Manufacture It
Intro | DIY Build Instructions | Manufacturing Method | GEK Licensing
The GEK project set out to solve the long-standing problems of small scale gasification. Along the way we found we needed to solve the manufacturing and distribution problem as well. One-off prototypes of custom builds only result in high dollar devices few can afford. To make gasifiers actually impactful in the world, we needed to figure out how to make them inexpensively and flexibly with contemporary manufacturing methods.
The result is the GEK manufacturing method. It is a method that makes it possible for you to start manufacturing the GEK in your local area, with minimal capital or technical hurdles. We are now using this system to enable distributed manufacturing and installation of the GEK system, not centralized manufacturing and export around the world. Local and regional manufacturing has many positive impacts beyond the basic gasifier, as well as the potential for viral growth not possible with typical commodity consumer product delivery.
Small scale distributed manufacturing is again possible and market competitive using new CNC and CAD/CAM tools. ”Desktop manufacturing” or “Digital Manufacturing” gives the small operator access to manufacturing solutions previously only possible at large scales and high capitalization. We have designed the GEK to leverage these new tools, and therefore you’re ability to start making the GEK at your location with a modest investment. The threshold to entry is the CNC plasma cutter table, which is about a US$10,000-15,000 problem. All the rest of the tools are common welders, saws and rollers. If the CNC plasma table is too much, there is also a fully manual method using jigs and a hand held plasma torch.
The materials to make the GEK are available globally, even in low tech rural areas. We’ve made a great effort to solve all building problems with simple sheet metal, black pipe plumbing, and common dimensioned steel. There are no exotic parts and esoteric materials needed to make the basics. Thus it is possible to make the GEK anywhere, as well as find parts to fix it near anywhere.
Commercial manufacturing and sale of the GEK requires a formal licensing agreement with ALL Power Labs. The licensing fee is a simple 10% on gross retail sales. This licensing or franchise fee goes far beyond the basic GEK dimension drawings. Manufacturing is as much a problem of internal operations, supply chain, inventory, sales, shipping, as it is any raw design. We can post the GEK drawings publicly as most who want to manufacture it realize there is a lot more involved, and they’ll gain more value by involving ALL Power Labs in their effort than trying to reinvent the whole thing from scratch. Somewhat like you can get the Linux kernal for free, but most commercial enterprises find it more valuable to work with RedHat or another fully integrated solution provider. If you are considering an endeavor in this direction, please read the licensing page and contact Jim Mason at “gek_(at)_allpowerlabs_(dot)_org.
In the interim, here’s some basic info on the maufacturing process.
The GEK is easily manufactured at small or large scale using standard sheet steel. The sheet steel is cut into three basic part types: vessel tubes, flange rings, and end plates. These are rolled then snap together for welding. A tab and slot system is used on all parts, thus they self-ji for easy and accurate welding.
Here are the CAD drawings for all parts to form the hopper, gas cowling, downdraft reactor (nozzle and constriction type) cyclone and swirl burner:
The resulting parts are pictured below. (left to right: hopper, gas cowling, downdraft reactor and insulation tube, cyclone, and swirl burner)
The full set of vessel tubes is cut from one sheet of 4′ x 8′ mild steel (1/16″ thick). A typical three wheel manual roller forms the flat parts into cylinders. All the flanges and end plates are cut from one third of a 4′ x 8′ sheet mild steel (1/8″ thick).
Below is the layout pattern for the 1/16″ and 1/8″ sheets. Note the nesting of “rings within rings” for the flange rings and end plates. The width of a plasma cut is about equal to the 1/16″ vessel tube thickness. Therefore the offset between the outer and inner cut parts corresponds nicely with the outer and inner diameter of the related vessel tube. This layout method minimizes wasted material and cut time, while insuring a perfect “on dimension” fit. The flange rings and end plates also second as the the “jig” to final form the tubes to true round before welding the tube seams.
The ALL Power Labs shop cuts these part with a CNC plasma table that achieves 0.05″ accuracy to the CAD drawings. The parts can also be cut by hand with a handheld plasma torch and a homemade protractor to guide the torch around the circles. For larger production runs, the pieces could be punched, likely also with a reduction in metal thickness. We are using metal that is thicker than necessary as it easier for the end user to weld and modify.
To simplify shipping, the kit is designed so vessel tubes nest inside each other like a “Russian Doll”. Flange rings and end plates similarly bunch into a thin pancake. Total package dimension: 24″ x 17″. The weight is below 150lbs, so it can ship UPS ground, avoiding the hassles of freight shipment. The tube pieces can also be left unrolled and the entire kit shipped as a flat package.
Here are pictures of a fully assembled GEK unit built from scrap tanks and manufactured plates.
All GEK parts and assemblies are built on location at the ALL Power Labs shop in Berkeley, CA, USA. You can see how we manufacture, stock and ship the GEK in the Fab Shop and Shipping photo gallery.
Detailed instructions for DIY fabricating, assembling and firing the GEK are in the GEK wiki sand box.
