A PROJECT REPORT ON DESIGN AND FABRICATION OF PORTABLE 3D …

A PROJECT REPORT ON

DESIGN AND FABRICATION OF PORTABLE 3D

PRINTER

Submitted in partial fulfillment of the requirements for the award of degree of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

VISVESVARAYA TECHNOLOGICAL UNIVERSITY BELAGAVI

SUBMITTED BY

Ishtiaq Ahmed (1AT14ME032)

M Syed Ismail Zeeshan (1AT14ME038)

Mohammed Shoaib Shariff (1AT14ME045)

Prashanth S (1AT14ME056)

Under the guidance of

Prof. Harsha N

Assistant Professor

Dept. of Mechanical Engineering, Atria IT

Department Of Mechanical Engineering

ATRIA INSTITUTE OF TECHNOLOGY

Bengaluru-560024

2017-2018

ATRIA INSTITUTE OF TECHNOLOGY (Affiliated to Visvesvaraya Technological University & Approved by AICTE, New Delhi)

ANANDNAGAR, BENGALURU-560024

DEPARTMENT OF MECHANICAL ENGINEERING

Certificate

Certified that the project work entitled

“DESIGN AND FABRICATION OF PORTABLE 3D PRINTER”

Is a bona fide work carried out by Ishtiaq Ahmed, M Syed Ismail Zeeshan,

Mohammed Shoaib Shariff, Prashanth S, in partial fulfillment of Bachelor of

Engineering Degree in Mechanical Engineering of Visvesvaraya Technological

University, Belagavi during the year 2017-2018. It is certified that all corrections or

suggestions indicated for internal assessment have been incorporated in the report

deposited in the department library. The project report has been approved, as it satisfies the

academic requirement in respect of the project work prescribed for the Bachelor of the

Engineering Degree.

Prof. Harsha.N Dr. Narasimha Murthy Project Guide & Asst.Professor Professor & Head

Department of Mechanical Engineering Department of Mechanical Engineering

Dr. K V Narayanaswamy Principal, Atria.I.T.

Name of the Students

Ishtiaq Ahmed (1AT14ME032)

M Syed Ismail Zeeshan (1AT14ME038)

Mohammed Shoaib Shariff (1AT14ME045)

Prashanth S (1AT14ME056)

Name of the Examiners Signature with date

1.

2.

ABSTRACT

3D printing is an additive manufacturing technique in which 3D objects are printed with

the help of CAD (computer-aided design) software. Different processes are available in 3D

printing technology such as (1) FDM (fused deposition method),(2) SLS(selective laser

sintering) (3) EBM (electron beam machining,(4) LOM(laminated object manufacturing),(5)

DLP (digital light processing),etc.

In this paper, we have focused on the design and fabrication of a portable 3D printer of bed

volume (150 x 180 x 200 mm3) which can be constructed economically. We are using 4 axis

mechanisms where 3 axes are x-y-z and the fourth axis is an extruder.

The process adopted by us is FDM technology, in which different the materials like

PLA (polylactic acid), ABS (acrylonitrile butadiene styrene), HIPS (high impact polystyrene),

etc. By heating any of the filament material to its melting point and it is deposited layer by layer.

Combination of many layers of such type will give us a final 3D model

i

ACKNOWLEDGEMENT

It gives us pleasure while submitting the report to the department to the department of

mechanical Engineering. Atria Institute of Technology, Bengaluru, as a part of our curriculum.

We give our senior gratitude to our management for providing support and encouragement.

We express our gratitude to Dr. K. V. Narayanaswamy, Principal, Atria Institute of Technology,

for providing the facilities.

We wish our grateful thanks to Dr. Narasimha Murthy, Professor & Head, Department of

Mechanical Engineering, for providing complete guidance, support and encouragement in all

aspects of our project.

We convey our regards to our project guide Prof. Harsha N, Assistant Professor, Department of

mechanical Engineering, for his never-ending support, valuable suggestions and guidance by

sharing his immense knowledge, which facilitated the successful completion of the project.

We are also grateful to Dr. Rajashekar Patil, Professor, Department of mechanical Engineering.

We are extremely thankful and indebted to him for sharing expertise sincere, valuable guidance

and encouragement extended to us.

We give our sincere thanks to prof. Bharath V G, Assistant Professor, Department of mechanical

Engineering, for providing guidance all through our project.

We owe our greatest debt of our lives to our parents for providing us good educations and for

teaching good values of life.

Finally, our sincere thanks to all teaching and non-teaching staffs of the department of

mechanical Engineering, Atria Institute of Technology for their support and co-operation.

ii

CONTENTS Abstract i

Acknowledgement ii

Contents iii

List of Figures vii

List of Tables ix

Notations x

Particulars Page No.

CHAPTER 1: INTRODUCTION

1.1 Three-dimensional printing 1

1.2 History 1

1.3 Principle 1

1.3.1 Modelling 4

1.3.2 Printing 5

1.3.3 Finishing 6

1.4 Application 6

1.4.1 Education 6

1.4.1 Apparel 7

1.4.4 Construction 8

1.4.4 Dental 9

1.4.7 Domestic Use 10

CHAPTER 2: LITERATURE SURVEY

2.1 Various techniques developed for additive manufacturing

2.1.1 Photopolymerization 11

2.1.2 Powder 13

2.1.3 Material Extrusion: Extruding a filament at appropriate temperature 14

2.1.4 Lamination 15

2.2 Motion Configuration in 3D Printers 15

iii

2.2.1 Cartesian configuration 16

2.2.2 Delta configuration 17

2.2.3 SCARA configuration 18

2.2.4 Polar configuration 19

2.3 Materials used in FDM 3D Printing 20

CHAPTER 3: METHODOLOGY

3.1 Flow chart 24

3.2 Selection of process 24

3.3 Selection of Mechanism 25

3.4 Electronics 25

3.4.1 Controller 26

3.4.2 Stepper Motors 26

3.4.3 Endstops 27

3.4.4 Heated Bed 27

3.4.5 Stepper Drives 27

3.5 Software 27

3.5.1 CAD Tools 27

3.5.2 CAM Tools 28

3.5.3 Firmware 28

3.6 Objectives of our present work 28

CHAPTER 4: DESIGN AND FABRICATION

4.1 Conceptual Design 29

4.2 Detail design 29

4.2.1 Selection of Motor for X and Y axis 30

4.2.2 X – axis Movement 30

4.2.3 Y – axis Movement 33

4.2.4 Z – axis Movement 35

4.3 BEARINGS 37

4.3.1 Linear bearings 39

iv

4.3.1.1 Linear ball bearing LM8UU 40

4.3.1.2 Linear ball bearing LM16UU 41

4.3.2 Ball bearings 41

4.3.3 Flanged bushing ball bearing 42

4.4 BELTS AND PULLEY

4.1 Belt Drive and its Types 43

4.1.1 Law Of Belting 43

4.5 Timing Belt 44

4.6 Pulley 45

4.7 Extruder 46

4.7.1 Introduction 47

4.7.2 Principle of Extruder 48

CHAPTER 5: ELECTRONICS

5.1 Introduction 50

5.2 Controller Board 50

5.2.1 Arduino Due 51

5.2.2 Beagle Bone Printer Board 51

5.2.3 Azteeg X5 51

5.2.4 Smoothieboard 52

5.3 Ramps 52

5.4 Stepper Motors 53

5.4.1 Selection Of Stepper Motor 54

5.4.2 Stepper Motor Applications 56

5.4.3 Types Of Stepper Motor 56

5.4.3.1 Nema 11 57

5.4.3.2 Nema 14 57

5.4.3.3 Nema 17 57

5.4.3.4 Nema 23 58

v

5.5 Stepper Drives 58

5.6 Lcd Controller 59

5.7 Thermistor 60

5.8 End Stops 61

5.9 Heated Bed 61

5.10 Power Supply 63

CHAPTER 6: FIRMWARE AND SOFTWARE

6.1 Introduction 64

6.2 List Of Firmware 64

6.2.1 Sprinter 64

6.2.2 Teacup 65

6.2.3 Sjfw 67

6.2.4 Marlin 67

6.2.5 Sailfish 68

6.3 Steps To Install Firmware 69

6.4 Software 70

6.5 Software Used For Designing The 3d Printer 70

6.5.1 Solidworks 71

6.5.2 Catia 72

6.6 Softwares Used For Printing The 3d Models 72

6.6.1 Cura 72

6.6.2 Repetier Host 74

6.6.3 G-Code Interpreter 75

6.6.4 G-Code Sender 75

CHAPTER 7: CONCLUSION

Conclusion 76

References 79

Publications 81

vi

LIST OF FIGURES

Figure 1.1 CAD modelling 4

Figure 1.2 printing of models 6

Figure1.3 planetary gear 7

Figure 1.4 3D Printed Shoe and Spectacle 8

Figure 1.5 building prototype printed 8

Figure 1.6 human jaw prototype 9

Figure 1.7 Domestic items 10

Figure 2.1 Stereolithography Apparatus (SLA) 11

Figure 2.2 Material Jetting 12

Figure 2.3 Two photon Polymerization 12

Figure 2.4 Selective Laser Sintering 13

Figure 2.5 Binder Jetting 14

Figure 2.6 Fused Deposition Modelling 14

Figure 2.7 Direct Writing Assembly 15

Figure 2.8 Laminated Object Manufacturing 16

Figure 2.9 Selective Deposition Lamination 16

Figure 2.10 Cartesian configuration 17

Figure 2.11 Delta configuration 18

Figure 2.12 SCARA configuration 19

Figure 2.13 Polar configuration 19

Figure 3.1 Flowchart 24

Figure 3.2 Cartesian type mechanism 26

Figure 4.1 cad design 29

Figure 4.2 Detailing of NEMA 17 30

Figure 4.3 X-Axis cad design 31

Figure 4.4 X-Axis holder cad design 32

Figure 4.5 Y-Axis cad design 34

Figure 4.6 Z-Axis cad design 36

vii

Figure 4.7 Mechanism for Z – axis movement (vertical direction) 37

Figure 4.8 Heat Bed 38

Figure 4.9 Linear Bearing 39

Figure 4.10 LM8UU linear bearing 40

Figure 4.11 LM16UU linear bearing 41

Figure 4.12 Ball Bearing 42

Figure 4.13 Flanged bushing ball bearing 42

Figure 4.14 Timing Belt 44

Figure 4.15 Pulley 46

Figure 4.16 E3D V6 Extruder used in our 3D Printer 48

Figure 4.17 Hot end of extruder 49

Figure 5.1 Ramps 1.4 53

Figure 5.2 A4988 Stepper drive[15] 58

Figure 5.3 LCD Controller 59

figure 5.4 Thermistor 60

Figure 5.5 Endstop 61

Figure 5.6 Heated Bed 62

Figure 5.7 Power Supply 63

Figure 6.1 valves of sprinter 65

Figure 6.2 shows configuration of teacup[16] 66

Figure 6.3(a) program of Arduino 69

Figure 6.3(b) marlin firmware 70

Figure 6.4 design in solid works 71

Figure 6.5 Cura 73

Figure 6.6 Repetier Host 74

Figure 7.1 Fabricated 3D Printer 77

Figure 7.2 3D printed parts 78

Viii

LIST OF TABLES

Table 2.1 Materials Used 20

Table 4.1 Flanged bushing ball bearing 42

Table 4.2 Pulley Specification 47

Table 7.1 Machine Specification 76

ix

NOTATIONS

V = Velocity in ms-1

r = Radius in mm

C = Center distance between rods in mm

A = Area in mm2

W = Width in mm

H = Height in mm

I = Inertia in mm4

E = Young’s modulus in N/mm2

Y = Deflection in mm

T = Torque in Nmm

F = Load in N

D = Diameter in mm

Dstd = Standard Diameter in mm

Dm = Mean Diameter in mm

ω = Angular Velocity in rads-1

Mt = Moment in Nmm

N = Speed in RPM

P = Pitch in mm

µ = Co-efficient of friction

σ = Stress in N/mm2

x

CHAPTER 1

INTRODUCTION

Design and Fabrication of Portable 3D Printer 2017-18

Department of Mechanical Engineering, Atria I T, Bengaluru 1

Chapter 1

INTRODUCTION

1.1 3D PRINTER

A 3d printer is an additive manufacturing technique where 3D objects and parts are made

by the addition of multiple layers of material. It can also be called as rapid prototyping. It is a

mechanized method where 3D objects are quickly made as per the required size machine

connected to a computer containing blueprints of any object.

The additive method may differ with the subtractive process, where the material is

removed from a block by sculpting or drilling. The main reason to use 3d printer is for 90% of

material utilization, increase product life, lighter and stronger. 3D printing is efficiently utilized

in various fields such as aerospace, automobile, medical, construction and in manufacturing of

many household products.

1.2 HISTORY

The 3D printing innovation is not a new concept as many think. When FDM (fused

deposition modeling) licenses had expired in 2009, the 3D printing became a new innovation

topic. What's more, because of which it turned out to be more mainstream, individuals

envisioned that FDM was the just a single added substance producing system. Be that as it may,

the initial 3D printing procedure was SLA not FDM, and its first patent was recorded in 1980's.

Here is the historical backdrop of 3D printing innovation, from 1980 to today.

In 1980's there was the introduction of 3 primary 3D printing systems. Dr. Kodana was

the first person to present layer by layer approach for assembling and furthermore he was the

principal individual to create fast prototyping strategy. What's more, he made a progenitor for

SLA. He polymerized a photosensitive gum with the assistance of UV light, however, did not

succeed. Shockingly for Dr. Kodana, the full patent detail was not recorded by him before the

one-year due date after the application. the causes of 3d printing innovation can be followed

from 1983.

In 1983 Charles hull was the person to do a patent on stereolithography. Frame designed

the term stereolithography in august 8, 1984 patent application for "Contraption for creation of

3 dimensional questions by stereolithography". Furthermore, was the main individual to make

SLA-1 (stereolithography) machine in 1987.



Charles hull was the founder 3D system Corporation (one of the biggest and more propel

association working in 3d printer division today). Hull characterized stereolithography as the

unique technique which is used for making solid objects by printing successive layers of

ultraviolet curable material on top of other. In frame's patent, he clarifies, a concentrated light

emission light is centered around the surface loaded with a fluid photopolymer. The light ray

which is controlled by a computer draws each layer of the model on the surface of the liquid.

wherever the bright light strikes the surface, the photopolymer polymerizes and changes to solid.

Using the software CAD/CAM mathematically slices (converts into layers) the models. then the

process builds the models layer by layer.

During the year 1990’s the other 3D printing innovation and processes were emerged

during this year. And the introduction of new 3D printer manufacturers and cad tools. 3D

systems make their first commercial sale of stereolithography (SLA) system. And the other

emerging processes were ballistic particle manufacturing (BPM) patented by William masters,

solid ground curing (SGC) was been patented by Itzchak Pomerantz et al.

Furthermore, other developing organizations saw amid the nineties till today - Stratasys, EOS,

and 3D systems. The 1990's were the time of first use of the 3D printer in medical researchers,

who consolidated the way of pharmaceutical and 3D printing and opening the chances to

numerous clients. In 1992 the patent done on fused deposition modeling was issued to Stratasys,

who had developed may 3D printers both for professional and for individuals. The SLA

(Stereolithographic) apparatus was made in this year by 3D systems. The first SLA machine

uses a UV laser solidifying photopolymer, and a liquid with the viscosity and color of honey

that makes the object layer by layer. This was the first rapid prototyping form that had changed

the engineering world and design for ever.

From 1993-1999, the main actors of the 3D printing sector, which had emerged with

various techniques. Sanders prototype (later Solidscape) and Z Corporation were set up in 1996

in terms of commercial operation, Arcam was established in 1997.

During that time where these 3D printing sector had started to begin the demonstrate

distinct diversification with these two very specific regions emphasis that is clearly defined

today. They were very high end 3D printing and still they are very expensive which were geared

up towards the par production for high value and complex parts. This are growing rapidly and

ongoing but the results are now visible in production applications across the automotive,

aerospace, medical and in jewelry sectors. And at the other end, some of the 3D printing system



manufacturers were developing and advancing the “concept modelers”, they were called at that

time. These 3D printers kept on focusing on overall development and improvement of these

functioning prototyping that were being developed on specifically as these offices and user

friendly and the cost effective systems. However, these systems were very much useful in

industrial applications.

At the lower end of market, the 3D printers that today are been seen. During this term

there, price was a war between the 3D printing companies with the increase in improvement,

accuracy, speed and materials. In 2007 the market saw the first system under 10,000$ from 3D

systems but it never hit the market as supposed to be. This was due to the market influence of

other companies.

All through in 2000 3D printing technology kept on developing to make lower-priced

models with multiple features. In 2003 there was the new invention that 3D printer was used to

construct cells when Thomas Boland of Clemson university patented for the use of inkjet

printers for printing of cells. To modify these spotting systems for deposition of the cells into

the very much organized 3D matrices placed on a substrate this process were used. The printing

of biological structures is known as Bioprinting. The millennium saw the first 3D printed kidney

working. Additionally, more techniques for printing came into action, such as extrusion

bioprinting, have been researched and introduced as a means of production. Due to which the

organs may be printed using bioprinting and can be transplanted.

In 2004 the initiating of RepRap project which consists of a self-replicating 3D printer.

This open source of the RepRap project led to spreading of FDM 3D desktop 3D printers and

popularity of 3D printers begins from here.

In 2005, Z-Corp launched the spectrum Z510. The first color and high definition 3D

printer. The first SLS machine commercially accessible in 2000, which gave opportunities to

the manufacturer to build industrial parts. A 3D printing startup company Objet built a machine

that could print more than one material, which allowed a single part that can be manufactured

and fabricated with different material properties.

In 2009, was the year where the FDM patents fell into the public domain, giving an

expansive wave for the development in FDM printers and due to the drop of the price of desktop

3D printers, the technology was more accessible and increased visibility. A French company

named Sculpteo was started in this year which had offered 3D printing cloud and online printing

services using stereo lithography or laser sintering. which was another step towards 3D printing



technology. A host of similar deposition printers have emerged with marginal unique selling

point and they continued to do so. The ethos of RepRap is all about open source developments

of 3D printing and keep it commercialize.

As the various additive processes developed. It is said that soon metal removal will no

longer be the only metal removal process done through a moving head through a 3D work

envelope converting the mass of raw material into desired shape layer by layer. In 2010 there

was a first decade in which metal end use parts like engine brackets and large nuts would be

made by printing instead of machining.

1.3 Principle

1.3.1 Modelling

The object or the model which has to be printed first it has to designed or modeled using

a CAD (computer aided drawing) tool like solid works etc. By the 3D scanner or by the digital

camera and a very unique photogrammetry software. These 3D printed models were created

with help of the CAD results in the reduction of errors which were found and can be corrected

before printing. In manual modelling process of preparing geometric data for 3d computer

graphics is similar to plastic arts such as sculpting. Based on this data 3-dimentional models of

the scanned object can be produced.

Figure 1.1: CAD Modelling

After modelling in CAD tool the model often be (in .skp, .dae, .3ds or some other format) then

it needs to be converted to either a .STL or .OBJ format, to allow the printing software to be

able to read it.



1.3.2 Printing

After the model has been converted to STL, it must be first examined for “errors”, this

step is called the “fixup”. In most of the cad applications produce errors in output STL files

errors like sekf intersection, improper holes, face normal has to be corrected.

Once the file is converted to STL, the file has to be processed by a software called

“slicer” which will convert the model into series of layers and produces a G-code file containing

instructions to a specific type of 3D printer. This G-code file can be printed by using 3D client

software (which loads the G-code and uses it to instruct the 3D printer during printing. In

practice the client software and the slicer program exist, including Cura, Slic3r, repetier host,

pronterface and skeinforge as well as closed source programs like simplify 3D and KISSIicer3D.

3D printer follows the G-code instructions to lay down successive layers of liquid,

powder, paper or sheet material to build model from a series of cross sections. The such as

plastic, sand, metal etc can be \used through a print nozzle. These layers, which correspond to

the virtual cross sections from the CAD model, are joined or automatically fused to create the

final shape. Depending on what the printer is making, the process could take up to minutes or

hours. Printer resolution describes the layer thickness and X-Y resolution dots per inch (dpi) or

micrometers(μm).The layer thickness which can be found can be around the 100gm mark,

although some of these machines such as the object connex series and the 3D Systems ProJet

series can be very much printed as thin layers as 16µm. These resolution of X-Y is comparable

to that of laser printers. The particles (3D dots) are around 50 to 500µm (510 to 250 Dpi) in

diameter.

The method of Construction of models can take away from several hours to several days,

depending how big the model is, method used, printing speed, and complexity of the model.

Typically, the time can be reduced to few hours depending on the type of machine used and

size. 3D printers give designers and concept models using a desktop size of 3D printer.



Figure 1.2: Printing Of Models

1.3.3 Finishing

The printer produced resolution is very much sufficient for many of the applications

but the printing will be a slightly oversized version of these desired object which can be the

standard resolution and then the process of removing material can give greater precision. Some

printable polymers allow the surface finish to be smoother and improved using chemical vapor

processes.

There are some of the additive manufacturing techniques which are very capable of using

multiple materials in these course of constructing parts. These techniques are very much able to

print in multiple colours and colour combinations simultaneously. Some printing techniques

require internal supports to be built for overhanging features during construction. These supports

must be mechanically removed or dissolved after completion of the printing. The

commercialized metal 3D printers which very much likely to involve in cutting the metal

component of the metal substrate after deposition. The very new process for the GMAW 3D

printing which will allow for substrate surface modifications to remove many aluminum

components manually with hammer.

1.4 Application

1.4.1 Education

New learning material: often you must want new teaching materials but may not be able

to afford to budget for them. Now their resources can be made using a 3D printer, saving money

on your department budget. When we will be Printing our own learning, materials is not only



cheaper but it will be almost always quicker too. Even though students are traditionally taught

through books and theory, kinesthetic learners prefer to learn through using aids and materials.

3D printing which also allows you to bring any of the subject matter to life as the physical aid

to engage all of your students for a very long period of time increasing that their learning and

improving their problem solving and critical thinking capabilities.

Figure 1.3: Planetary Gear

1.4.1 Apparel

3D printing has spread into the world of clothing with fashion designers experimenting

with 3D-printed bikinis, shoes, and dresses. When we talk about the commercial production,

Nike is using 3D printing to prototype and manufacture the very same football shoe for the

American football players and the company New Balance is 3D manufacturing custom fit shoes

for all the athletes.

3D printing has come to the point where companies are printing consumer grade eyewear with

on demand custom fit and styling (although they cannot print the lenses). On demand

customization of glasses is possible with rapid prototyping.



Figure 1.4: 3D Printed Shoe And Spectacle

1.4.4 Construction

With the help of 3D printers, we are able to build civil models like prototype of building

or plan structures. So that the customers can easily visualized the models.

Figure 1.5: Building Prototype Printed



1.4.4 Dental

With the help of 3D printers, we are able to print jaws it can be a prototype or it can be

a jaw bone which can be transplanted as per the needs. An 83-year-old British woman recently

underwent the first-ever custom transplant of a lower jaw made by a 3D printer.

Figure 1.6: Human Jaw Prototype

1.4.5 Medical

Medical applications for 3D printing are expanding rapidly and are expected to

revolutionize health care. Medical uses for 3D printing, both actual and potential, can be

organized into several broad categories, including: tissue and organ fabrication; creation of

customized prosthetics, implants, and anatomical models; and pharmaceutical research

regarding drug dosage forms, delivery, and discovery. The application of 3D printing in

medicine can provide many benefits, including: the customization and personalization of

medical products, drugs, and equipment; cost-effectiveness; increased productivity; the

democratization of design and manufacturing; and enhanced collaboration. However, it should

be cautioned that despite recent significant and exciting medical advances involving 3D

printing, notable scientific and regulatory challenges remain and the most transformative

applications for this technology will need time to evolve



Figure 1.6.1: Cranium Bone Prototype

1.4.7 Domestic Use

The domestic market of the 3D printing was mainly practiced by hobbyists and

enthusiasts and was very little used for many of the practical household applications which are

inapplicable. A working clock was made and gears were printed for home woodworking

machines among other purposes. 3D printing was also used for ornamental objects. Websites

associated with home 3Dprintins include coat hooks, doorknobs etc.

Figure 1.7: Domestic Items

CHAPTER 2

LITERATURE SURVEY



CHAPTER 2

LITERATURE SURVEY

2.1 Various techniques developed for additive manufacturing

2.1.1 Photopolymerization

Curing of photoreactive polymers/ resins with laser or UV light (Ex SLA, MATERIAL

JETTING, TPP) [1] Stereolithography Apparatus (SLA) method was invented in 1986 and

was typically used in the first-generation commercial 3D printers. Printers which are using

stereolithography to concentrate the beam of UV rays on the top of the surface of the object

which should be replicated. The object is filled with resin. When light hits the resin, you get a

high resolution 3 D model of the object you have used.[2]

Figure 2.1: Stereolithography Apparatus (SLA)

The Material jetting is one of a unique and the only additive manufacturing technology that

can be a combination of many different print materials within the same 3D printed model inside

the same print job. The multi material is obviously a printing process is very much capable of

constructing functional assemblies which reduces the need for multiple builds. With the

respective ASTM standard of material jetting is the only process in which where there are some

of the droplets that can build material can be selectively deposited onto a heated bed to develop

a 3D object.



Figure 2.2: Material Jetting

Two photon Polymerization (TPP) is a promising three-dimensional microfabrication method

that has recently attracted considerable attention is based on two photon polymerizations with

ultrashort laser pulses[2]. It is determined that when it is focused into the volume of a

photosensitive material the pulses initiate two photon polymerization two photon absorption and

subsequent polymerization[3].

Figure 2.3: Two photon Polymerization

2.1.2 Powder



High power laser to sinter small particles of material (Ex: SLS, BINDER JETTING)

Selective Laser Sintering (SLS) is a rapid prototyping process that builds media in powder

form, which is fused together by using powerful carbon-dioxide laser to form final product. SLS

uses a high-powered C02 laser to fuse small particles of powdered material to create 3

dimensional parts. When a laser where it will selectively which will fuse the powdered materials

by scanning X&Y cross sections on the top of the surface of a powder bed. The model is built

one layer at a time from supplied 3D CAD data [4]. SLS is very much capable of producing

very highly durable parts for real world testing [12].

Figure 2.4: Selective Laser Sintering

Binder Jetting is a rapid prototyping where the material being jetted is a binder, and is

selectively sprayed into a powder bed of the part material to fuse it a layer at a time to print the

required part



Figure 2.5: Binder Jetting

2.1.3 Material Extrusion: Extruding a filament at appropriate temperature (Ex: FDM, DWA)

Fused Deposition Modeling (FDM): This is a process by which a machine deposits a filament

(Thermoplastics or wax)[11]. On top or next to same material, in order to create a joint by heat

or adhesion[4].

Figure 2.6: Fused Deposition Modelling

Direct Writing Assembly where the term direct writing is to describe the fabrication methods

that will be employed on the computer control translation stage which will move a pattern



generating device which is an ink deposition nozzle to create a lot of materials with can be under

controlled architecture and composition.

Figure 2.7: Direct Writing Assembly

2.1.4 Lamination

Layering sheet materials which are cut and laminated together

Laminated Object Manufacturing (LOM): In the LOM technology, the layered material is

rolled on the building platform . The material which is coated with an adhesive layer and when

the feeding roller starts heating to melt down the adhesive. After that the top layer will be glued

to the previous one[8]. A blade or a laser is will be used to draw the geometry of the object to

build and draw crosses on the rest of the surface to facilitate the extraction of the final objects.

https://www.sculpteo.com/en/glossary/printer-bed-definition/



Figure 2.8: Laminated Object Manufacturing

Selective Deposition Lamination: In this process it will involve the layers of adhesive which

are coated with paper that are very successively glued together with the heated roller and cut to

the required shape with a laser cutter layer by layer[9]. When the roller with these materials

moves each of the new sheet of material over the last and repeats the process until the object is

complete.

Figure 2.9: Selective Deposition Lamination

2.2 Motion Configuration in 3D Printers

2.2.1 Cartesian configuration

Cartesian 3D printers are pretty much named after the coordinate system the X Y and Z

axis which is used to determine where and how to move in three dimensions and the Cartesian

3D printers which have a heated bed which moves only in the Z axis. The extruder sits on the

X-axis and Y-axis, where it can move in four directions on a gantry. This is the principle which



can be seen in action on the models from Ultimaker and MakerBot [14]. With the Printrbot

Simple instead of moving the print head purely in XY space, one of the axes are changed by

moving the print bed itself. This is a very easy and simple design, and therefore it will be easier

to maintain, but at the sacrifice of printing speed.

Figure 2.10: Cartesian Configuration

2.2.2 Delta configuration

Delta 3d printers feature a circular print bed. The extruder will be suspended above that

by three arms in a triangular configuration thus the name “Delta” (Figure 2.11). These nifty

robots were designed for speed and they also have the advantage of a print bed that does not

move which could be advantageous for certain prints. The benefits which are obtained from the

Delta configuration is that when the moving parts are lightweight it will be easier to travel. That

results in faster printing with greater accuracy. Most “traditional” printers have a moving build



platform. This means that the object you are printing is always moving which can lead to prints

coming loose due to the constant jerks and to inaccurate prints especially when the prints get

higher. Delta configuration are much more better in building higher objects like a vase because

the platform is fixed. They tend to be higher anyway which creates a bigger build volume[13].

Because of the way they are build it is also fairly easy to make them bigger (not in width but

certainly in height). When the overall construction is much less complicated and uses very less

parts which will be reducing the maintenance and costs. Because of the arm construction it must

be a lot taller than your build volume.

Figure 2.11: Delta Configuration

2.2.3 SCARA configuration

Selective Compliance Assembly Robotic Arm abbreviated as SCARA type robotic

system has three degrees of freedom and it is actuated by three servo motors to do one vertical

and two horizontal motions. Feeding system for 3d printing is placed to back of robot and it is

extended at the end of the robotic arm.



Figure 2.12: SCARA Configuration

2.2.4 Polar configuration

This category uses a polar coordinate system. It is pretty much similar to that of

Cartesian configuration except that the coordinate sets describe points on a circular grid rather

than a square. All of which means that you can have a printer with a spinning bed, plus a print

head that can move up and down. The biggest advantage of a polar configuration 3D printer is

that the printer can easily function with only two stepper motors.

Figure 2.13: Polar Configuration



2.3 Materials used in FDM 3D Printing

Table 2.1 Materials used in FDM 3D Printing

Material Description Printing

Temp

Bed

Temp

PLA

PLA (Polylactic Acid) is one of the two

most commonly used desktop 3D printing

materials (with the other being ABS). It is

the ‘default’ recommended material for

many desktop 3D printers, and with good

reason - PLA is useful in a broad range of

printing applications, has the virtue of

both odorless and low warp and it will not

require a heated bed. PLA plastic is also

one of the eco-friendlier 3D printer

materials available; it is made from

annually renewable resources (corn-

starch) and requires less energy to process

compared traditional (petroleum-based)

plastics.

180 - 220 20 - 55

ABS

ABS (Acrylonitrile Butadiene Styrene) is

another commonly used 3D printer

material. Best used for making durable

parts that need to withstand higher

temperatures. In differentiating to PLA,

ABS plastic is less brittle. It can also be

post-processed with acetone to provide a

glossy finish.

220-235 °C 80-110 °C



Nylon

(Polyamide)

Nylon is an incredibly strong, durable,

and versatile 3D printing material. It is

very Flexible when it is thin but it is high

inter layer adhesion and the nylon lends

itself well to things like the living hinges

and the different functional parts. Nylon

filament prints as a bright natural to white

with a translucent surface and can absorb

color added post process with most

common, acid-based clothing dyes. Nylon

filament is very sensitive towards the

presence of moisture so taking drying

measures during storage and immediately

prior to printing is highly recommended

for best results.

235-270 °C 60-80 °C

PET (Polyethylen

e Terephthalate)

PET (Polyethylene terephthalate) is an

industrial strength filament with several

great features. Its strength is much higher

than PLA, it is FDA approved for food

containers and tools used for food

consumption, it barely warps, and

produces no odors or fumes when printed.

PET filament is not biodegradable, but it

is 100% reclaimable

230-255 °C 55-70 °C

TPE

TPE filament is a flexible 3D printing

material that feels and acts much like

flexible rubber. TPE filament can be used

to make parts that can bend or must flex to

fit their environment - stoppers, belts,

springs, phone cases and more.

210-225 °C 20-55 °C



TPU

(Thermoplastic

Polyurethane)

TPU is an elastic grease resistant and

abrasion resistant material with a Shore

Hardness of 95A. TPU has various

applications that are used inside

automotive instrument panels, caster

wheels, power tools, sporting goods,

medical devices, drive belts, footwear,

inflatable rafts, and a variety of extruded

film, sheet and profile applications. It is

also commonly used in mobile phone

cases.

240-260 °C 40-60 °C

LAYBRICK

LAYBRICK is a 3D printing material that

gives parts the look and feel of grey stone

while retaining the resiliency of plastic,

making it ideal for landscape and

architectural designs. Which is made up of

the LAYBRICK can be painted and

sanded. In the lower range of 165°C to

190°C, the print will come out mostly

smooth, whereas with higher temperatures

it will begin to have a more pitted,

sandstone-like texture.

180-200 °C 20-55 °C

LAYWOO-D3

LAYWOO-D3 is a wood-like 3D printer

material that gives 3D printed objects the

look and feel of fiberboard. It also imbues

parts with other wood-like attributes, such

as the ability be cut, painted, and sanded.

LAYWOO-D3 which will be created from

the combination of recycled wood

combined with polymer binders that are

allowing it to be melted and extruded

through your extruder on to the heated

bed.

175-250 °C 30 °C



Gel-Lay

Gel-Lay is best characterized as a jelly-

like material that is very porous. This 3D

printing material is made from a rubber-

elastomeric polymer and a PVA-

component. Once you rinse this material

in water, the PVA component disappears

and the rubber polymer remains as your

micro-porous object. Gel-Lay is ideal for

creating artificial limbs or body parts,

marine animals (like an octopus) or

floatables. There are several great

applications which will very much include

objects in water marine organism flow

simulation and bio mechanics. After

finishing the printed model you will

notice that the material is strong and only

slightly bendable.

225-235 °C 20-55 °C

CHAPTER 3

METHODOLOGY



CHAPTER 3

METHODOLOGY

3.1 Flow chart

The following flow chart shows the methodology used by us in construction of 3D

printer. The first step is to select one of the additive manufacturing process among many process

explained in chapter 2. Then an appropriate mechanism is selected for X, Y and Z axis

movements, considering various factors such as cost of fabrication, simplicity of design,

synchronization, accuracy etc. Once the mechanism is selected the next step is integration of

electronics and software then the machine is designed and fabricated. The last step is,

synchronization of mechanical, electrical and software elements of the machine.

Figure 3.1: Flowchart

3.2 Selection of process

The rundown of 3D printing innovations and procedures keeps on developing as 3D

printing is continually evolving. The 3D printing industry continues upgrading its hardware and

the materials and strategies to make protest or parts. Contingent upon numerous factors, for

example, spending plan, outline or capacity, picking the fitting 3D printing process and also the

correct material is imperative.



The FDM technology is clean, simple to use and it is environmentally stable. Complex

shapes and intricate parts can be printed. FDM is at the very entry of the market as it mainly

used by individuals. FDM is an affordable 3D printing process compared to other 3D printing

technologies.

FDM starts with a product procedure which forms an STL file (stereolithography file

format), scientifically cutting and situating the model for the building procedure. In the event

that required, support structures might be created. The machine may apportion numerous

materials to accomplish diverse objectives. The model or part is created by extruding little

amount of thermoplastic material to the desired shape layers as the material solidifies promptly

after expulsion from the nozzle. A plastic filament or metal wire is loosened up from a loop and

supplies material to an extrusion nozzle which can turn the flow on and off. There is commonly

a worm drive that pushes the filament into the nozzle at a controlled rate. The nozzle is warmed

to soften the material. The thermoplastics are warmed past their glass change temperature and

are then saved by an expulsion head.

The nozzle can be moved in both even and vertical bearings by a numerically controlled

component. The nozzle takes an instrument way controlled by a PC helped producing (CAM)

programming bundle, and the part is developed from the last, one layer at any given moment.

Stepper engines or servo engines are commonly utilized to move the expulsion head. The system

utilized is frequently an X-Y-Z rectilinear outline, albeit other mechanical plans have been

utilized. In spite of the fact that as a printing innovation FDM is exceptionally adaptable, and it

is fit for managing little shades by the help of bringing down layers.

3.3 Selection of Mechanism

Presently mechanisms such as, for example, SCARA, Cartesian, Polar, Delta and so on

are utilized as a part of development of FDM 3D Printers. We have chosen cartesian

arrangement of developments, where the bed moves in the vertical heading i.e., in Z pivot

bearing and the extruder spout moves horizontal way i.e., both in X and Y hub course. Z hub

development on such a 3D printer is extremely exact and requires low increasing speeds,

however the bed should be lightweight with a specific end goal to look after precision, which

makes it harder to include a completely programmed bed leveling framework. Controlling a

straight Cartesian framework like this is mechanically straightforward and furthermore

generally simple from a product point of view, which is the reason most 3D printers available



today utilize this kind of plan. The Cartesian arrange frameworks has for quite some time been

utilized for instruments like plotters, CNC processing machines, and 2D printers.

Figure 3.2: Cartesian Type Mechanism

3.4 Electronics

3.4.1 Controller

The controller is the brains of our 3D Printer. Almost all 3D Printer controllers are based

on the of the Arduino microcontroller. While a lot of variations exist. they are exchangeable and

basically all do the same thing. Now and then the controller is a remain solitary circuit load up

with chips on it, in some cases the controller is an Arduino Mega with an extra board (called a

"shield').

3.4.2 Stepper Motors

A stepper motor (or step motor) is a brushless DC electric motor that partitions a full

pivot into a numerical of equivalent advances. The motor's position would then be able to be

instructed to move and hold at one of these means with no criticism sensor, as long as the engine

as deliberately measured to the application. Stepper motor moves a known break for each beat

of vitality. This beat of vitality is given by a stepper driver and is suggested as a stage. As every

movement moves the motor a known partition it makes them helpful gadgets for repeatable

arranging. We will utilize stepper motor to move the bed carriage and different gatherings in

their individually X - Axis, Y - Axis, Z-Axis.



3.4.3 Endstops

Mechanical switches are less complicated to implement and cheaper than optical end

stops because they do not require a circuit board and only use 2 wires for connecting the switch.

Resistors Pull up and down can put close to the main board. Contact-less magnetic switches are

called read switches. They are proximity switches that close (or switch over) if a magnet comes

close enough (usually 1 mm or less) and open if the magnet moves away. Reed switches are

utilized as sensors in home caution frameworks to identify open windows and doors.

3.4.4 Heated Bed

A heated build platform HBP improves in the printing quality of the 3d model by helping

prevent warping. As extruded plastic cools it shrinks slightly. When this shrinking process does

not occur throughout the printed part evenly, the result is the warped part. This warping is very

commonly seen as corners being lifted off of the build platform. Printing on a warmed bed

permits the printed part to remain warm amid the printing procedure and permit all the more

notwithstanding contracting of the plastic as it cools underneath softening point. The warmth

bed prompts higher complete quality that works with materials, for example, ABS and PLA. A

HBP can likewise enable clients to print without rafts.

3.4.5 Stepper Drives

A stepper driver is a motor that acts as the kind of intermediate person between a stepper

motor and the controller. It streamlines the signs that should be sent to the stepper motor keeping

in mind the end goal to motivate it to move. Here and there the stepper drivers are on

independent circuit sheets that are connected to the controller through links. Now and then the

stepper drivers are on little circuit sheets that connect straightforwardly to the controller itself.

For this situation, the controller Will have space for no less than 4 of these little circuit sheets

(one for every stepper motor). Finally, sometimes the stepper drivers are soldered right onto the

controller itself.

3.5 Software

3.5.1 CAD Tools

Computer Aided Design are used to design 3D parts for printing. Computer aided design

(CAD) is where we use the computer system to assist in the creation modification analysis or

optimization of a design. Computer aided design software is utilized to expand the efficiency of

the creator, enhance the nature of configuration, enhance interchanges through documentation,

and to make a database for manufacturing.



Computer-aided design files in the most genuine sense are intended to enable you to effectively

change and control parts in view of parameters. Now and then CAD files are alluded to as

parametric records. The parts which are being represented as a tree of Boolean operations which

are performed on primitive shapes such as cubes, spheres, cylinders, pyramids.

3.5.2 CAM Tools

Computer Aided Manufacturing, or CAM, tools handle the intermediate step of

translating CAD files into a machine-friendly font used for our 3D printer electronics. Here we

will be using a software which will be an integration of object slicing, Generation of G codes

and M codes, Object Placement and other printer settings. Usually to turn a 3D part into a

machine format, CAM software needs a STL file. The machine friendly format that is used for

printing is called G-code.

3.5.3 Firmware

3D Printer electronics are controlled by an inexpensive CPU such as the Atmel AVR

processor. Atmel processors are what Arduino-based microcontrollers use. These processors are

exceptionally weak contrasted with even the normal 10 to 15-year-old PC you find in the landfill

these days. However, these are CPUs so they do run primitive software. This primitive software

they run is the firmware. The entire software chain that makes the 3D Printer work, the firmware

portion of it is the closest you get to actual programming. In fact, the term for what you are

doing with firmware is called cross compiling.

3.6 Objectives of our present work

The objectives of our present work are as follows:

• To print complex and intricate parts

• To build large printing volumes accurately

• To solve the problems of bed levelling

CHAPTER 4

DESIGN AND FABRICATION



CHAPTER 4

DESIGN AND FABRICATION

4.1 Conceptual Design

The design of the model has to be done in software where the actual model with the required

dimensions is developed so that it can be used to print the model. To develop and fabricate

thmodel there are many process and parameters involved mainly design of the model. The

design process started by keeping the print volume as a basic design parameter. As the objective

of the project is the construction of economical and sizable 3D Printer, a print volume of 200 x

180 x 150 mm3 is selected. The 3 – Dimensional motion is achieved by synchronization of

movements in X, Y and Z directions. Hence mechanism of our 3D Printer is Z plus core XY.

This mechanism uses 4 stepper motors, two for Y-axis movement (to and fro movement), one

for Z-axis movement (Vertical movement) and one for Extruder filament. This mechanism uses

the single motor to control lead screws to which the print bed is connected to the movement in

Z – direction. The lead screws are driven by the motor which in turn moves the bed in the vertical

direction. Two motors have been used here because the print volume is large, there will be a

disruption in the movement if only a single motor is used. The conceptual design has been

initially visualized in Sketch-up software.

Figure 4.1: Cad Design



4.2 Detail design

4.2.1 Selection of Motor for X and Y axis

Assumptions:

Constant speed of the motor = 400rpm=6.667rps

v = r ω

ω = [2πN]/60

= 41.908rad/s

Therefore;

400 = r*41.908

r = 9.547mm

Torque = Force*Radius

Force = 41.87N (considering NEMA 17 stepper motor having torque = 0.4Nm)

Conclusion for motor design

4.2 kg can be pulled over a distance of 500mm in 1second using NEMA 17.

Figure 4.2: Detailing of NEMA 17



4.2.2 X – axis Movement

Figure 4.3 shows the rendered CAD model of the mechanism of Lateral movement. It

consists of the pulleys, timing belt ,carriage, cylindrical rods, and extruder nozzle (used in FDM

process) arranged as shown.

The rotary motion from the motor in the y-axis is converted into linear sliding motion

and this linear motion is transfer by flange bearing by timing belt- pulley connection as shown.

The extruder nozzle is the main printing part of the machine. For its movement in a horizontal

direction, the carriage is provided. The extruder nozzle is mounted onto to the carriage on one

side, this may result in imbalance and failure of the machine. To avoid this, the carriage is

mounted on two rods and designed for balance.

The carriage slides in the horizontal direction over these two cylindrical rods using linear

bearings. These cylindrical rods are fixed rigidly into the holes present in the carriages that move

in the Y direction. The timing belt is mounted on the pulley which is driven by the motor on one

side and a support pulley on the other side.

Figure 4.3: X-Axis Cad Design

The carriage is fixed to the lower timing belt of the loop, such that the belt movement

results in the movement of the carriage. When the motor rotates in clockwise direction, since

the carriage is connected to the lower belt in the loop, it moves from right to left. When the

motor rotates in an anticlockwise direction, the carriage moves from left to right. To design this

mechanism for horizontal movement, the carriage is designed first for balance, so that the weight



of the carriage and the extruder nozzle is distributed equally on both the rods Figure 6. The

weight of the extruder nozzle is found and accordingly, the carriage is designed. The carriage is

designed using the free body diagram of the carriage..

Figure 4.4 shows the free body diagram of the carriage. The thickness of the carriage is decided

based on the diameter of the rods. The width is decided based on the dimensions of the extruder

nozzle.

Design of X Carriage

Assumptions:

Weight of the extruder assembly = Kg

L1 = Distance between 2 SS rods in carriage.

L2 = Distance between 2nd rod and end of carriage.

Taking Σ FY = 0

R1 + R2 = 10

Taking Moments about point 1:

Σ Mt = 0

10 × (L1 + L2) – (R2 × L1) = 0

Figure 4.4: X-Axis holder cad design



L1 = -2L2

Conclusion for X axis carriage design

The distance between 2nd rod and end of carriage must be half of distance between 2

HSS rods in carriage Next is the design of the rods. Depending on the print volume the length

of the rods is determined. To determine the diameter of the rods, all the loads acting on the rods

along with carriage weight is considered. The diameter of the rods is determined by trial and

error method. Starting with a standard diameter, a moment of inertia I am found using the (1).

Then the maximum deflection is found by using (2). The maximum deflection should be less

than the layer thickness, for high-quality printing the maximum deflection should be less than

1% of the layer thickness.In the below equations, ‘I’ denotes the moment of inertia, ‘d’ denotes

the rod diameter, ‘Ymax’ denotes the maximum deflection, ‘W’ denotes the overall load acting

on each rod, ‘E’ denotes the modulus of elasticity and ‘L’ denotes the length of the rods.

Y max= (1 *WL3) / (48 * EI) (2)

➢ Design of steel rods for X - axis movement

Bearing weight = 0.065kg

Extruder + Heating element + Nozzle = 0.2kg

Carriage weight = 0.05kg

Length of the rod = 320mm

Total Load = 0.315kg

Considering FOS = 2, The acting Load = .63kg

Material: High Speed Steel (HSS)

Young’s modulus, E = 210MPa

Using Center Load condition: -

I = [πd4]/64 = 201.06mm4

𝑌max =1

48(

𝑊𝐿3

𝐸𝐼) = 10.18 microns

Conclusion for X axis rod design

In order to increase the accuracy of the print maximum deflection in rods must be less

than 120microns, by trial and error method the diameter of steel rods is found to be 7.65mm and

standardized to 8mm.

I = [πd4] / 64

(1)



4.2.3 Y – Axis Movement

Figure 4.5 shows the rendered CAD model of the mechanism for Y – axis movement. It

consists of Carriage, Cylindrical Rods, Pulleys and Timing Belt arranged as shown.

Figure 4.5: Y-Axis Cad Design

The rotary motion of motor is converted into linear sliding motion by timing belt – pulley

connection as shown. The X – axis rods are fixed to the carriages with the help of holes in side

face of the carriages. The carriages will slide along the Y – axis over the two cylindrical rods

using linear bearings.

These cylindrical rods are fixed rigidly to the frame. The timing belt is mounted onto

the pulley which is driven by the motor on one side and a support pulley on the other side. The

carriage is fixed to the lower timing belt of the loop, such that the belt movement results in the

movement of the carriage. When the motor rotates in one direction, the carriages are connected

to the lower belt in the loop moves from front to back or in opposite direction depending on the

motor orientation. The two motors should be in perfect synchronization for high quality printing.

To design this mechanism for Y – axis movement, first the carriages are designed. The

carriages are designed to mount the motor, pulley and to hold X – axis rods. Since these carriages

are symmetric there is no problem of imbalance and hence the carriage dimensions are

determined by the mounting area required by the motor, supporting pulley and the holes to hold

the X – axis rods rigidly.



➢ Design of Y - axis carriage

Standard Dimensions:

Linear Bearings Outer Diameter = 28mm

NEMA 17 Length*Width*Height = 42.3*42.3*40 mm3

Conclusion for Y axis carriage design

To mount the motor, pulley and to hold X axis carriage rod the dimensions of the carriage

should be as follow: -

Length*Width*Height = 170*120*50 mm3

Next for the design of the rods, depending on the print volume, the length of the rods is

determined. To determine the diameter of the rods, all the loads acting on the rods along with

carriage weight is considered. The diameter of the rods is determined by trial and error method.

Starting with a standard diameter, a moment of inertia I am found using (1). Then the maximum

deflection is found by using (2). The maximum deflection should be less than the layer

thickness, for high-quality printing the maximum deflection should be less than 1% of the layer

thickness.

➢ Design of steel rods for Y - axis movement

Weight of X-axis carriage assembly = 4.6 Kg

Total Load on each carriage = 2.3Kg

Load on each rod = 2.3/2 = 1.15Kg

Considering FOS= 2

Length of the rod = 300 mm

Material: High Speed Steel (HSS)

Young’s modulus, E = 210MPa

Using Center Load condition: -

I = [πd4]/64 = 3216.99mm4

𝑌max =1

48(

𝐹𝐿3

𝐸𝐼) = 26.9 microns

Conclusion for Y axis rod

In order to increase the accuracy of the print maximum deflection in rods must be less

than 100 microns, by trial and error method the diameter of steel rods is found to be 14mm and

standardized to16mm.



4.2.4 Z – axis Movement

Figure 4.6 shows the rendered CAD model of the mechanism of vertical movement. It

consistsof lead screws, shaft coupler, flange nut and print bed arranged as shown in the image.

Figure 4.6: Z-Axis Cad Design

The rotary motion of the motor is transfer by rotating the leadscrews connected to the

bed by using flange nut and shaft coupler as shown. The torque produced by the motor is

transmitted to the lead screws by using shaft coupler and flange nut. When the motor rotates,

say in a clockwise direction, shaft coupler rotates lead screws in the same direction, say in a

clockwise direction. The bed is connected to the lead screws using threaded couplers, this makes

the bed move in a vertical direction when the lead screw rotates.



Figure 4.7: Mechanism for Z – axis movement (vertical direction)

To design this mechanism for vertical movement, we have to first decide the print volume of

the3D printer. Depending on the volume, the height of the lead screw and area of the bed are

calculated. Figure 4.7 shows the print bed, it consists of a PCB to heat the bed which is attached

to the aluminum sheet of area 500 X 500 mm2. To give bed structural stability fiberglass is

provided at the bottom with the help of a rubber pivot.

Components of bed

Thickness of PCB = 2.5mm

Dimensions of Bed

Length*Width*Height = 570* 812 *17

Figure 4.8: Heat Bed



Next is to calculate the weight of the object the bed should withstand. Based on the weight the

diameter (Dm) of the lead screw is found using (3) where L is the lead and µ is coefficient of

friction:

𝑇 = 𝐹 × (𝐷𝑚

2) [

𝐿+µπ𝐷𝑚

π𝐷𝑚−µL]

Design of Lead Screw for Z - axis movement

Total load acting on the bed = Volume of bed * Density of filament(ABS)

= 0.5×0.5×0.5×1050 = 131.25kg = 1290 N

Considering:

Single start thread n = 1

Lead =n×p = 1×2 = 2mm

Pitch = 2mm

Coefficient of friction µ = 0.17

Torque = 3Nm

Considering Torque equation: -

𝑇 = 𝐹 × (𝐷𝑚

2) [

𝐿+µπ𝐷𝑚

π𝐷𝑚−µL]

Dm = 9.77mm

Dstd = 12mm

Conclusion for lead screw

The diameter of lead screws is found to be 9.77mm and standardized to12mm.

4.3 BEARINGS

Bearings is a device used to support and guide a rotating Oscillating, or sliding shaft, pivot

or wheel. At whatever point a pole pivots, it needs a heading for smooth, powerful activity. A

heading is intended to:

• Reduce friction

• Support a load

• Guide moving part – wheel, shaft, pivots

Types of Bearings:

There are two major types of bearings we use in this project , they are:

➢ Linear Bearing

➢ Ball bearings

(3)



4.3.1 Linear bearings

This linear bearing is sort of the opposite of the radial ball bearings you may be familiar

with. Its Intended to slide along a 16mm linear shaft, rather than to rotate around it. We chose

16mm bearings because based on the diameter of the rod design. Linear Bearings come in open

and close package. The closed ones have their own lubrication and no additional lubrication is

needed while open ones need additional lubrication.

Figure 4.9: Linear Bearing

High-viscosity PTFE filled oil (super-lube) for example shown best results here. Synthetic Gear

Oil also showed very good results. On the other hand, The Gremlin recommends low viscosity

lithium soap-based lube when using bushings. In a High viscosity greases, such as axle grease,

can clog up roller bearings and cause them to slide instead of rolling. This will wreak havoc on

your expensive precision round linear rods. He recommends a grease, NLGI Grade.

4.3.1.1 Linear ball bearing LM8UU

Figure 4.10: LM8UU Linear Bearing



Bearing number: LM08UU

Size (mm): 8x15x24

Brand: CX

Bore Diameter (mm): 8

Outer Diameter (mm): 15

Width (mm): 24

Bearing dimensions and specification in brand catalogue:

d - 8 mm

D - 15 mm

B - 24 mm

B1 - 17,5 mm

D1 - 14,3 mm

W - 1,1 mm

Weight - 0,011 Kg

Basic dynamic load rating (C) - 0,365 kN

Basic static load rating (C0) - 0,24 kN

4.3.1.2 Linear ball bearing LM16UU

Figure 4.11: LM16UU Linear Bearing

Bearing number: LM16UU

Size (mm): 16x28x37

Brand: CX

Bore Diameter (mm): 16

Outer Diameter (mm): 28



Width (mm): 37

Bearing dimensions and specification in brand catalogue:

d - 16 mm

D - 28 mm

B - 37 mm

B1 - 26,5 mm

D1 - 27 mm

W - 1,6 mm

Weight - 0,05 Kg

Basic dynamic load rating (C) - 0,71 kN

Basic static load rating (C0) - 0,53 kN

4.3.2 Ball bearings

A ball bearing is a sort of moving component bearing that can utilizes balls to keep up

the detachment between the bearing races.

Figure 4.12 Ball Bearing

The reason for a ball bearing is to reduce rotational friction and support radial and axial

loads. It can be achieved this by using at least two races to contain the balls and transmit the

loads through the balls. In most applications, one race is constant and the other is attached to

the turning/rotating assembly (e.g., a center point or shaft). As one of the bearing races pivots

it makes the balls turn too. Since the balls are rotating as they have a much lesser coefficient of

grating than if two level surfaces were sliding against each other

4.3.3 Flanged bushing ball bearing

Figure 4.13 Flanged bushing ball bearing



Specification

Brand Machifit

Model F623ZZ

Material Bearing steel

Size 3x10x4mm

Outer Diameter 10mm

Inner Diameter 3mm

Thickness 4mm

4.4 BELTS AND PULLEY It is in the form of a loop. It connects mechanically two shafts for transmitting power

smoothly from one shaft to another.

4.4.1 Belt Drive and its Types

Belt drive consists of two shafts and a belt. One of this shaft is a motor shaft on which

electric motor is mounted. On the other shaft, the machine is mounted to which power is

transmitted by the belt drive. Normally speed of the motor is high because high-speed motors

are more efficient. Therefore motor shaft is the driving shaft and the machine shaft is the driven

shaft. There are two types of belt drive, namely flat belt drive and V-belt drive.

In this drive, both drive and driven shafts keep running a similar way. For smooth power

transmission, belt on one side is tighter than the opposite side. In an even drive, the fixed side

is constantly kept in the lower side of two pulleys on the grounds that the hang of the upper side

marginally expands the edge of contact of the belt on the two pulleys. More edge of contact

implies more power transmission

A belt is a circle of adaptable material used to mechanically connect at least two turning

shafts. regularly parallel. Belts might be utilized as a wellspring of movement, to transmit

control effectively. or then again to track relative development. Belts are circled over pulleys

and may have a curve between the pulley. furthermore, the poles require not be parallel. In a

two-pulley framework. the belt can either drive the pulleys regularly one way (the same if on

parallel shafts). or on the other hand, the belt might be crossed. with the goal that the heading

of the determined shaft is (the other way to the driver if on parallel shafts). As a wellspring of

movement, a transport line is one application where the belt is adjusted to ceaselessly convey a

heap between two focuses.

Belts are the least expensive utility for control transmission between shafts that may not

be axially adjusted. Power transmission is accomplished by extraordinarily outlined belts and

pulleys. The requests on a belt drive transmission framework are extensive and this has

prompted numerous minor departure from the topic.They run smoothly with little noise,



provides cushioning against load changes, albeit with less strength than gears or chains.

However, improvements in belt engineering allow the use of belts in systems that only formerly

allowed chains or gears.

4.1.2 LAW OF BELTING

The middle line of the belt as it approaches the pulley must agree with the central plane of that

pulley generally belt will take off from the pulley.

4.5 TIMING BELT

A Timing belt, timing chain or cambelt is a part of an internal combustion engine that

synchronizes the rotation of the crankshaft and the camshaft(s) so that the engine's valves open

and closes at the correct circumstances during each cylinder's intake and exhaust strokes

Design of timing belt for X and Y axis

D=d= Diameter of pulley = 2cm

C = Center distance between two pulleys = 700mm

L = Length of the timing belt

L =π

2(D + d) + √4c2 + D2 + d2 (5)

L=1.46319m

Figure 4.14 Timing belt

The ultimate strength of polyurethane = 20.77MPa

Considering FOS = 4

Force = 40N (From Motor)



𝜎 =𝐹

𝐴 (6)

Area = 7.703 mm2

Width=5.925mm

Standard width=6mm

Conclusion for timing belt selection

The width of the belt is found to be 5.925mm and standardized to 6mm. MXL pitch of 2.032mm

is selected for smooth movement.

➢ Design of timing belt for Z axis

D=d= Diameter of pulleys = 15mm

C = Center distance between two pulleys = 0.736

L = Length of the timing

T=Thickness of the belt = 1.3mm

L =π

2(D + d) + √4c2 + D2 + d2

L = 1.540 m

The ultimate strength of polyurethane = 20.77MPa

Considering FOS = 2

Force = 250/2=125 (From Torque of NEMA 23 – 150Ncm)

σ =F

A

Area = 12.03mm2

Width=9.25mm

Standard width=10mm

Conclusion for Z axis belt

The width of the belt is found to be 9.25mm and standardized to 10mm. XL pitch of 5.08mm is

selected for smooth movement.

4.6 PULLEY A wheel with a furrowed edge around which a rope passes, which acts to alter the course of

a power connection to the rope and is utilized to raise overwhelming weights.

➢ Fixed pulley



➢ Movable Pulley

➢ Compound Pulley

A pulley is a wheel on a pivot or shaft that is intended to help develop and alter of course of

a link or belt along its outline. Pulleys are utilized as a part of an assortment of approaches to

lifting loads. apply powers, and to transmit control. In nautical settings, the gathering of the

wheel, pivot, and supporting shell is alluded to as a "piece." A pulley may likewise be known

as a sheave or drum and may have a section between two ribs around its perimeter. The drive

component of a pulley framework can be a rope, link, belt, or chain that keeps running over the

pulley inside the section.

Figure 4.15 Pulley

By and large talking, for best execution, you need no less than 6 teeth in contact with

the pulley at any given time. That limits the possibility of the belt slipping, and decreases

kickback significantly further. By and by that implies you need at least a 12-tooth pulley. Past

that base, fewer teeth are for the most part superior to more teeth, since a little pulley gives both

more torque and more determination. You get more torque in light of the fact that the more

drawn out your "arm", the less torque you have (Imagine the heap is mounted on an arm the

length of the range of the pulley, the shorter that arm, the less demanding it is to lift the heap),

and you get higher determination, since you have a settled number of steps per unrest, and a

little pulley moves a shorter straight separation for every progression. A wheel with a notched

edge around which a string passes, which acts to alter the course of a power connection to the

string and is utilized to raise substantial weights.

For the most part talking, for best execution you need no less than 6 teeth in contact with

the pulley at any given time. That limits the shot of the belt slipping, and decreases kickback

significantly further. By and by that implies you need at least a 12-tooth pulley. Past that base,

fewer teeth are for the most part superior to more teeth, since a little pulley gives both more



torque and more determination. You get more torque on the grounds that the more drawn out

your "arm", the less torque you have (Imagine the heap is mounted on an arm the length of the

range of the pulley, the shorter that arm, the less demanding it is to lift the heap), and you get

higher determination, since you have a settled number of steps per transformation, and a little

pulley moves a shorter straight separation for each progression.

Design of pulley for X and Y axis

From section 4.2.1 we have the radius of the pulley,

Radius = 9.55mm = 10mm

Diameter = 20mm

Pitch = 2mm

Circumference = 2πr

= 62.84mm

Number of teeth = [circumference/pitch]

=31.42

≈32 teeth

Table 4.1 Pulley Specifications

Parameter X axis Y axis

Inner diameter 5mm 5mm

Outer diameter 20mm 20mm

Pitch 2.032mm 2.032mm

Width 6mm 6mm

Thickness 1.3mm 1.3mm

4.7 Extruder

4.7.1 Introduction

Extrusion is a procedure used to make objects of a settled cross-sectional profile. A

material is pushed or pulled through a die of the desired cross-sectional profile. The two main

advantages of this process over manufacturing processes are its ability to create very complex

cross-sections and to work with materials that are brittle. Because the material only encounters

compression and shear stresses. It also forms parts with an excellent surface finish.Commonly

extruded materials include metals Polymers, ceramics, concrete, play dough, and foodstuffs.



The products of extrusion are generally called “extrudates". Drawing metal is themain way to

produce wire, sheet, bar, and tube.

Figure 4.16 E3D V6 Extruder Used In Our 3D Printer

4.7.2 Principle of Extruder

To extrude molten plastic filament, the "Cold End" forces the raw material (usually a

1.75mm or 3mm diameter filament) into the hot end. The feeding filament should then go

through the "Hot End" of the extruder with the heater and out of the nozzle at a reasonable speed.

The extruded material falls onto the fabricate stage (now and again warmed) and after that layer

by layer onto the part as it is constructed.

➢ Hot end

The "Hot End" is the active part of the 3D printer that melts the filament. It enables the liquid

plastic to exit from the small nozzle to shape a thin and cheap dab of plastic that will stick to the

material it is laid on. Researchers have also made hot ends from glass or aluminum. The hot end

consists of a melting zone or chamber with two holes. The cold end forces the filament into the

heating chamber of the hot end through one hole. The molten plastic exits the heating chamber

through the other hole at the tip. The hole in the tip (nozzle) has a diameter of between 0.01mm

and 1.0mm with a typical size of 0.4mm with present generation extruders. The heating is done

by a cartridge having induction coil just outside the tip of the barrel. The required heat is use to

generate in order of 20W with typical temperatures around 150 to 250 degrees centigrade. For

feedback control of the nozzle temperature, a thermistor is usually attached close to the nozzle,

through a thermocouple may serve as suitable control hardware. High-temperature materials are



needed here. These include metals, cement, glues, glass, mineral fiber materials, PEEK, PTFE,

and Kapton tape.

Figure 4.17 Hot End Of Extruder

CHAPTER 5

ELECTRONICS



CHAPTER 5

ELECTRONICS

5.1 INTRODUCTION

The electronics board controls the printing process, as they are the most essential in the printing

process. Electronics purpose of the designed is easy to connect and used by Beginner, Developer or

Manufacturer. With the multiple quick connectors, these can put the power cables of parallel connection

together.

The electronic board consists of :

➢ CONTROLLER BOARD

➢ STEPPER MOTOR

➢ STEPPER DRIVE

➢ LCD CONTROLLER

➢ THERMISTER

➢ END STOPS

➢ HEAT BED

➢ EXTRUDER

➢ POWER SUPPLY

5.2 CONTROLLER BOARD:

Controller boards are the brains of your 3D printer, and their taking care of energy decides how

pleasant or how point by point your completed prints will be.Printer controller boards are rapidly

expanding to incorporate boards with more features that allow for more simplified resolution through

micro stepping. There are also more powerful processors for complex calculations and even boards that

run their own operating system. There are additionally more capable processors for complex counts and

even boards that run their own particular working framework. Here are some types of controller boards:

➢ Arduino Due

➢ Beagle Bone Printer Board

➢ Azteeg X5

➢ Smoothieboard



5.2.1 ARDUINO DUE

The Arduino Due was the first Arduino board to run a Cortex processor. It has a Cortex-M3 32-

bit processor with enough processing power to run serious projects like automated drones to 3D printers.

Being Arduino, it requires a shield. For 3D printers, there are two shields available: the Ramps-Fd and the

RADDS shield. If you choose this option, completely skip the Ramps-FD as it is not well supported and

is only available from overseas makers so expect the build quality and the soldering to not be the best.

5.2.2 BEAGLE BONE PRINTER BOARD

It is based on the Texas Instruments Raspberry Pi alternative Beaglebone. Unlike other boards,

this board is actually a little computer, and it runs a Linux operating system. It has a Cortex A-8 chip and

depending on the version, comes with either 5 steppers and 3 heaters (BBP 1) or 7 steppers and 3 extruders

with the upgraded BBP 1S board. Both boards run integrated drv8825 stepper drivers with 1/32 micro

stepping, and it claims to fame is being able to allow your printer to print faster through very smart

algorithms which modulate the frequencies of the stepper voltage so your printer can operate faster.

5.2.3 AZTEEG X5

The acting X5 GT is a 32-bit ARM-based movement controller for 3D printers, CNC machine,

and laser cutters. The X5 GT keeps running on Smoothieware firmware and is depends on Smoothieboard

by the great Arthur Wolf. The X5 GT utilizes the capable 32bit, 120Mhz NXP LPC1769 ARM chip able

to do speedier calculations for faster and Smoother movements.

Configuration is easier using a text-based configuration file loaded on SD card, no need to upload

firmware every time you make the change. Just edit the config file from your or then reboot the board

with the new config and you are done.

The X5 GT highlights the new Bigfoot stepper driver impression which is double the size of the normal

drivers. This impression enables higher current drivers to run on the X5 GT for demanding CNC

applications. It additionally permits utilization of further developed SPI controlled drivers. The X5GT will

acknowledge both Bigfoot and Pololu style drivers.

5.2.4 SMOOTHIEBOARD

It runs a Cortex M-3 with integrated A4982 stepper drivers that support 1/16 micro stepping. There

are 3 types of boards available the 3x, 4x, and 5x… the number denotes the number of stepper motors that



it supports. Communication between developers and the public leaves a lot to be desired. Being younger

than the Stallworth’s Marlin and Repetier, safety features lag behind. Features that prevent your printer

from catching fire are not as developed as some of the other firmware.

5.3 RAMPS

Arduino and its compatible boards utilize printed circuit extension boards called "shields", which

connects to the regularly provided Arduino pin headers. Shields can guide the motor controls, GPS,

Ethernet, LCD, or breadboarding (prototyping). Ramps are the best-opted shield for Arduino Mega

2560Ramps have turned into the most famous, most utilized 3D Printer hardware from 2012 up until the

present date. It shares hardware ideas (stepper driver, thermistor, radiator MOSFETs, and so forth.) with

numerous different gadgets. Likewise, take note of that the cost of both the RAMPS board and the Arduino

Mega 2560 and the Pololu drivers has been relatively sparing than different shields and controllers.

Figure 5.1: Ramps 1.4

Features of Ramps

➢ Built on stable Arduino Mega 2560 Base

➢ Modular - Easier to TroubleshootUp to 1/32 microstamping (using DRVSS2S based driver boards)

➢ It has provisions for the cartesian robot and extruder

➢ Expandable to control other accessories



➢ 3 Mosfets for heater/fan outputs and 3 thermistor circuits

➢ Fused at 5A additional safety and component protection

➢ Additional 11A fuse can control heat bed

➢ Fits 5 Pololu stepper driver board

➢ Pololu boards are on pin header sockets so they can be replaced easily or removed for use in future

designs

➢ 12 C and SPI pans left available for future expansion

➢ All the MOSFETs are hooked into PWM pins for versatility

➢ USB type B receptacle

➢ LEDs indicate when the heater output is on

CONCLUSION

We here use a RAMPS 1.4 version which is easily available and most effective for the performance and

stability of the Arduino board.

5.4 STEPPER MOTORS

5.4.1 Selection of Stepper Motor

The selection of the stepper motor depends on properties like

➢ Step Angle

Stepper motor has a step angle. An entire 3600 circles separated by the progression edge gives number of

steps per revolution. For instance, 1.80 for every full advance is a typical advance size rating, proportional

to 200 steps for each revolution.

Most stepper motors utilized for a Mendel have a step angle of 1.8 degrees. It is once in a while

conceivable to utilize a motor with bigger advance points, however, to print to be precise, they should be

outfitted down to diminish the edge moved per step, which may prompt a slower most extreme speed.

➢ Micro-Stepping

A stepper motor dependably has a settled number of steps. Smaller scale venturing is a method for

expanding the number of ventures by sending a sine/cosine waveform to the curls inside the stepper motor

In many cases, miniaturized scale venturing permits stepper engines to run smoother and all the more

precisely. Smaller scale venturing between post positions is made with bringing down torque than with



full-venturing, however, has a much lower propensity for mechanical swaying around the progression

positions and you can drive with significantly higher frequencies. On the off chance that your motor is

close to mechanical confinements and you have high erosion or flow, smaller scale steps don't give you

substantially more exactness over half-venturing. At the point when your motor is 'overwhelmed' and you

don't have much grating, at that point smaller scale venturing can give you substantially higher exactness

over half-venturing. You can exchange the higher situating exactness for moving precision as well.

➢ Bipolar

Bipolar can refers to the internals of the motor, and each type has a different stepper driver circuit board

to control them. Bipolar motors are the strongest type of stepper motor. You identify them by counting

the leads there should be four or eight. They consists of two coils inside and stepping the motor round is

achieved by energizing the coils and changing the direction of the current within those coils. This requires

more mind-boggling electronics than a unipolar motor, so we utilize an extraordinary driver chip to deal

with all that for us.

➢ Unipolar

Unipolar motors consists of two coils, but each one has a center tap. They are readily recognizable

because they have 5, 6 or even 8 leads. It is possible to drive 6 or 8 lead unipolar motors as bipolar motors

if you ignore the center tap wires. A 5-lead motor has both middle taps connected, so re-wiring them to a

4-lead version requires at least opening the motor if it can be done at all. The fundamental excellence of

unipolar engines is that you can stop them without reversing the direction of current in any coil, which

makes the gadgets less difficult. Since the inside tap is utilized to empower just 50% of each loop at once,

unipolar engines, for the most part, have less torque than bipolar engines.

➢ Holding Torque

Stepper engines don't offer as much torque or holding power as practically identical DC servo engines or

DC equip motors. Their leverage over these engines is one of positional control.



➢ Size

The physical size of stepper motors is generally portrayed through a US-based NEMA standard, which

describes the dart up an example and shaft width notwithstanding the NEMA estimate rating, stepper

motors are additionally evaluated by the depth of the motors in mm. Regularly, the energy of a motor is

proportional to the physical size of the motors.

➢ Shaft

Any part that goes on a stepper motor shaft expects the shaft to be roughly 5 mm Dia. On the shaft there

is a different size, you will need to make allowances for this in the (plastic) parts you obtain. Based on all

the above factors we will be using a NEMA 17 and NEMA 23 Stepper Motor which is a permanent magnet

type stepper motor.

A stepper motor is one sort of electric motor utilized as a part of the apply autonomy industry. Stepper

motor moves a known interim for each pulse of power. These pulses of power are provided by a stepper

motor driver and are referred to as a step. As each progression moves the motor a known separation it

makes them convenient gadgets devices for repeatable positioning.

5.4.2 Stepper Motor Applications

Stepper motors are generally used in a variety of applications where precise position control is

desirable and the cost or complexity of a feedback control system is unwarranted. Here are a few

applications where stepper motors are often found:

• Printers

• CNC machines

• 3D printer/prototyping machines

• Laser cutters

• Pick and place machine

• Linear actuators

• Hard drives

5.4.3 Types of Stepper Motor

• NEMA 11

• NEMA 14



• NEMA 17

• NEMA 23

5.4.3.1 NEMA 11 :

This hybrid bipolar stepping motor which consists of a 1.8-degree step angle which is 200

steps/revolution. Each phase draws a 670mA at 3.5V, allowing for a holding torque of 600 gcm. These

motor consist a four colored coded wires which will be terminated to the bear leads black and green

connected to one coil; red and blue connected to the other. It can also be controlled by a pair of suitable

H bridges.

5.4.3.2 NEMA 14

This hybrid bipolar stepping motor has a 1.8-degree step angle which is 200 steps/revolutions.

Each of the phases draws a 500mA to 10V, allowing for a holding torque of 1 kg-cm. these motor consist

of four color-coded wires which will be terminated with bare leads which are black and green connected

to one coil; red and blue connected to other. It can be controlled by a pair of a suitable H bridge.

5.4.3.3 NEMA 17

A NEMA 17 stepper motor is a typical motor with 1.7x1.7 inch faceplate. The NEMA 14 is bigger

and for the most part exceptionally heavier than the alternate motors, for example, NEMA 14, yet this

additionally implies it has more space to put a higher torque. Its size isn't an indication of the power. This

4 wire bipolar stepper has a 1.8 degree for each progression for smooth movement and the decent holding

torque. The engine was is determined to have a maximum current of 350mA so it could be driven

effectively with Adafruit engine shield for Arduino and the divider connector or lead corrosive

battery.obally accessible.

5.4.3.4 NEMA 23

This high torque hybrid stepping motor has a 1.8-degree step angle. Each of the phases draws 1A

at 5.7V allowing for holding torque of 4 kg-cm. the motor has a six-colored coded wire terminated with

bare leads that will allow it to be controlled by the unipolar and the bipolar stepper motor drivers. When

it is used with a unipolar stepper motor all six leads are used. When it is used with a bipolar stepper motor

driver the center tap yellow and the white wires can be left disconnected.



CONCLUSION For our 3D printer, we are using a NEMA 17 stepper motor which satisfies the demand

for our design and requirements of the 3d printer.

5.5 Stepper Drives

A stepper driver is a chip that goes about as a sort of mediator between a stepper motor and the

controller. It rearranges the signs that should be sent to the stepper motor, so as to inspire it to move. Once

in a while, the stepper drivers are on independent circuit sheets that are connected to the controller by

means of links. Here and there the stepper drivers are on little circuit sheets that are connected

straightforwardly to the controller itself. For this situation, the controller will have space for no less than

four of the little circuit sheets (one for every stepper engines). At last, some of the time the stepper drivers

are fastened directly to the controller itself. Here we will utilize a standard Pololu driver as said by the US

measures.

Figure 5.2: A4988 Stepper Drive[15]



5.6 LCD CONTROLLER

Figure 5.3: LCD Controller

This full graphic smart controller contains an SD Card peruser a turning encoder and the 128x64

dot matrix LCD display. IT can without much of a stretch be associated with the slopes of the 3d printer

utilizing the keen connector included.

After the connection with ramps, it doesn't require pc any longer as the smart controller supplies control

for your SD card. Facilitate all activities like Further all actions like the calibration, axes movements can

be done easily with this Smart controller.

5.7 THERMISTOR

Figure 5.4: Thermistor



A thermistor is utilized to detect the temperature of the hot end. Frequently a Second thermistor

detects the temperature of the Heated Bed.

Thermistors are the resistors that difference in protection with the difference in temperature. Great

characteristics of the thermistor are an anticipated precisely known protection esteem at each temperature

in its working extent. The bringing down or rise relies upon the kind of the thermistor per degree Kelvin

this is called as its coefficient. Positive warm coefficient PTC will increment as in protection from the

expansion in temperature, negative ones NTC will diminish. The recipe by and by isn't straight so now

and then a precise table of estimations is superior to the direct equation. These estimations can be normally

found in the datasheet of that goes with the thermistors. NTC thermistor for the temperature sensor is one

where has the thermistor chip welded with leads by composite patching procedure and after that

incompletely treated by glass fixing. They are comprised of these semiconductors which will be for the

most part silicon and germanium and these offer a protection esteem can be differed by numerous request

of extents in their temperature run. A 100k NTC thermistor has a protection estimation of 100k ohms at

room temperature and drops as low as 100 ohms at 300 degrees Celsius.

5.8 END STOPS

Cartesian axes all that need a datum to reference their movements. At the start of their, each build

each axis needs to be backed up until the datum point has to be reached. The switches also help protect

the machine from moving the past of its intended range and damaging itself.

Figure 5.5: Endstop



5.9 HEATED BED

A heated build platform HBP improves in the printing quality of the 3d model by helping prevent

warping. As extruded plastic cools it shrinks slightly. In this process shrinking will not occur throughout

the printed part evenly, the result is the warped part. This warping is very commonly seen as corners being

lifted off of the build platform. Printing on the heated bed allows the printed parts to remain warm until

the printing process is going on and allow more even shrinking of the plastic as it cools below the melting

point. The heated bed which can be usually yield higher quality for the finished builds with the materials

such as ABS and PLA.

Figure 5.6: Heated Bed

An HBP can also allow users to print without rafts. These Flat and their respective heated parts on the

bed will be of many various materials each with different advantages and disadvantages.



5.10 POWER SUPPLY

Figure 5.7: Power Supply

The motor plus single hot end takes up to 5A or so, The heated bed typically takes 5A-15A. For a

standard setup with the heated bed, look to a total 18-30A which are about a 220-360W at 12V. for some

setup might be able to use fewer power ones. Switch mode power supplies have relatively complex circuits

that are to convert mains AC electricity to DC voltages that required by the Steppers and the Electronics

circuit. The main advantage is that of a Switch mode power supply is highly efficient in converting energy.

CHAPTER 6

FIRMWARE AND SOFTWARE



CHAPTER 6

FIRMWARE AND SOFTWARE

6.1 INTRODUCTION

Firmware is the permanent software used in read-only memory(ROM) in the form of nonvolatile

memory in a computer program that provides to control the device in hardware. It can provide a standard

operating environment to the devices to more complex software that allows hardware to run on the

operating system (os), to perform various devices to complete all monitoring and other manipulation

functions. The firmware is used for different purposes like consumer appliances, computer peripherals

etc. 3D printer electronic devices are controlled by CPU such as Intel processor and Based on Arduino

microcontroller used in the 3D printer. These processors are used in the computer to run the primitive

software. The firmware of entire software makes the 3D printer work, the firmware portion of it is the

closest you get to actual programming. Therefore, the term what you are doing with firmware is called

cross-compiling.

6.2 LIST OF FIRMWARE

• Sprinter

• Teacup

• SJFW

• Marlin

• Sailfish

6.2.1 SPRINTER

Firmware in the sprinter use for adjustment of motor to move from each time from one place to

another and they are calibrated at by seeing the movement of motor



matches your setup

// MEGA/RAMPS up to 1.2 = 3,

// RAMPS 1.3 = 33

// Gen6 = 5,

// Sanguinololu up to 1.1 = 6

// Sanguinololu 1.2 and above = 62

// Teensylu (at90usb) = 8

// Gen 3 Plus = 21

// gen 3 Monolithic Electronics = 22

#define MOTHERBOARD 3

Figure 6.1: valves of sprinter

6.2.2 TEACUP

Firmware in the Teacup is fast and runs steppers smoothly. It avoids C++ in favor of plain C, uses

100% integer math to the given works and very hard to minimize/eliminate long math operations in

interrupt context.

Installation Using Arduino IDE

While in Teacup Configuration tool should be needed some configuration, there might be some

situations where you want to give Arduino IDE a try. Here's the following steps:

• Especially on Windows 7 or 8, make sure you can see file extensions. Where as in Vista is known

to do funny things when they're hidden.

• In case you have an ATmega2570, or -1284P based electronics, also install Gen7 Arduino 2570

will get supported in any desktop.

• Before opening in the Arduino IDE, we must rename the unpacked folder into Teacup and

Firmware. E.g. from Traumflug-Teacup_Firmware-448df5d to Teacup Firmware.

• If you're using Arduino IDE 1.6.x to 1.6.9, delete these folders inside the top level

folder: attic, simulator, extruder, and research.

• Do basic setup like above.



• Menu -> File -> Save board as.... If your Arduino IDE is v1.0.x or earlier, save not, as offered by

default, into configuration, but directly into the main Teacup folder.

• Same for the printer configuration.

• Menu -> File -> Save configuration.

Then you can open Teacup and Firmware. Predirectly in Arduino IDE. If it asks to rename this file to

*.ino, accept this. It should build and upload

Figure 6.2: shows configuration of teacup[16]

6.2.3 SJFW

SJFW Perl host is mainly based on test bed, but is perfectly useable for printing the 3 D model. if

you have Perl and the Device like Serial Port Perl library installed. This should be available for all

operating systems such as windows 7, 8 and 10 etc. In addition, the sjfw Perl host is the only host presently

to support advanced CRC calculations.

6.2.4 MARLIN

Marlin is an open source firmware in which any of RepRap family to replicate in Rapid

prototyping and it is popularly known as a 3D printer. It was obtained by Grbl and Sprinter and it

became open source for all 3D printer. Marlin is used for a respected 3D printers like ultimate, Prusa,



and Printrbot for just a few of the vendors who ship a variant of marlin. Marlin runs in 8-bit micro-

controllers the chips are at the center of open source reference platform for marlin Arduino Mega2560

with RAMPS 1.4.

Marlin is firmware can be used in any of single-processor electronics, like supporting for

ultimaker, ramps, and several other Arduino2570-based on 3D printers. It supports printing over USB or

from SD cards with folders and uses look-ahead trajectory planning. Marlin is licensed under the GNU

GPL v3 or later. It is based on sprinter firmware, licensed under GPL v2 or later. Marlin Firmware runs

through a 3D printer’s main board, to manage all the real-time activities on the machine. It coordinates

the heaters, buttons, sensors, steppers, LCD display, lights and everything will be involved in the 3D

printing operation. Marlin implies on additive manufacturing process called as FUSED DEPOSITION

MODELING. In this process a motor pushes the thermoplastic filament into a hot nozzle which melts and

extrudes the material while the nozzle is moved under computer control. After several minutes it start

laying layer by layer to form a physical object. The control-language for Marlin is used to derivative of

G-code. G-code gives commands about machine to do simple things like to “set heater 1 to 210°,” or

“move to XY at speed F.” To print a model through Marlin, it must be converted to G-code using a

program called a “slicer.” Since every printer is different, but we won’t find G-code files from download

we should need to slice by yourself. As Marlin receives movement of all commands it allows themselves

into a movement queue to be executed in the order received. The stepper will interrupt the processes for

queue and they start converting linear movements into precisely-timed electronic pulses to the stepper

motors. Even at modest speeds Marlin needs to generate thousands of stepper pulses every second. Since

CPU speed limits how fast the machine can be moved, we’re always looking for new ways to optimize

the stepper interrupt! Heaters and sensors are managed in a second interrupt that executes at much slower

speed, while the main loop handles command processing, updating the display, and controller events. For

safety purpose in Marlin firmware it will actually reboot the CPU gets too overloaded to read the sensors.

6.2.5 SAILFISH

Better print quality in the Sailfish and it is careful to run critically timed operations at the highest

priority in the microprocessor. Unfortunately, not so easy in the MBI firmware. When printing very fine

detail at high print speeds, this can make a difference. Also, while printing over USB, through connecting

to pc in the fact that the firmware returns error messages actually leads to improved print quality. It is used

for support for auto leveling requires printers with AT mega 2560 processors and a Z height probe. Sailfish



can be enhanced to control software for any 3D printers, for incorporating new features intended for

advanced users. With its numerous features, Sailfish has evolved into the firmware users of MakerBot-

style printers based upon the Replicator 1 and 2 series of 3D printers. A 3D printer’s firmware is the

software used in any printer to controls the printer’s behavior in Desktop. If the software which can receive

printing instructions from Arduino, Replicator G, SD card files, and other desktop programs which can

execute themselves to create your 3D printed models. This documentation of firmware will be able

intended to help you or navigate according to the firmware on your 3D printer, from this basic setup and

navigation of the LCD screen, in advanced coming to adjustments or updates and the particulars of the

diagnosing Sailfish-specific issues.

6.3 Steps to install firmware

Step 1: The first step in firmware is to be download the Arduino IDE from the Arduino website and install

it following the usual procedure for your OS. Marlin can be compiled in Linux, Windows, and Unix.

Step 2: Download marlin firmware source code from website choose the proper version based on code

bases from the given website

Step 3: See Configuring Marlin for an explanation of the configuration file format and a synopsis of most

of options in these files to specify which hardware is in use.

Step 4: Verify/Compile the firmware using Arduino IDE

Step 5: connect the controller to PC via USB cable

Step 6: upload the firmware program to controller CPU



Figure 6.3(A) Program Of Arduino

Figure 6.3(B) Marlin Firmware



6.4 SOFTWARE

Computer software is an part of a computer system which can be consists of data or computer

instructions software is all information processed by computer systems program and data. In the 3D

printer, the software performs an important role for sending the information from one place to another

without software we cannot perform any virtual object which is to be sliced and printed is not obtained.

The programming platform is an embedded C and C++ program where C++ program acts an important

role in the 3D printer the specification required for movement and parameter are directly calibrated and

loaded on the controller. the software is the platform where it can create any 3D model by using any 3D

software.

6.5 SOFTWARE USED FOR DESIGNING THE 3D PRINTER

6.5.1 SOLIDWORKS

It was published by Dassault system. The solid works are used for solid modeling computer-aided

design (CAD). It runs on operating systems like windows7 or 8 etc. the 3D printed parts were designed

using solid works to develop an assembly of a 3D printer with complete design with solid works you can

print directly to 3D printer, similar to how you would print a document to your normal printer.it can also

give different types of output like STL, IGES, VRML and JPEG etc.

Figure 6.4: Design In Solid Works



Most probably we are using STL file because it accepts the format of 3D printing and there are many

formats provide more information about the model being printed. It does not require any post-processing

to define data such as orientation, color, material etc. solid works support any slicing software to produce

any G-code for printing the 3D models, so we have preferred solid works 2015 for designing complete

model in this software.

6.5.2 CATIA

It was also published by DASSAULT SYSTEM. CATIA stands Computer Aided Three-

dimensional Interactive Application. it can be used to create 3D CAD models, but this cannot be used

directly for input in a 3D printer.The 3D printer is a layer-by-layer process, hence it does not support any

slicing software. This process cannot be done CATIA, whereas it does not have any STL file to convert

any G-code. this is problems faced while designing the 3D model in the catia

6.6 SOFTWARES USED FOR PRINTING THE 3D MODELS

6.6.1 CURA:

The world’s most advanced 3D printer software. Cura is the Eco-friendly to face the slicing

software so that many users don’t know how to realize what it’s doing. Just load the cad model into the

software, select the quality should be printed by pressing the print option in the software. It’s as easy as

traditional 2D printing. Essentially that’s all Cura is print software can get a digital file from any computer

to the 3D printer in any format. so that the 3D printing can understand itself for printing. Cura can be

available free for you to download, but it is also open source. It is the standard software of 3D slicers

worldwide. If you compare Cura to other 3D slicing software, it seems very simple in cura there are many

features available for slicing when compare to other software with limited options and adjustments. But

Cura’s has more complex settings are there if you need them; it’s just been designed very neatly and user-

friendly. Cura is developed by 3D printer manufacturer Ultimaker and, as everyone is know from their

hardware, they’re perfectionists. In the Cura software are almost all those settings and options that can be

seen in the majority of other slicing software. We can change setting according to what we want to print

by changing a few quality and speed options, then in Cura, it’s all carefully laid out and ready to go. We’re

only going to assume that you’ve switched to the printer and loaded the filament. From that point, it can

help to guide operation in the ways of Cura 3D and getting started with 3D printing. Cura which can be

creates a seamless integration between hardware, software and materials for best 3D printing experience



around it support different file formats such as STL, 3MF, AND OBJ. we are using in our 3D printer is

STL file format because the model is completely designed from solid works and the file format is in STL.

Every model we design for print it must be translated by cura into instructions your ultimaker will

understand. The first thing you will need is a 3D model just make sure export file is in STL file format so

that cura understand it. within moments, cura slices your models ready for print. You can do any changes

required for a 3D printer using printer setting.

Figure 6.5: Cura

6.6.2 REPETIER HOST

The STL file from the solid works is imported such that one or more 3D models are sliced from

slicing software which can produce G-code. Once G-code is done then turn on the software connect via

USB to pc and do the printing setting such that can adjust the bed leveling from the repetier software. The

repetier can directly heat the heating bed and extruder up to given temperature. The software is very easy

and intuitive to use, were Repetier host is most popular for 3D FDM printer. The repetier server can run

on windows, mac and also on the small and cheap system. Add the file which as has been sliced and start

printing with accurately setting which required for printing.



Figure 6.6: Repetier Host

6.6.3 G-code interpreter

It is commonly used language to control CNC machines. In 3D printer the designed to be able to

run on modest hardware the Arduino loaded with the firmware and is a file format that can be prepared in

advance from design file like CAD files. the G-code interpreter reads each line of the file that sends to

actual signals to the motor for moving the devices symmetrically. Firmware on a printer electronic

platform will be integrated into hardware interpreter

6.6.4 G-code sender

It creates communication between computer and 3D printer and sends the G-codes file to printer

we need to generate the G-code from any slicing software and after generating the G-code from slicing

software then load the file on a memory card if it can support or connect the USB connection via computer

to 3D printer with help of microcontroller it can understand the G-code language and can connect program

on your workstation like,

• Proterface

• Repetier-host

• simply 3D

• matter control

CHAPTER 7

CONCLUSION



CHAPTER 7

CONCLUSION

The outcome of this project was to build a portable 3D Printer which has been successfully

completed. The design of the frame is made robust and compact using aluminum sections. The material

selection of the various elements is economical. Using a single motor for vertical movement along with

a proximity sensor makes bed leveling easy and the bed movement is monitored with resolution in

microns. The drawback in few of the 3D Printer which uses bed movement in Y axis has distortion of the

printed layer at high rates of printing. To overcome this drawback, a new mechanism has been developed

which uses bed movement in Z. The control of the mechanism becomes easy because of less number of

motors and good synchronization can be achieved using this new 3D printer technique.

Table 7.1: Machine Specifications

Specifications

Build Volume 150L x 180W x 180H mm3

Method Fused Deposition Modeling

Layer Resolution Height 55 microns

Number of Extruders One

Machine Size 380mm(L) x 550mm(W) x 610mm(H)

Machine Weight 8Kg

Power Supply DC 12V, 5amp

Power Consumption 250v, 50-60Hz, 5amp, 600W

Connectivitiey USB, SD

Filament Diameter 1.75mm

Nozzle Diameter 0.3mm

Filament Material PLA, ABS, Thermoplastics

Print File Type Gcode, STL, Obj



Figure 7.1: Fabricated 3D Printer



Figure 7.2: 3D Printed Parts



REFERENCES

INTERNATIONAL JOURNAL PAPERS

[1] A. Ramya and Sai leela Vanapalli, 3d Printing Technologies In Various Applications.

International Journal of Mechanical Engineering and Technology, 7(3), 2016, pp. 396–409.

http://www.iaeme.com/currentissue.asp?JType=IJMET&VType=7&IType3

[2] C.W. Hull, Apparatus for Production of Three-dimensional Objects by Stereolithography,

in, Google Patents, 1986.

[3] Dr. Rajashekar Patil, Deepak D, Dharshan Gowda S, Krishna Kashyap C S, Mohammed

Murtaza, Prashanth S N, Harsha N and Bharath V G, Economical 3d – Printer by Adopting

FDM Technique, International Journal of Mechanical Engineering and Technology, 8(4),

2017, pp. 442-447.

http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=8&IType=4

[4] Hideo Kodama, "Automatic method for fabricating a three-dimensional plastic model with photo-

hardening polymer," Review of Scientific Instruments, Vol. 52, No. I l, pp 1770-1773, November

1981

[5] Hideo Kodama, "A Scheme for Three-Dimensional Display by Automatic Fabrication of Three-

Dimensional Model," IEICE TRANSACTIONS on Electronics (Japanese Edition), vol. J64-C,

No.4, , April 1981

[6] Beck, J.E.; Fritz, B.; Siewiorek, Daniel; Weiss, Lee (1992). "Manufacturing Mechatronics

Using Thermal Spray Shape Deposition" (PDF). Proceedings of the 1992 Solid Freeform

Fabrication Symposium.

[7] Amon, C. H.; Beuth, J. L.; Weiss, L. E.; Merz, R.; Prinz, F. B. (1998). "Shape Deposition

Manufacturing With Microcasting: Processing, Thermal and Mechanical Issues" (PDF).

Journal of Manufacturing Science and Engineering 120 (3).

[8] Freedman, David H. "Layer By Layer." Technology Review 115.1 (2012): 50—53.

Academic Search Premier. Web. 26 July 2013.

[9] Jason King Book Review: 3D Printing — The Next Industrial Revolution, 3D Printing Direct

Digital Manufacturing Pioneers, Headquarters, 27th April 2014.Replicator World, June 2013

[10] Gary Anderson Christopher Barnatt on "The Business of 3D Printing", 10th October 2013.



[11] T. Prabhu. Modern Rapid 3D Printer - A Design Review. International Journal of Mechanical

Engineering and Technology, 7(3), 2016, pp. 29–37

[12] Jabbar Qasim Al-Maliki, Alaa Jabbar Qasim Al-Maliki (2015), the Processes and Technologies of

3D Printing, International Journal of Advances in Computer Science and Technology, pp. 161–

165

BOOKS

[13] Jacobs, P.F., Rapid Prototyping & Manufacturing, Fundamentals of

Stereolithography, Pg.2.35. pg.18.8

[14] Machine design data Hand-book by Dr.K. Lingaiah and Professor B. R. Narayana

Iyengar Society of Manufacturing Engineers, 1992, Chapter 1: 11–18

INTERNET SOURCES

[15] https://www.pololu.com/product/1182

[16] http://forums.reprap.org/read.php?1,516185

[17] http://scholar.harvard.edu/files/lewisgroup/files/lewis_afm_2006.pdf

[18] https://www.sculpteo.com/en/glossary/selective-deposition-lamination-definition/

[19] http://marlinfw.org/

PUBLICATIONS

INTERNATIONAL JOURNAL

[1] Dr. Rajashekar Patil, Ishtiaq Ahmed, Mohammed Shoaib Shariff, Syed Ismail Zeeshan, Prashanth S,

Harsha N and Pradeep Kumar K, Design and Fabrication of Portable 3D Printer, International Journal of

Mechanical Engineering and Technology 8(11), 2017, pp. 129–135.

http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=8&IType=11

[2] Ishtiaq Ahmed, Mohammed Shoaib Shariff, M Syed Ismail Zeeshan, Prashanth S, , , .

“Troubleshooting for FDM Technology”, Volume 6, Issue I, International Journal for Research in

Applied Science & Engineering Technology (IJRASET) Page No: , ISSN : 2321-9633, www.ijraset.com

http://scholar.harvard.edu/files/lewisgroup/files/lewis_afm_2006.pdf

https://www.sculpteo.com/en/glossary/selective-deposition-lamination-definition/

http://marlinfw.org/




Awards And Recognition

I. International Exhibition (IMTEX 2018)





II. Karnataka State Level Exhibition (2018)

OUR PUBLICATION’S



International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 11, November 2017, pp. 129–135, Article ID: IJMET_08_11_015

Available online at http:// http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=8&IType=11 ISSN

Print: 0976-6340 and ISSN Online: 0976-6359

DESIGN AND FABRICATION OF PORTABLE 3D

PRINTER

Dr. Rajashekar Patil

Professor and Head, Department of Mechanical Engineering, Atria Institute of Technology,

Bengaluru, Karnataka, India

Ishtiaq Ahmed, Mohammed Shoaib Shariff, Syed Ismail Zeeshan, Prashanth S

UG Students, Department of Mechanical Engineering,

Atria Institute of Technology, Bengaluru, Karnataka, India

Harsha N, Pradeep Kumar K

Assistant Professor, Department of Mechanical Engineering, Atria Institute of Technology,

Bengaluru, Karnataka, India

ABSTRACT:

3D printing is an additive manufacturing technique in which 3D objects are printed with the help of CAD

(computer-aided design) software. Different processes are available in 3D printing technology such as (1) FDM (fused

deposition method),(2) SLS(selective laser sintering) (3) EBM (electron beam machining,(4) LOM(laminated object

manufacturing),(5) DLP (digital light processing),etc. In this paper, we have focused on the design and fabrication of

a portable 3D printer of bed volume (150 x 180 x 200 mm3) which can be constructed economically. We are using 4

axis mechanisms where 3 axes are x-y-z and the fourth axis is an extruder. The process adopted by us is FDM

technology, in which different the materials like PLA (polylactic acid), ABS (acrylonitrile butadiene styrene), HIPS

(high impact polystyrene), etc. By heating any of the filament material to its melting point and it is deposited layer by

layer.

Combination of many layers of such type will give us a final 3D model.

Key words: 3D Printing, Mechanism, FDM, Rapid Prototyping.

Cite this Article: Dr. Rajashekar Patil, Ishtiaq Ahmed, Mohammed Shoaib Shariff,

Syed Ismail Zeeshan, Prashanth S, Harsha N and Pradeep Kumar K, Design and Fabrication of Portable 3D Printer,

International Journal of Mechanical Engineering and Technology 8(11), 2017, pp. 129–135.


© IAEME Publication Scopus Indexed



I. INTRODUCTION 3D printing refers to as additive manufacturing method basically used for making threedimensional objects. The object may be

of any form. The method of making this object is known as additive manufacturing. In this additive method, an object is built

from its base by adding multiple layers of materials to it. The additive method is taken from the subtractive process, where the

material is removed from a block by using the methods such as drilling or sculpting. The material used in the development of

3D objects is mainly plastic, though in recent development there has been an additional development toward the alternative

materials like metals of various composition and organic matter like carbon and its derivatives. 3D printing technology is used

by manufacturers like automobiles, aerospace, dental, medical companies due to the accurate and efficient production of objects

[1]. The 3D printed objects will be lightweight and rapid prototyping of the objects can be done.

II. VARIOUS PROCESSES OF 3D PRINTING There are different processes available in 3D printing technology to create a 3D object. These processes may be selected based

on the use of material, the purpose of design, the complexity of the object and application of the object. The processes are as

follows,

2.1 Stereolithography - SLA uses the laser for printing it uses polymers as the printing material [2]. The high beam Ultra-

violet laser traces the first layer of an object on the liquid surface, which creates a very thin layer of photopolymer and then

hardens. The perforated platform will be very slightly lowered and then another layer will be traced and then it will be hardened

with the help of a laser. Multiple layers will be traced until the full object has been printed. The excess material may be removed

to get the desired object.

2.2 Fused Deposition Modelling (FDM) – In this process the machine deposits multiple layers of the filament (thermoplastic)

material on top of another in order to create a joint by heating the filament to appropriate temperature [3]. Here the hot filament

is extruded basically thermoplastic from a controlled temperature head to obtain a robust object with high accuracy.

2.3 Selective laser sintering (SLS) – it is a type of 3D printing process which builds objects from a powder form (such as

ceramic, metal, nylon, etc), which is fused together with the help powerful laser. The powder gets melted and compacted to

join the grains together to obtain a final product. Once the model is cooled the excess powder must be simply brushed [4].

2.4 laminated object manufacturing (LOM)- in this technology, the layered material is rolled on a building platform. In this

process, the adhesive coated layers which are glued together by the heated rollers and cut to the desired shape with the help of

laser layer by layer. A roller with the material moves each new sheet of material over the previous sheet and repeats the process

until the model is completed [5]. Then with the help of laser or blade, the appropriate object is cut to obtain the final object.

2.5 Inkjet 3D printing – in this process the models are created by spreading a layer of powder (resins or plaster) one layer at

a time. When the entire layers are formed by jetting, to get uniform thickness a milling head is passed over the layer. The

process to be repeated to obtain a final object. After the process is completed, the support material may be melted or dissolved.

This technology is widely used to this day due to the following reasons; low cost, easy to use, it can be optimized for speed [6].

III. MECHANISM

A. Conceptual Design

The design of the model has to be done in software where the actual model with the required dimensions is developed so that

it can be used to print the model. To develop and fabricate the model there are many process and parameters involved mainly

design of the model. The design process is started by keeping the print volume as a basic design parameter. As the objective of

the project is the construction of economical and sizable 3D Printer, the print volume of 150 x 180 x 200 mm3 is selected. The

3 – Dimensional motion is achieved by synchronization of movements in X, Y and Z directions. Hence mechanism of our 3D

Printer is Z plus core XY. This mechanism uses 4 stepper motors, two for Y-axis movement (to and fro movement), one for Z-

axis movement (Vertical movement) and one for Extruder filament. This mechanism uses a single motor to control lead screws

to which the print bed is connected for the movement in Z – direction. The lead screws are driven by the motor which in turn

moves the bed in the vertical direction. Two motors have been used here because the print volume is large, there will be a

disruption in the movement if only a single motor is used. The conceptual design has been initially visualized in Sketch-up

software.

B. X-axis Movement

Figure 1 shows the rendered CAD model of the mechanism of Lateral movement. It consists of the carriage, cylindrical rods,

pulleys, timing belt and extruder nozzle (used in FDM process) arranged as shown.



The rotary motion from the motor in the y-axis is converted into linear sliding motion and this linear motion is transfer by

flange bearing by timing belt- pulley connection as shown. The extruder nozzle is the main printing part of the machine. For

its movement in a horizontal direction, the carriage is provided. The extruder nozzle is mounted onto to the carriage on one

side, this may result in imbalance and failure of the machine. To avoid this, the carriage is mounted on two rods and designed

for balance.

The carriage slides in the horizontal direction over these two cylindrical rods using linear bearings. These cylindrical rods

are fixed rigidly into the holes present in the carriages that move in the Y direction. The timing belt is mounted onto the pulley

which is driven by the motor on one side and a support pulley on the other side.

Figure 1 X-axis Movement

The carriage is fixed to the lower timing belt of the loop, such that the belt movement results in the movement of the

carriage. When the motor rotates in clockwise direction, since the carriage is connected to the lower belt in the loop, it moves

from right to left. When the motor rotates in an anticlockwise direction, the carriage moves from left to right. To design this

mechanism for horizontal movement, the carriage is designed first for balance, so that the weight of the carriage and the extruder

nozzle is distributed equally on both the rods Figure 2.The weight of the extruder nozzle is found and accordingly, the carriage

is designed. The carriage is designed using the free body diagram of the carriage.

C. Y–axis Movement

Figure 3 shows the rendered CAD model of the mechanism for Y-axis movement. It consists of Carriage, Cylindrical Rods,

Pulleys and Timing Belt arranged as shown.

Figure 2 Y – axis Movement

The rotary motion of the motor is converted into linear sliding motion by timing belt – pulley connection as shown. The

X-axis rods are fixed to the carriages with the help of holes in the side face of the carriages. The carriages slide along Y – axis

over the two cylindrical rods using linear bearings. These cylindrical rods are fixed rigidly to the frame. The timing belt is



mounted onto the pulley which is driven by the motor on one side and a support pulley on the other side. The carriage is fixed

to the lower timing belt of the loop, such that the belt movement results in the movement of the carriage. When the motor

rotates in one direction, the carriages are connected to the lower belt in the loop moves from front to back or in opposite

direction depending on the motor orientation. The two motors should be in perfect synchronization for high-quality printing.

To design this mechanism for Y-axis movement, first, the carriages are designed. The carriages are designed to mount the

motor, pulley and to hold X-axis rods. Since these carriages are symmetric there is no problem of imbalance and hence the

carriage dimensions are determined by the mounting area required by the motor, supporting pulley and the holes to hold the X-

axis rods rigidly.

D. Z-axis Movement

Figure 4 shows the rendered CAD model of the mechanism of vertical movement. It consists of lead screws, shaft coupler,

flange nut and print bed arranged as shown in the image.

Figure 4 Z-axis Movement

The rotary motion of the motor is transfer by rotating the leadscrews connected to the bed by using flange nut and shaft

coupler as shown. The torque produced by the motor is transmitted to the lead screws by using shaft coupler and flange nut.

When the motor rotates, say in a clockwise direction, shaft coupler rotates lead screws in the same direction, say in a clockwise

direction. The bed is connected to the lead screws using threaded couplers, this makes the bed move in a vertical direction when

the lead screw rotates.

IV. CONCLUSION The outcome of this paper was to build a portable 3D Printer which has been successfully completed. The design of the

frame is made robust and compact using aluminum sections. The material selection of the various elements is economical. Using a single motor for vertical movement along with a proximity sensor makes bed leveling easy and the bed movement

is monitored with resolution in microns. The drawback in few of the 3D Printer which uses bed movement in Y axis has

distortion of the printed layer at high rates of printing. To overcome this drawback, a new mechanism has been developed

which uses bed movement in Z. The control of the mechanism becomes easy because of less number of motors and good

synchronization can be achieved using this new 3D printer technique.



Figure 5 CAD model of the machine

Table 4.1 Machine Specifications

Speci fications

Build Volume 150L x 180W x 200H

Method Fused Deposition Modeling

Layer Resolution Height 50 microns

Number of Extruders One

Machine Size 380mm(L) x 550mm(W) x 610mm(H)

Machine Weight 8Kg

Power Supply DC 12V, 5amp

Power Consumption 250v, 50-60Hz, 5amp, 600W

Connectivity USB, SD

Filament Diameter 1.75mm

Nozzle Diameter 0.3 mm

Filament Material PLA, ABS, Thermoplastics

Print File Type Gcode, STL, Obj



ACKNOWLEDGEMENT The authors thank Mr. Deepak Dwarkanath and Mr. Mohammed Murtaza who helped us in the development of the machine.

REFERENCES

[1] A. Ramya and Sai Leela Vanapalli, 3d Printing Technologies In Various Applications. International

Journal of Mechanical Engineering and Technology, 7(3), 2016, pp. 396–409.

http://www.iaeme.com/currentissue.asp?JType=IJMET&VType=7&IType=3

[2] Jacobs, P.F., Rapid Prototyping & Manufacturing, Fundamentals of Stereolithography, Society of

Manufacturing Engineers, 1992, Chapter 1: 11–18

[3] Dr. Rajashekar Patil, Deepak D, Dharshan Gowda S, Krishna Kashyap C S, Mohammed Murtaza,

Prashanth S N, Harsha N and Bharath V G, Economical 3d – Printer by Adopting FDM Technique,

International Journal of Mechanical Engineering and Technology, 8(4), 2017, pp. 442-447

[4] Helena N Chia, Benjamin M Wu (2015), Recent advances in 3D printing of biomaterials, Journal of

Biological Engineering, pp. 1–14

[5] Kaufui V. Wong and Aldo Hernandez (2012), A Review of Additive Manufacturing, International

Scholarly Research Network, pp 1–10

[6] T. Prabhu. Modern Rapid 3D Printer - A Design Review. International Journal of Mechanical

Engineering and Technology, 7(3), 2016, pp. 29–37

[7] Jabbar Qasim Al-Maliki, Alaa Jabbar Qasim Al-Maliki (2015), the Processes and Technologies of 3D

Printing, International Journal of Advances in Computer Science and Technology, pp. 161–165.



International Journal for Research in Applied Science & Engineering Technology (IJRASET)

ISSN: 2321-9653; IC Value: 45.98; SJ Impact

Factor :6.887

Volume 6 Issue I, January 2018- Available at www.ijraset.com

Troubleshooting for FDM Technology

Ishtiaq Ahmed1, Mohammed Shoaib Shariff2, M Syed Ismail Zeeshan3, Prashanth S 4 1, 2, 3, 4

A. UG Students, Department of Mechanical Engineering, Atria Institute of Technology, Bengaluru, Karnataka,

India

Abstract: 3D printing is a technology where the objects are by the addition of multiple layers one top of another to form a

solid object. Different processes involved in 3D printing technology are as follows (1) FDM (Fused Deposition Modeling),

(2) SLS (Selective Laser Sintering), (3) EBM (Electron Beam Machining), (4) LOM (Laminated Object Manufacturing),

etc. In this paper, we are focusing on the problems faced while 3D printing and solutions to those problems. The most

common problems faced during printing may be Clogged Extruder, layer shifting, grinding filament, Weak Infill,

overheating, etc.The technology adopted by us is FDM for which the problems and solutions are discussed in this paper.

Without resolving all these problems, it is not possible to get a good print. By resolving all these problems, we can improve

the quality of the 3D printed parts that are being printed.

Keywords -3D printing, filament, extruder or nozzle, FDM (Fused Deposition Modeling)

A. I. INTRODUCTION

1) A. Fused Deposition Modeling (FDM)

This is a process by which a machine deposits a material (Thermoplastics or wax). One-layer top of other layer of the same

material, in order to create a solid joint by adhesion or heat. fused Deposition Modeling (FDM) was produced by Stratasys in

Eden Prairie, Minnesota. In this procedure, a plastic or wax material is expelled through a nozzle that follows the part's cross-

sectional geometry layer by layer [1]. The fabricate material is generally provided in fiber shape, however a few setups use

plastic pellets nourished from a container. The nozzle contains resistive warmers that keep the plastic at a temperature simply

over its liquefying point with the goal that it streams effortlessly through the nozzle and structures the layer. The plastic

solidifies instantly subsequent to spilling out of the nozzle and bonds to the layer underneath. Once a layer is fabricated, the

stage brings down, and the expulsion nozzle stores another layer. This will dramatically decrease the bond strength between

the layers and overall build quality. For example, if a 3D printer is using a 0.6mm nozzle, then the maximum layer height

should not exceed 0.5mm[2]. In the X-Y plane, 0.001inch determination is achievable. A scope of materials are accessible 25

counting ABS, polyamide, polycarbonate, polyethylene, polypropylene, and venture throwing wax (16, 17). Today in FDM

process there are many problems facing by us such as extruder is clogged, extra filament etc. So to over this we have come up

with various problem and their solution by FDM process:

B. II. TROUBLESHOOT

1) A. Clogged Extruder

The 3D printer must soften and expel numerous kilograms of plastic over its lifetime. To make things more convoluted, the

greater part of this plastic must leave the extruder through a little gap that is just as large as a solitary grain of sand. Definitely,

there may come a period where something turns out badly with this procedure and the extruder is never again ready to push

plastic through the nozzle[3]. These jams or obstructs are more often than not because of something inside the nozzle that is

hindering the plastic from uninhibitedly expelling. While this might plague the first occasion when it happens, yet we will

stroll through a few simple investigating steps that can be utilized to settle a stuck nozzle. This problem is due to the following

reason:

1) Manually pushing the filament into the extruder



2) Reload the filament Clean out the nozzle

C. B. Layer Shifting

Many of the 3d printers nowadays use an open loop control system that they have no feedback to the actual location of the

nozzle. The printer attempts to move the nozzle to a location but it doesn’t happen due to powerful stepper motors that will

drive the printer. if something goes wrong the printer would never detect it .and this causes misaligned layers in the print. The

layer shifting problem can be avoided as what problem we may occur and how to fix it given below:-

1) Nozzle moves too fast

2) Mechanical or Electrical issue

D. C. Weak Infill

The infill inside your 3D printed part assumes a critical part in the general quality of your model. The infill is in charge of

associating the external shells of your 3D print, and should likewise support and upper surfaces that will be imprinted over the

infill. On the off chance that your infill gives off an impression of being powerless or stringy, you might need to change a

couple of settings inside the product to add extra quality to this segment of your print.

1) Trying different infill pattern

2) Reducing the print speed

3) Increasing the infill extrusion width

E. D. Grinding Filament

The 3D printers use small drive which grab the filament and sandwich it against another bearing .The sharp teeth that allows

the filament to push it forward or backward .If the filament is unable to move then the drive gear will keep spinning and will

grind away plastic from the filament as this situation is termed as stripped .To overcome this problem there are some fix to the

problem given below

1) Increase the extruder temperature

2) Print too fas

3) Check for nozzle clog



F. E. Blobs and Zits

In 3D print, the extruder should always stop and begin expelling as it moves to various bits of the fabricate stage. Most

extruders are great at delivering a uniform expulsion while they are running, be that as it may, each time the extruder is killed

and on once more, it can make additional variety. For instance, in the event that you take a gander at the external shell of

your 3D print, you may see a little stamp at first glance that speaks to the area where the extruder began printing that segment

of plastic. The extruder needed to begin printing the external shell of your 3D show at that particular area, and after that it in

the end came back to that area when the whole shell had been printed. These imprints are normally alluded to as blobs or zits.

As you can envision, it is hard to join two bits of plastic together without leaving any check at all, yet there are a few devices

in 3D printer that can be utilized to limit the presence of these surface imperfections.

1) Movement Behavior

2) Choose start point that is closest to specific location

G. I. Extruder Not Extruding Enough Plastic

The software used for 3D printing have some settings to determine how much plastic to be extruded. However, the 3D printer

does not give any feedback that how much material must be extruded from the nozzle[4]. There may be some chance that less

plastic exiting the nozzle than what software expects (else it would be a under extrusion process). In this case we may notice

gaps between extrusion of each adjacent layer. There are some typical ways to solve this problem

1) diameter of the filament is not correct

2) high extrusion speed

H. J. Inconsistent Extrusion

For 3d printer to have the capacity to make exact parts, it should be fit for expelling an exceptionally steady measure of plastic.

On the off chance that this expulsion fluctuates crosswise over various parts of your print, it will influence the last print quality.

Conflicting expulsion can for the most part be distinguished by viewing your printer intently as it prints. For instance, if the

printer is printing a straight line that is 20mm long, however you see that the expulsion appears to be fairly rough or appears

to fluctuate in estimate, at that point you are likely encountering this issue. We have outline the most widely recognized

foundations for conflicting expulsion, and clarified how everyone can be tended to.

1) Filament becomes tangled

2) Low layer height

3) Low quality filament

4) Mechanical issues with extruder

I. K. Extruder Not Extruding At The Beginning Of Print

This is the very common problem faced by the 3D printer owners, but this problem can be easily resolved. But If this issue is

not resolved then it may affect the print quality. There are some possible causes if the extruder is not extruding at the

beginning of the print. The possible solutions for this problem may be due to

1) extruder not loaded before the printing



2) gap between the bed and nozzle is too close

3) blockage of extruder

4) grinding filament against the drive gear

J. L. Print Not Adhering To The Bed

The first layer of the print must be strongly adhered to build platform because it will the foundation for any print model. If

the first layer is not adhering to the bed it will create a problem at the end of the print. There are some typical ways to solve

this problem 1) bed not levelled

2) extruder extrudes far away from the bed

3) first layer being printed too fast

4) temperature settings

5) extra materials to use for the adhesion(tape, glues, etc)

K. M. Extruder Not Extruding Enough Plastic

The software used for 3D printing have some settings to determine how much plastic to be extruded. However, the 3D printer

does not give any feedback that how much material must be extruded from the nozzle. There may be some chance that less

plastic exiting the nozzle than what software expects (else it would be a under extrusion process). In this case we may notice

gaps between extrusion of each adjacent layer. There are some typical ways to solve this problem

1) diameter of the filament is not

correct

2) high extrusion speed

L. N. Too Much Extrusion Of Filament Material

To obtain a good print quality the extrusion must be precise. The software constantly keeps tracking the nozzle to extrude the

correct amount of filament material. But however the printers have no way to monitor that how much plastic is in flow. If the

extrusion flow settings are not properly configured then the printer may extrude excess plastic as expected by the software.

This excess extrusion may affect the dimension of the model. In order to solve this problem, the extrusion speed must be

reduced in the printer settings to obtain the filament material as required.

M. O. Gaps And Holes Present In The Top Layer

In the 3D printed parts there are solid shells created to cover the partially hollow interior in order to save the material. For

example, the interior part of an object may use 20% of the interior area which is filled with a solid plastic material and rest of

the portion is air. This technique can help in saving the material and time for printing, while can still give a strong part. The

interior part may be anything but the exterior must be a solid. To do this we must make settings in the software like top-bottom

layers and the infill required as per requirement. However what ever settings we use, we may notice that the layers on the top

of the print are not completely solid. We may notice some gaps and holes between the extrusion of solid layers. There are some

typical ways to fix this problem

1) insufficient top solid layers

2) low infill percentage 3) under extrusion

N. P. Layer Sepration And Splitting

3D printer works by building object one layer at a time so after a successive layer sis printed on the top of previous layer and

at the end we will get the desired shape. The final layers must be strong and reliable to bond the layers below it. if it doesn’t it

will split or separate. The layer separation causes and to resolve the causes are given below:

1) Layer height is too large

2) Print temperature is too low

O. III. CONCLUSIONS

In this paper we have focused on the problems faced while 3D printing. The problems focused in this paper are Clogged

Extruder, layer shifting, grinding filament, Weak Infill, overheating, etc. The outcome of this paper was to list out the all the



problems faced during 3D printing and solution to those problems. By solving all these problems, the 3D print quality can be

improved and strong parts can be obtained.

P. REFERENCES [1] Dr. Rajashekar Patil, Ishtiaq Ahmed, Mohammed Shoaib Shariff, Syed Ismail Zeeshan, Prashanth S, Harsha N and Pradeep Kumar K, Design and

Fabrication of Portable 3D Printer, International Journal of Mechanical Engineering and Technology 8(11), 2017, pp. 129–135. http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=8&IType=11

[2] Fused Deposition Modeling (FDM) Mechanism by Fawaz Alabdullah, International Journal of Scientific & Engineering Research, Volume 7, Issue 5,

May- 2016 41 ISSN 2229-5518

[3] file:///C:/Users/HP/Downloads/D-R-516-Banding-and-Clogged-Nozzles.pdf [4] http://www.egr.msu.edu/classes/ece480/capstone/spring14/group08/MartezAN.pdf



(PAPER UNDER REVIEW) MODELLING AND DEVELOPMENT OF A PORTABLE FDM 3D PRINTING

MACHINE 1Ishtiaq Ahmed, 2Mohammed Shoaib Shariff, 3Bharath V G and 4Harsha N

12UG Students, Dept of Mech Engg, Atria Institute of Technology, Bengaluru, Karnataka, India

34Assistant Professor, Dept of Mech Engg, Atria Institute of Technology, Bengaluru, Karnataka, India

ABSTRACT: 3D printing is an additive manufacturing technique where the 3D parts are made with the

addition of multiple layers one top of other with the help of CAD software. The printing can be done with

the help of different procedures like SLS (Selective Laser Sintering), LOM (Laminated Object

Manufacturing), SLA (Stereolithography), etc. 3D printing machine have 4 axis in which 3 axis are x,y,z

and the fourth one is extruder. The process adopted by us is FDM technology in which different materials

such as ABS (acrylonitrile butadiene styrene), HIPS (high impact polystyrene), PLA (polylactic acid), etc

can be used. By heating any filament material upto its melting point and laying it layer by layer.

Combination of multiple layers one top of other will give required 3D object.

Key words: 3D Printing, Rapid Prototyping, FDM, SLA, SLS, LOM.

1. INTRODUCTION

Rapid Prototyping is a procedure of taking

a computerized 3D model and transforming that

advanced document into a physical object.

manufacturing across the globe are utilizing 3D

printing as an approach to decrease costs, spare

time, and deliver better items.

By never again expected to outsource the

prototyping of parts, organizations can rapidly

repeat upon plans on the fly, as a rule sparing a

long time of sitting tight for outsiders to return

molds or models. From car makers to hardware

organizations and anybody in the middle of, 3D

printing is an important innovation. Effective and

precise generation of models or low-volume

items can lessen an opportunity to market and

increment item flexibility. This 3D printing

technique is used by the manufacturers like

aerospace, automotive, medical, dental, etc, due

to accurate and efficient production of models[1].

2. LITERATURE SURVEY

3D Printing was concocted by Charles W.

Hull in 1986 [2], it is an added substance

producing system in which advanced 3D show is

changed over document into a physical protest.

Frame's creation focused exclusively on a

manufacture procedure called Stereolithography

(SLA). Since that time various other 3D printing

advancements have been produced, for example,

Stereo lithography (SLA), fused deposition

modelling (FDM), selective Laser Sintering

(SLS), PolyJetting and others, all of which

depend on layer-by-layer manufacture and

depend on a G-code encouraged to the printer.

While there are various advancements which can

be utilized to 3D print a question, the larger part

of 3D printers one will discover inside a home or

an office setting depend on the FDM or SLA

forms, as these advancements are presently less

expensive and less demanding to actualize inside

a machine.

3. METHODOLOGY

The following flow chart shows the

methodology used by us in construction of 3D

printer. The first step is to select one of the

additive manufacturing process among many



process. Then an appropriate mechanism is

selected for X, Y and Z axis movements,

considering various factors such as cost of

fabrication, simplicity of design,

synchronization, accuracy etc. Once the

mechanism is selected the next step is integration

of electronics and software then the machine is

designed and fabricated. The last step is,

synchronization of mechanical, electrical and

software elements of the machine.

Figure 1.1 Flowchart

Once a 3D demonstrate is composed, the

document (these generally have augmentations,

for example, 3MF, STL, OBJ, and so forth.) must

be changed over into G-code. G-code is a

numerical control script utilized basically for PC

supported assembling (both subtractive and

added substance fabricating). It is a dialect which

advises a machine how to move. Software such

as, Slic3r are required so as to change over 3D

show records into G-code. Once the G-code is

made it can be sent to the 3D printer, giving a

diagram regarding what its next a few thousand

moves will comprise of. These means all indicate

the total creation of a physical protest. There are

other scripts out there and maybe many will in

the long run pick up fame, yet until further notice

G-code is by a wide margin the most critical.

4.Various Methods in 3D printing

Different strategies are there to make model.

These strategies are utilized in view of the many-

sided quality of the plan, the material utilized as

a part of the plan, the motivation behind the

outline, and the measure of the plan. They are as

per the following:

➢ Stereo lithography –

Stereo lithographic 3D printers (known as

SLAs) position a punctured stage just beneath the

surface of a vat of fluid photograph treatable

polymer [3]. An UV laser shaft at that point

follows the in the first place cut of a question on

the surface of this fluid, making a thin layer of

photopolymer solidify. The punctured stage is

then brought down somewhat and another cut is

followed out and solidified by the laser. Another

cut is at that point made, and after that another,

until the point when a total model has been

printed and can be expelled from the vat of

photopolymer, depleted of overabundance fluid,

and cured.

➢ Fused Deposition modeling(FDM) –

It is a procedure by which a machine stores a

fiber (Thermoplastics or wax), to finish

everything or alongside same material, keeping

in mind the end goal to make a joint by warmth

or attachment [4]. Here a hot thermoplastic is

expelled from a temperature-controlled print

head to obtain high accuracy object at the end.

➢ Selective laser sintering (SLS) –

The process builds the object with the help of

Laser in order to fuse the successive layers of

wax, ceramic, nylon, metal powdered. The

powder gets liquefied and compacted to

consolidate the grains to acquire a last item. Once

the model is cooled the abundance powder must

be essentially brushed [5].



➢ Laminated object

manufacturing(LOM)-

In this method, the layered material is moved

on a building platform. In this procedure, the

adhesive covered layers which are stuck

together by the warmed rollers and slice to the

coveted shape with the assistance of laser layer

by layer[6]. A roller with the material moves

over each previous sheet and repeats same

procedure until the model is finished.

➢ Inkjet 3D printing –

It makes the model one layer at once by

spreading a layer of powder (mortar, or gums)

and inkjet printing cover in the cross-area of the

part. when the whole layers are framed by flying,

to get uniform thickness a processing head is

disregarded the layer.

The procedure to be rehashed to get a last

question. After the procedure is finished, the

material might be liquefied or broken down[7].

This innovation is the special case that Takes into

account the printing of full shading models. Not

at all like stereo lithography, inkjet 3D printing is

advanced for speed, minimal effort, and

convenience. No harmful chemicals like those

utilized as a part of stereo lithography are

required. Insignificant post printing complete

work is required

5.Applications of 3D Printing

While at first 3D printing was

principally an innovation for prototyping,

this is rapidly evolving. Presently various

makers are delivering end-utilize parts and

whole items by means of added substance

fabricating. From the aviation industry, to

medicinal displaying and implantation, to

prototyping of different sorts, 3D printing is

being utilized by for all intents and purposes

each real industry on the planet somehow.

Rather than depending on 2D and 3D pictures

on a PC screen or a printout, specialists can

really touch and feel physical copies of the

patient's organs, bone structures, or whatever

else they are going to take a shot at . 3D

printed models of human organs have been a

regular instrument for specialists in the

course of the last a few years, as they give a

more multifaceted perspective of the current

issues. Furthermore, there is inquire about in

progress by many organizations to 3D print

fractional human organs, for example, the

liver and kidney of human beings [8].

Throughout the following decade, it's

extremely conceivable that we will be 3D

printing whole human organs for

transplantation. Due to the special geometries

offered by added substance producing,

militaries around the globe, and additionally

offices for example, NASA and the ESA,

alongside various air ship producers are

swinging to 3D imprinting keeping in mind

the end goal to decrease the general weight of

their airplane. Complex geometries and new

materials offer predominant quality with less

mass, conceivably sparing associations like

NASA boatloads of fuel, and in this way

cash, amid the starting of shuttle or rockets

out of our air [9]. In the meantime,

organizations like Boeing and Airbus are

utilizing 3D printing to diminish the

heaviness of their flying machine, enabling

them to cut fuel costs for each.

6.FDM

Fused Deposition Modelling (FDM)

is an additive manufacturing process, in this

process, thermoplastics in the form of

filament is passed through a heating element



which melts the filament and thrusts

thorough a small nozzle [6]. The nozzle

moves in three dimensions laying down the

melted plastic layer by layer in the required

shape resulting in realization of final physical

object. Articles made with a FDM printer

begin as PC helped outline (CAD)

documents. Prior to a protest can be printed,

its CAD record must be changed over to an

arrangement that a 3D printer can see, for the

most part .STL organize. FDM printers

utilize two sorts of materials, a displaying

material, which constitutes the completed

question, and a help material, which goes

about as a platform to help the protest as it's

being printed. Amid printing, these materials

appear as plastic strings, or fibers, which are

loosened up from a loop and nourished

through an expulsion spout. The spout

dissolves the fibers and expels them onto a

base, in some cases called an assemble stage

or table. Both the spout and the base are

controlled by a PC that deciphers the

measurements of a protest into X, Y and Z

facilitates for the spout and base to take after

amid printing. In a run of the mill FDM

framework, the expulsion spout moves over

the assemble stage on a level plane and

vertically, "drawing" a cross area of a

question onto the stage. This thin layer of

plastic cools and solidifies, quickly official to

the layer underneath it. Once a layer is

finished, the base is brought down — as a rule

by around one-sixteenth of an inch — to

prepare for the following layer of plastic.

Printing time relies upon the extent of the

protest being made. Little protests — only a

couple of cubic inches — and tall, thin

questions print rapidly, while bigger, all the

more geometrically complex items take more

time to print. Contrasted with other 3D

printing techniques, for example,

stereolithography (SLA) or specific laser

sintering (SLS), FDM is a genuinely

moderate process. Once a question falls off

the FDM printer, its help materials are

expelled either by absorbing the protest a

water and cleanser arrangement or, on

account of thermoplastic backings, snapping

the help material off by hand. Items may

likewise be sanded, processed, painted or

plated to enhance their capacity and

appearance.

7. Design of 3D Printing

The figure 1.2 demonstrates the

rendered perspective of CAD model of the

instrument for development every which way

[3]. The 3 – Dimensional movement is

accomplished by synchronization of

developments in X, Y and Z direction. The

Extruder nozzle is the main part of the printer

in which the plastic which is in the form of

filament melts and prints on a heated bed.

The objective of the instrument is to ensure

that this extruder nozzel will have the

capacity to print anyplace inside the

foreordained print volume. This component

utilizes 4 stepper motors, one for X – axis

development (Lateral development or Left –

Right development), two for Y – axis

development (back and forth development)

and one for Z – axis development (Vertical

development). This component utilizes single

engine to control 4 lead screws to which the

print bed is associated for the development in

Z – axis direction. The lead screws are driven

by the engine which thus moves the bed

vertical way. For the development in Y – axis

direction, two separate motors are utilized to



move two separate carriages[8]. Two motors

have been utilized here on the grounds that

the print volume is huge, there will be

disturbance in development if just a single

motor is utilized. For littler print volumes,

single motor might be adequate. For the

development is X – axis direction of a single

motor is utilized which is mounted onto the

carriage that moves in Y – axis bearing. The

point by point working and outline of the

system in particular ways are clarified in

additionally areas. This system is intended

for exactness, the stepper motors utilized is

having determination of 0.36o, i.e., 1000

steps per revolution which provides high

precision, the mechanism used for movement

in Z – axis provides precision, ease of control

and easy synchronization

Figure 1.2: CAD model of the Printer

8. FEA ANALYSIS OF 3D PRINTER

FEA analysis forms a very important

procedure in developing a new machine. FEA

software can easy to use and has a

tremendous amount of power to calculate

stress and displacement for the complex

shapes and sizes which is difficult to be

calculated in the mechanical theory. FEA can

be used for variety of analysis, from static to

dynamic analysis, from modal to heat

transfer, etc.

The Analysis of the x axis rod is as given in

the table 1.

Name Minimum Maximum

Volume 1.85982e-

005 m^3

Mass density 7800

kg/m^3

Von Mises

Stress

9.00429e-

5Mpa

1.14285MP

a

Displacemen

t

0 mm 0.0046861

mm

Safety

Factor

8 ul 8 ul

X Reaction

Force

0.00061859

9

Y Reaction

Force

20.2494

Z Reaction

Force

-2.5155e-

005

Equivalent

Strain

2.26962e-

009

3.56398e-

006

➢ Stress:

The figure 1.3 demonstrates the reaction

force and the stress acting in the bars, the

response powers are acting close to the

limitations given where the most extreme

pressure is created close to the settled district

and close to where the heap is acting from the

carriage. The most extreme stress and the

base stress created is given in the table 1.1.



Figure 1.3: Von-Mises Stress for x-axis

➢ Displacement:

For a successful design, the displacement

has to be minimum, the rod has been selected

in such a way that the displacement has to be

minimum. Thus the rod is selected as per the

Theoretical calculation and then Analyzed. In

figure 1.4, the maximum displacement is near

the carriage where the load of 30N is acting

on it. The rods selected for the x axis is able

to withstand the load and thus the material

and diameter can be selected as per analysis

done.

Figure 1.4: Displacement pattern for x-

axis rods

➢ Strain:

The Hooke’s law stated that stress is directly

proportional to strain, in the figure 5, the

Strain is as low as 3.56398e-006. This low

strain value allows us to select a suitable

diameter for the rod and to select the material

for the rod. Since the displacement and the

stress is minimum for the selected material

which can be used for the development of the

machine.

Figure 1.5: Strain for x-axis rods

9. CONCLUSION

This machine is intended for accuracy.

Utilizing a solitary motor for vertical

development makes Bed leveling simple and

the bed development can be observed with

determination in microns. In some machines,

the extruder nozzle is made to move in Z –

axis direction and bed is made to move in Y

– axis direction, these mechanisms face

problem of mutilation of printed parts while

printing at high rates because of fast

development of bed in Y – hub bearing. The

outcome of this paper was to build a portable

3D Printer which has been successfully

completed. The design of the frame is made

robust and compact using aluminum sections.

The material selection of the various

elements is economical. Using a single

motor for vertical movement along with a

proximity sensor makes bed leveling easy

and the bed movement is monitored with

resolution in microns. The drawback in few

of the 3D Printer which uses bed movement



in Y axis has distortion of the printed layer at

high rates of printing. To overcome this

drawback, a new mechanism has been

developed which uses bed movement in Z.

The control of the mechanism becomes easy

because of less number of motors and good

synchronization can be achieved using this

new 3D printer technique.

REFERENCES

[1] A. Ramya and Sai Leela Vanapalli, 3d

Printing Technologies In Various

Applications. International Journal of

Mechanical Engineering and Technology,

7(3), 2016, pp. 396–409.

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[2] Bak, D. (2003). Rapid prototyping or

rapid production? 3D printing processes

move industry towards the latter. Assembly

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doi:10.1108/01445150310501190

[3] Jacobs, P.F., Rapid Prototyping &

Manufacturing, Fundamentals of

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[4] Dr. Rajashekar Patil, Deepak D, Dharshan

Gowda S, Krishna Kashyap C S, Mohammed

Murtaza, Prashanth S N, Harsha N and

Bharath V G, Economical 3d – Printer by

Adopting FDM Technique, International

Journal of Mechanical Engineering and

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[5] Helena N Chia, Benjamin M Wu (2015),

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biomaterials, Journal of Biological

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[6] Kaufui V. Wong and Aldo Hernandez

(2012), A Review of Additive

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[7] T. Prabhu. Modern Rapid 3D Printer - A

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Mechanical Engineering and Technology,

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[8] Dr. Rajashekar Patil, Ishtiaq Ahmed,

Mohammed Shoaib Shariff, Syed Ismail

Zeeshan, Prashanth S, Harsha N and Pradeep

Kumar K, Design and Fabrication of Portable

3D Printer, International Journal of

Mechanical Engineering and Technology

8(11), 2017, pp. 129–135.

http://www.iaeme.com/ijmet/issues.asp?JTy

pe=IJMET&VType=8&IType=11

[9] Bethany C. Gross, J. L. (2014).

Evaluation of 3D Printing and Its Potential

Impact on Biotechnology and the Chemical

Sciences. Analytical Chemistry, 3240 –

3253.

[10] Prof. Deepa yagnik, Fused Deposition

Modeling – A Rapid Prototyping technique

for Product Cycle Time Reduction cost

effectively in Aerospace Applications, IOSR

Journal of Mechanical and Civil Engineering

(IOSR-JMCE) e-ISSN: 2278-1684, p-ISSN:

2320-334X, PP 62-68





Mr. Ishtiaq Ahmed, UG Students, Dept of

Mech, Atria Institute of Technology, Bengaluru,

Karnataka, INDIA

Mr. Bharath V G, Associate Professor. Dept

of Mechanical, Atria Institute of Technology,

Bengaluru, KARNATAKA, INDIA.

Mr. Mohammed Shoaib Shariff, UG

Students, Dept of Mech, Atria Institute of Technology,

Bengaluru, Karnataka, INDIA

Mr. Harsha N, Associate Professor. Dept of

Mechanical, Atria Institute of Technology, Bengaluru,

KARNATAKA, INDIA.

Documents

A PROJECT REPORT ON DESIGN AND FABRICATION OF PORTABLE 3D …