Fab Lab 0.0 to Fab Lab 0.4 - Learning from running a lab in an Indian Village
Abstract
Fab Lab in developing countries have different
operational problems. Within the constraints of resources, they have to prove
effectiveness and the impacts of utilization of Fab Lab for their community. Vigyan Ashram (VA)
Fab Lab was started in Pabal, a small village in western India
with the support of MIT and Fab Foundation in 2002 and has been operational
since then. It was started in a small 150 sq.ft tin shed with few machines.
This lab is used by rural youth mainly, school dropouts. As the utility of the Fab Lab was
experienced by the community, the lab grew in size. It saw three phases of
expansion in terms of physical space and machinery. This paper is presenting
challenges faced in this evolution in terms of machinery, inventory,
infrastructure, manpower and projects. It is also presenting different
approaches tried by VA to overcome these challenges.
1 Introduction
Vigyan Ashram
(www.vigyanashram.com) is located in a drought prone village Pabal, which is approximately 60 kms from nearest city, Pune in
western India.
It is engaged in training rural youth on various rural technologies. VA helps
these youth to start their own micro-enterprises in the villages. Dr. Kalbag, the founder of the ashram, was a firm believer that instead
of giving ready made solutions to the poor
community, we must give them means to find out their own solutions. Dr. Neil Gershenfeld (Center for Bits and
Atoms, MIT) first visited VA on the 27th January 2002 and stressed the need to use advanced
technology to find out solutions to some of the pressing developmental issues in the community. Through this interaction between Dr. Kalbag
and Dr. Gershenfeld, the first Fab Lab outside MIT was established, hence the title Fab Lab 0.0.
The VA Fab Lab end-users are mainly rural youth with minimum qualification and computer
literacy. Machines in the Fab Lab are often too sophisticated for them. There were
challenges in terms of the
quality of electricity, dusty atmosphere and high ambient temperatures which
caused troubles in the appropriate functioning of the Fab
Lab. In spite of all these odds, VA Fab
Lab could sustain its momentum. This paper documents the learning and
difficulties faced in each of the operational areas. The operational areas are
divided into machines, man power, education, projects, camps and community
outreach, funding and support from the Fab network. It also documents alternative
strategies found by VA. This learning may help new Fab Labs setup in
rural areas of developing countries.
2
Fab Lab Machines
It is often said that the Fab Lab is not
about the machine. It is about the makers and them making things! But
tools for digital fabrication differentiate Fab Labs from maker spaces
and tool rooms. There was initial hesitation at VA about using digital
fabrication. Teachers and students were finding it convenient & faster to
use traditional tools for making things. Use of computers for drawing design
was taking considerable time due to lack of practise and skills. Further the originally installed Fab Lab machines were not found suitable for making projects
involving metals, as
required for example in making improved agricultural
tools etc. Table 1
presents a machine wise analysis of the problems faced
in the machine operations. Overall learning curve of VA fab lab was long to
master digital fabrication. Now, VA fab lab is comfortable with these tools and
have become an integral part of Vigyan Ashram programs.
|
Machine (year of installation)
|
Applications
|
Frequency of use
|
Technical Problems faced
& solutions found
|
Outcomes
|
|
Vinyl Cutter (2002)
|
Screen Printing, Name Plates, flexi-circuits
for wearable electronics.
|
Good
|
Not major issues other than software
re-installation.
|
Two of VA alumni started their micro
enterprises. They have purchased machine and providing letter cutting
service.
|
|
Laser Cutter (2006 & 2016)
|
Acrylic / thin plywood for casings, sign
boards
|
Good
|
- Severe problems due to bad quality of
electric supply, needed replacement of controller and laser tube. Normal
earthing did not work due to dry & rocky soil so chemical
earthing was used.
- Cost of acrylic and MDF sheets was overcome
by using packaging cardboard for practice.
|
Most loved machine! Many projects and all
electronics casings made
on this machine.
VA wrote a manual on ‘How to do earthing?’
for laser cutting machine based on this experience.
Got additional CO2 laser machine
from corporate donor.
|
|
Plasma Cutting (2007 & 2016 )
|
For making Agri tools using metal.
|
Not used
|
The machine never worked since beginning.
There were issues with critical parts. Other issues related to electricity
and voltage led to its failure.
|
There are lots of applications in agri tools
and solar using sheet metal plates.
Therefore in consultation & support from
local metal fabrication industry, VA has recently purchased new plasma
cutting machine.
|
|
CNC Milling M/C
|
PCB making, Moulding &
Casting
|
Average
|
- End mills are
expensive. Therefore unless essential (e.g. fab Academy), VA students used
traditional PCB making methods.
- Availability of SMD components was
problems in the past. Making through hole PCB was difficult on CNC milling.
Therefore traditional PCB making methods were used.
|
- The use is limited to Fab Academy projects
and in the Fab Camps.
- Moulding and casting is mainly used for
training.
|
|
3D Printer (2014, 2015, 2016)
|
Science project, Jewellery design, casings,
prosthetic project.
|
Good
|
- VA tried to make our own 3D Printer using
D-I-Y kit. But it did not work.
- Then VA purchased PLA 3D printer from local
start-up. It had several maintenance issues, the company closed down. VA fab
lab could not use it any more.
- VA have purchased ABS printer from another
start-ups. It is performing satisfactorily.
- All this experimentation was funded from
the awards received by VA.
|
Now 3D printer is working fine.
VA team are working on making open sourced
prosthetic hand in our lab.
Recently, VA have got 3D printer from
corporate foundation for secondary school.
|
Table 1: A machine wise analysis of the problems faced by the various
machines installed in VA Fab Lab.
3
Fab Lab Staff
Vigyan Ashram (VA) is a voluntary organisation.
There are challenges in attracting qualified persons due to limitation in
salary, limited resources and remote location. Therefore VA employed
technically qualified freshers from surrounding areas and trained them on the
job. They were encouraged to learn digital fabrication. Bright and committed
members are sponsored to Fab Academy course. Sometimes, the trained person
leaves the job for better opportunity. It has impact on VA lab operations due
to such changes. But over a period, VA has many trained users of the lab. Now
many of ex-VA staff and students have joined other Fab Labs. As such
the efforts in training of youth are benefiting the Fab movement
in India.
Volunteers / Interns: VA being a social
organisation attracts many youth from India & abroad for volunteering. They
have worked with VA Fab Lab in
durations of 1-6 months. VA used their expertise to
streamline some of the processes of the VA Fab Lab. Every year, about 4-5 volunteers
contributed to the VA Fab Lab. These volunteers helped VA to complete projects, develop
curriculum, conduct Fab camps and solve maintenance issues of the equipments. Beside
volunteers, students from MIT/Fab Foundation introduced new tools and
techniques. Realizing contribution of volunteers, VA has developed modest
residential facility for volunteers. There were few volunteers who took
sabbatical from their corporate job and worked in VA Fab Lab for a
few months. In short volunteers are important strategic contributors in the VA Fab
Lab operations.
4
Education
Education is the most important
activity of VA Fab Lab. Students of VA are the primary users of the lab. They
are youth in the age group of 14-20 years and have studied up to secondary school
level. VA uses pedagogy of involving student in ‘Socially useful productive
work’. The work activity is selected in such a way as to introduce curricular
concept to students. Students provide various services to the community as a
part of their learning. Services include agriculture, fabrication, electrical
fitting, food processing, repair and maintenance, construction, etc. Digital
fabrication tools become addition to this bouquet of services.
VA has developed a program to introduce them to
the fab lab environment. Following programs are conducted for new students:-
1. Fab
camp – To introduce machine operations in 3 days sessions. It involves
introducing drawing software, operation of machines, printing of job &
documentation. There is also small introduction to Arduino and
micro-controllers.
2. Think
like an innovator – A manual to select project ideas and work on them. It is
available on http://www.navazkarim.com/works/think-like-an-innovator/
3. FabEd – For secondary school children, VA has
started a FabEd program. It is designed to link fab lab activity with
curricular areas. The process of conducting FabEd activities can be found in
the following link: https://drive.google.com/file/d/0B_Jk2xLqAXjcVmNydHRSc0EtVnRGOWNqSzdJLURLSHQ4MW1R/view?usp=sharing
4. VA is
working with 122+ rural secondary schools and implementing ‘Introduction to
basic Technology (IBT)’ program. In IBT program, students learn while doing for
20% of the school time. These schools have conventional fabrication & electrical
tools. They also have computers. These
schools are encouraged to work on design software and use VA fab lab for
creating from their files. Projects on automation & microprocessors were
introduced last year. This year, VA has planned to introduced electronics and
3D printing by conducting 40 camps for secondary school children targeting 300
students.
5. How
to start Fab Lab : VA has designed and conducted 3 day workshop for
organizations willing to start Fab Lab. It was successful and many new labs are
opening up because of the training.
6. The
new programs are announced and communicate through social media. Schedule of
Fab events are on : http://www.vigyanashram.doattend.com/
7.
On an average, VA fab lab is used by approx. 100
+ youth every year.
5
Fab Projects
Fab lab environment helps to generate new ideas
from VA students. Many projects ideas were born at VA Fab lab and developed
into prototypes. There ideas have great potential. A few ideas, VA could not
take it to the logical conclusion. Students, however, learned very well through
these projects. It was very good academic exercise. But harnessing the good
ideas to its full potential remains the main challenge of VA Fab Lab. Some of the
good projects on which VA has worked but remain unfinished are listed in Table 2. These examples show the
variety of projects that were handled by VA Fab lab. VA has invested time and
resources on the projects. They could have benefited Fab lab and society. Such
unfinished project remains main worry of VA fab lab.
On the other hand, VA has been successful in completing many other projects. Members have used traditional fabrication tools
like arc welding, CO2 welding, lathe machine, electrical motor
rewinding unit, etc., along with tools for digital fabrication. VA has a food processing unit, poly-house,
dairy, goat farm, poultry, traditional fabrication shop etc., on our campus. In
true sense, VA can make almost anything on the VA campus. The completed or near-completion projects are listed in Table 3.
|
Name
|
Progress
Made
|
Difficulty
Found
|
Status
|
|
Milk
testing Device. (2002)
|
VA got
initial circuit & program from MIT. It was reproduced in the lab. It was
able to detect difference in the quality of milk samples.
|
VA team
could not carry out the calibration of the circuits between good milk and
spoilt milk. VA could not get technical report to make the efforts
successful.
|
Projects
still remains relevant.
|
|
Admin
Device for Teachers (2005)
To help
teachers to maintain students records.
|
A device
was made in the fab lab to record attendance of students.
|
Only one
device was made. It worked and was tested in Pabal. Some more refinement was
needed. But the person in-charge left the job.
|
There is no
more need of the handheld device due to availability of Smart phone and apps.
|
|
Low cost
weather station(2006). Unlike commercially available weather station this
device measures only customized parameters necessary for pest management.
|
This was
made with the help of volunteers from Engineers Without Borders.
|
One device
was made. Refinement was not done. After first prototype, new person was not
able to take it forward.
|
Still
relevant and required.
|
|
Leaf
Wetness duration sensor (LWSS).
This need
was expressed by grape growers. They want to know duration of dew wetness on
the leaf to control pest attack.
|
Prototype
was made and tested in the lab. There were issues in the consistency of the
readings and sensor.
|
Two
engineers worked on it for almost a year but could not take it to the field.
|
Project is
still needed. It requires competence and patience in taking solution to the
field.
|
|
Bull
Controller -
To control
bulls in bullock race.
|
Idea is to
make remote control reins to control bull. The circuit was made and it worked
as prototype.
|
Did not get
high torque motors to pull bulls reins. Therefore not tested in the field.
The person
doing the project lost interest and it remains incomplete.
|
Task
remains incomplete.
|
Table 2: Unfinished projects at VA Fab Lab
|
Name
|
Applications
|
Status
|
|
LED lights
for lighting (2003)
|
This was
one of the first circuits made in the VA fablab.
LED circuit
was used to teach beginners on electrical concepts.
Many
students designed innovative lamp holders for their light unit.
|
VA
published manuals and trained 40 youth in making such units. All together, VA
& its students have sold approx.5000+ light units.
VA won
‘Development Marketplace’ award 2012 by World Bank to train 300 village level
entrepreneurs.
|
|
Pedal Power
Generator (2006)
|
To charge
batteries. Made a generator in the lab. It was later improved &
commercialized and manufactured by BOPEEI.
|
VA won
‘Development Marketplace’ award 2007 by World Bank and supplied generators to
42 tribal residential schools.
|
|
Egg
Incubator (2011)
|
To hatch eggs on small scale (100-500-1000) using grid /solar/wood
as fuel. To maintain Temperature 37oC and humidity 87% in the
chamber.
|
Rotation of
the tray and controller circuit was made in the lab. Now it is manufactured
by firm M/S Future Innovative Solutions. They have sold 10 units so far.
|
|
Personal
sanitary napkin Incinerator
|
To dispose
of used sanitary napkin. It is for domestic use and can incinerate 1-2 pads
at a time.
VA also
made a solar incinerator using Fresnel lens.
|
Made 10
units. The parts are cut using plasma cutter.
|
|
Automation
system for hydroponic, poly-house and biome dome.
|
Automation
system to maintain temperature, humidity, soil moisture. It is mainly used to
make fodder with less water.
|
System made
in the Fab lab is installed at poly-house, biome dome and hydroponic system
at VA. It is also under testing at farmer’s poly-house.
|
|
Smaller
projects in use at Vigyan ashram
|
i. Talking
Ganesha Question/Answer system
ii. Water
tank controller
iii.
Automatic street lights
iv. Various
educational toys
|
Used in VA
campus. Designs are shared on the blog.
|
Table 3: Completed
or near-completion projects at VA Fab Lab.
6
Peoples Involvement
VA is located in a small village and farming is the
main occupation of the community. There are regular visitors to ashram. Through open
house exhibition and demonstration, community become aware about the potential
of Fab lab. Now, they come with their problems and ideas to VA. These are their
needs and they are willing to pay for solutions from the lab. This helps VA, to
work on real life problems. Following are few examples of projects done on
demand from community :--
|
HTP spray pump attachment to a two wheeler.
|
For spraying pesticides in small farms.
|
|
High rise fruit cutter / Fruits on thorny bushes
|
Simple clutch and cutter attachment that can
we fitted on any rod or bamboo.
|
|
Mahua collector
|
To collect flowers falling on the ground and
getting spoilt in the soil.
|
|
Terrace dryer - low cost dryer
|
It uses basic drying principle and customised
to local vegetables & climate.
|
Table 4: Service to the local community provided by VA Fab Lab
7
Fab Network & Fab
Conferences
In last 13 years of Fab operations, there were
many disappointments and frustrations. Sometimes, nothing seems to work at VA
Fab lab. The problems range from electricity to laser & computer
software. Strength of network helps in
overcoming such anxious moments. Visit of MIT students from Fab Foundation
helped to overcome technical difficulties. Most importantly, VA team learned a
lot from attending Fab Conferences. These conferences and workshops helped VA
team to learn from other labs and implement the ideas at VA. Attending Fab
conferences abroad by village based institute are not considered priority by
many donors and foundations in countries like India. Therefore attending Fab
conference remains a challenge and it has became possible so far due to support
of Fab foundation. It can be concluded that investment in attending fab
conferences greatly contributed to human resource development at VA.
8
Funding
VA is working with support of foundation and
individual donors. VA mainly caters to student from socially and economically
disadvantaged community. Foundations are mainly interested in funding skill
training which will give youth immediate livelihood. Long term and capacity
building initiative like Fab Lab goes into lower priority activities. Fortunately, VA got initial support from MIT
for machines. Department of Science and Technology (Govt. of India) supported
salary of one Fab Lab engineer & a small financial support for recurring
cost. Other than this, VA-Fab Lab has
not got any significant financial support from 2002-2014.
VA-Fab Lab operation is funded by combination of
following –
i)
Government (Dept of science
& Technology) : 20 % of total cost of operation, mainly for salary of Fab Engineer
ii)
Fees of students: 40 % to cover
mainly cost of project materials.
iii)
Private donors and foundation :
10 % for machine up-gradation
iv)
Projects against orders :10%
(fees paid by the customers)
v)
Fab Foundation : 20% (scholarship for Fab Academy students
and Fab conference)
With the success of the Fab projects and
awareness about the Fab Lab increased, VA started getting support from
foundation to upgrade its machines and replenish its inventory. In 2015, VA got
Laser cutting machine from corporate foundation and others.
In 2012, Government of Maharashtra sponsored
establishing Mini Fab Lab in Pune. At present, Govt of India and State
Government of Maharashtra are planning to establish tinkering labs, innovation
centres at block & district levels. VA fab lab is regularly visited by
authorities for consultation.
9
Way Ahead: Fab Lab for Appropriate Technologies
In last 13 years of operation, VA Fab Lab is
becoming focussed on Appropriate Technologies (AT) for rural and under
developed regions. Mr. Schumacher (1973) wrote a book ‘small is beautiful’. His
ideas give rise to concept of AT. AT technology solutions ask for:-
1.
People’s involvement in finding
solution to their problems.
2.
Solution which is
environmentally friendly and uses local resources.
AT movement was at its peak in 1980. It has lost
its momentum due to the following:-
1.
AT solution was seen as
inferior technology solution.
2.
AT solution requires local
skills and workmanship to make it locally.
3.
AT solutions were difficult to
replicate and hence its impact remains limited.
Fab Lab is for people to find solutions to their
own needs with local resources. From the experience of Fab Lab at VA, it can be
said that Fab lab can provide answer for the shortcoming of AT movement of
1980’s.
1.
Digital fabrication and
computer cutting machine will reduce dependence on the local skills for
reproducing the product.
2.
Sharing of designs and files
become easy in the fab lab network.
3.
Fab network will make it is
easier to work with the other labs with similar interest and problems.
At present, Vigyan ashram is concentrating on AT
projects in the following areas-
1.
Precision agriculture
2.
Prosthetic solutions
3.
Clean Energy solutions
Design Innovation Center (DIC) : VA has
started DIC to overcome the problems of incomplete project ideas. DIC started a
course on design for graduate students. They will work in the Fab Lab for six
month and learn design concepts by working on real life projects. The project
will be evaluated on the criteria of user experience and field testing. They
will get academic credit from Savitribai Phule Pune university (SPPU). This
initiative started in March 2016 and now has ten engineering students working
on their projects.
10
Conclusion:
In 2002, Journey of VA fab Lab started in small
tin-roof room of 150 sq.ft. In 2005, Fab Lab was shifted to slightly bigger
room of 800 sq.ft. In 2011, Fab Lab was shifted to well-constructed workplace
of 1000 sq.ft. In 2016, VA fab Lab shifted to 2000 sq.ft place. The journey is
described as Fab Lab 0.0 to Fab Lab 0.4.
The journey was full of challenges and
fulfilment. Lots of questions are asked about sustainability of the Fab Lab. Anything
which is useful and needed by the society, sustains itself. VA Fab Lab survived
and grew up in last 13 years. It became possible due to support of various
stakeholder and Fab network.
Acknowledgement
Vigyan Ashram Fab Lab is thankful to Fab
Foundation, Massachusetts Institute of Technology (MIT), Dept of science and
Technology (Govt of India), and the RGSTC (Govt of Maharashtra) for their
continual support.
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