cleaning the Work area:
1. Storage of materials in the Lab is prohibited.
2. The lab is not responsible for any projects left unattended.
3. Each user is responsible for clean-up and tool return.
4. Each machine and work area should be cleaned immediately after use.
5. Machines should be blown off using the air hose and the floor area around it should
be swept clean.
6. The last person to use a machine is responsible for cleaning the machine and
surrounding work area.
7. Users who consistently fail in their clean-up responsibilities will be denied Lab
access.
3. Selection of Materials
Tools and Machinery in the Lab each have an intended use to specific materials.
Please see the Lab coordinator if you wish to work with unique materials in the Lab.
Following guidelines may be adopted for selecting materials/ consumables not from Fablab.
1. Used wood and wood based materials may be processed in the Lab as long as the
material is clean, free of dirt, grit, grime, metal, paint, varnishes, enamel, moisture or
abrasive materials.
2. Material that is excessively contaminated with any of the above will not be permitted.
3. Lab users using used materials may be found liable for damage to the tools and
equipment caused by those materials.
4. No green wood - tree limbs, etc. unless they are completely dry.
5. Plaster objects may not be worked on any of the equipment or machines in the Lab.
6. With the exception of the scrap bins below the table saw and miter saw table, the Lab
does not provide free materials.
7. The Lab does sell a limited selection of plastics.
8. These rules are meant to insure a safe and orderly work environment; please respect
them.
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ANNEXURE III
Fab Lab Machines Overview
1. Shopbot PRSAlpha-96-48-6 Full Size PRSalpha CNC
2. Weller WES51 Analog Soldering Station
3. Ultimaker 2
4. Modela
5. Laser cutter
6. Digital Storage Oscilloscope
7. 3D printer. Dimensions sst 12000es
8. Scroll Saw
9. Band Saw
10. Shopbot PRSAlpha-96-48-6 Full Size PRS alpha CNC
ShopBot is a CNC solution for production that delivers high performance, high volume, speed
and reliable power for all cutting tasks. This CNC delivers affordable, full-production
performance in digital fabrication of wood, plastic, aluminum, and other materials.
Traditional shop-size and larger.
ShopBot builds CNC gantry tools in many sizes to suit the varying needs of manufacturers: 96 x
48, 96 x 60, 120 x 60, 144 x 60. (This m) Give us a call to discuss your production needs. We‘ll
help you to choose the right tool to get the job done.
How to Use ?
Loading Design
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1. Open or Import the vector design
2. Select the regions to VCarve or machine
3. Specify the tool details and calculate tool paths
4. Preview the job in any material
5. Save the CNC code (save the tool paths)
Turning it on - checklist
1. Flip the big switch on the front (cooling fan on spindle will turn on)
2. Press reset button on pendant (VFD will turn on)
3. Set VFD to 150.0
4. Turn on Shopbot 3 software
Warming up the spindle
(This doesn't need to be done if the machine has recently been used and chances are the
bearings are still warm)
Open yellow hand-control window
1. Check that tool is at safe height above material
2. Toggle output 1
3. Press start
4. Slowly increase the VFD speed up to 270
Zeroing the table
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1. Use hand control window to move bit to it's zero point
2. In the main window, select zero->zero three axis
3. Move z axis to safe height
Starting a job
1. Select File->Part file execute
2. ( Check scaling, you normally want scaling to be 1 on all axis )
3. Click ok
4. Press start on pendant
5. Turn on dust sucker
6. Click ok on screen
Emergencies
There are two emergency stop buttons that you can hit
You can press space on the keyboard
You can click with the mouse
Troubleshooting
If error 91 comes up, delete c:\Program Files\Shopbot\Shopbot 3\shopbot.ini
then, when you turn it on, select settings for PRS Alpha 120x60
Set software to mm in the "other settings" tab.
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1. Weller WES51 Analog Soldering Station
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What is Soldering Iron?
A soldering iron is a hand tool used in soldering. It supplies heat to melt solder so that it can
flow into the joint between two work pieces.
How to start ?
Clean the tip using soft cloth , do not file the tip.
Connect the device to 120V power supply ,via 230v - 120v adapter.
Set the temperature , please look at electronic device specification for the right
temperature.
Constant bright green LED indicates the heating process of the iron.
Blinking LED indicates trickle heating , which means the soldering iron is at the set
temperature.
Now you may start soldering.
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2. Ultimaker 2
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What is 3D printing?
3D printing or additive manufacturing is a process of making three dimensional solid
objects from a digital file. The creation of a 3D printed object is achieved using additive
processes. In an additive process an object is created by laying down successive layers of
material until the entire object is created. Each of these layers can be seen as a thinly sliced
horizontal cross-section of the eventual object.
How to start ?
Load the design file (.stl) to Cura software in system - FAB6
Save the GCode to SD card.
Insert the SD card into Ultimaker 2
Turn on Ultimaker , switch is located on the bottom left to the back of the device.
Make sure that the Printer head is home , to be at the top extreme left corner away
from the user and the bottom plate should be at the extreme bottom position.
Check whether the print material is properly fed and sufficient quantity is available.
Use the roller switch to seek to the print file and click to print.
Ultimaker 2 will start printing once the print head reach its optimum temperature.
When the print is complete, carefully remove it from the bottom plate.
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3. Modela
Use:
Milling PCB, Carving models in wax.
Description:
34
The Modela is a nice little milling machine that cranks out most of the circuits. To be
able to mill on it, you need to have FR1 which is a paper based copper plate. You cannot mill
the fiberglass copper plates on the Modela as it will break your bit and the dust it will create is
irritant. The FR1 is more tan than the fiberglass, which is more green, and the FR1 is in stock in
016 in 2x3 inch and 4x6 inch pieces.
Instructions for operation:
Design your circuit and save the traces alone as .png file.
Switch on Modela and connect to your pc that has fab-modules installed.
Have the drill head changed according to the work.
Open fab-module and give .png as input format.
Select Roland Mill(.rml) as output format.
Then select the process as PCB traces for milling traces and PCB outline for the outline.
Correct xmin and ymin. Zero correct the drill bit after that.
Now you can send instruction for starting the milling.
Remember traces and outer boundaries should be done separately.
4. LASER Cutter .
The TROTEC Speedy 100, is used for engraving and cutting of signs, stamps and suchlike. A wide variety of materials such as rubber, acrylic, coated metal, tin, special steel, anodized aluminum, cork, cardboard, glass, leather, marble, several plastics and wood can be processed on the laser.
STATUS DISPLAY
35
How to Operate?
1. Switch machine on with the ON / OFF switch.
2. The working table automatically references in X/Y/Z direction.
3. Open the protection cover and place work piece on the working table.
Usually you position the work piece into the upper left-hand corner of the engraving table against the horizontal and vertical rulers. However, any other position on the engraving table is also possible.
4. Focusing the Laser Beam
There are three methods to focus the laser beam:
A: Manual focusing
B: Focusing by software
C: Automatic focusing by means of light barriers (optional)
5. Printing / Engraving using Laser Cutter
Generate a graphic with the help of your graphics software. (Adobe Illustrator, Corel Draw )
The size of the graphic does not matter .
36
Select "File -> Print", to access the printer driver, where you can perform work piece and material settings as well as specify a job name or a job number.
6. Specify engraving material, the engraving direction, die orientation of the work piece and the orientation of the plate have been specified in the TROTEC Job Control under
"Plate --> Setup Plate".
7. Make sure that on engraving flammable materials the air assist is on (e.g. rubber engraving)!
8. Establish a connection with the engraver by clicking on the button "Establish Connection" in JobControl.
9. Switch on the exhaust system / check only, whether in the indicator "Exhaust Ready" is green in the Engraver Control of the JobControl.
10. Finally press the START button (green arrow) in the Control of the JobControl, to start the engraving process.
11. When the engraving is complete, the JobControl offers you the following possibilities: - delete the job - Job Reset and placing back in to the waiting list for later repeat of the engraving.
5. EZ Digital DS-1100 100MHz Digital Storage Oscilloscope
37
Features
● DC to 100MHz frequency bandwidth with 2 channels
● Equivalent 25Gs/s (Max Real Time 200MS/s)
● 10ns peak detection for glitch capture
● 10K bytes long memory for flexible waveform Zoom in/out
● Auto trigger level setting to 50% and Auto-set
● Automatic measurements and FFT analysis
● Direct single trigger capture function by using a hot-key
● Saving 10 waveforms & 10 setup parameters
● PC interface with RS-232C and/or USB
● Parallel port for hard copy
● 100-240V, 30W Operation
38
6. 3D printer Dimensions sst
12000es
Use:
3-D printing using ABS.
Description:
The Dimension 1200es is your gateway into one
of the family of professional 3D printers. Make your
models where you hatch your ideas. The money you
save will make you feel even smarter.
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It is powered by FDM Technology, it prints in nine colors of real ABSplus thermoplastic.
This 3D printer lets you choose fine resolution or faster printing, with layer thicknesses of 0.254
mm (0.010 in.) or 0.33 mm (0.013 in.).
Instructions for operation:
Have the design ready and saved as ‗.stl‘ file.
Install CatalystEX Software
CatalystEX provides:
A 3D view of the model or models to be printed.
The ability to scale 3D models to your desired size.
Control over how to orient your model in the build chamber.
Automatic or custom packs for multiple models in one build.
A print queue to assign many jobs, with estimated print time and material consumption.
Connect your computer with the printer using LAN cable and setting up a local network.
Load your STL file and set the desired position for printing, the scale, mesh size etc.
After printing is done, the output will be having both make and support material, from
which the support material has to be removed.
For simple designs we can breakaway the support material. But for complex materials
use SCA-1200. The SCA-1200 is a support removal system that lets you dissolve support away
in a water-based solution, hands-free and unattended.
After removing the support material completely we get the desired print.
Scroll Saw
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Model: 20‖ Scroll Saw- DW788
Technology: Blade of different weights
Uses: The scroll saw is an electric saw that can be used to cut intricate patterns in a variety of
materials. In the FabLab, the scroll saw is used for freehand cutting and finishing both wood
and metalwork based projects.
Safety: Wear safety glasses or goggles, or a face shield , protective footwear etc.
Band Saw
Model: Jet 10‖ Band Saw
Technology:
Uses: The Band Saw is an electric saw that can be used to cut intricate patterns in a variety of
materials. In the FabLab, the scroll saw is used for freehand cutting and finishing both wood
and metalwork based projects.
Safety: Wear safety glasses or goggles, or a face shield , protective footwear etc.
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ANNEXURE IV
This is a list of consumables of the main machines used in Fab Lab.
Modella:-
Copper Cladded plate, FR1 only, for making PCB's
Wax block for carving out 3-D models.
Aluminium sheet (But not recommended for big jobs).
Vinyl Cutter:-
For cutting out vinyl stickers.
For cutting paper thin cardboard.
PVC sheets. Note: This cannot be cut using laser.
ShopBot:-
Timber, Wood, Plywood, thin metal sheets.
Aluminium blocks and sheet ( But for big jobs not recommended).
Laser Cutter:-
Wood
Stones
Glass
Metal
Rubber
Plastic
Acrylic etc.
3-D Printer:-
PLA plastic
ABS plastic
