DEVELOPMENT OF FUSED DEPOSITION TYPE 3D PRINTING MACHINE

CHAPTER 1:
INTRODUCTION
There are a lot of similar definitions and terminologies used to describe 3D printing such as:
additive manufacturing, and rapid prototyping. However, all of them describes the main
distinguishing idea from ordinary subtractive methods which is Additive manufacturing.
Generally speaking, 3D printing: is a process by which 3D solid objects of any shape or
geometry can be created from a digital file. The creation is achieved by laying down
successive layers of a specific material until the entire object is created. Each of these layers
represents a thinly sliced horizontal cross-section (similar to the output of an ordinary printer,
this is why it is called printing) of the eventual object, in contrast to traditional subtractive
manufacturing methods which relies upon the removal of material to create something. 3D
printing refers to processes in which material is joined or solidified under computer control to
create a three dimensiona object with material being added together (such as liquid molecules
or powder grains being fused together). 3D printing is used in both rapid prototyping and
additive manufacturing (AM). Objects can be of almost any shape or geometry and typically
are produced using digital model data from a 3D model or another electronic data source such
as an Additive Manufacturing File (AMF) file (usually in sequential layers). There are many
different technologies, like stereolithography (STL) or fused deposit modeling (FDM). Thus,
unlike material removed from a stock in the conventional machining process, 3D printing or
AM builds a three-dimensional object from computer-aided design (CAD) model or AMF
file, usually by successively adding material layer by layer.The term "3D printing" originally
referred to a process that deposits a binder material onto a powder bed with inkjet printer
heads layer by layer. More recently, the term is being used in popular vernacular to
encompass a wider variety of additive manufacturing techniques.

1.1 HISTORY
The inception of 3D printing can be traced back to 1976,when the inkjet printer was
invented.In 1984 adaptation and advances on the inkjet concept morphed in the technology
from printing with ink to printing with materials. In 1984 charles hull,cofounder of 3D
systems,invents a method of printing process that enables a tangible 3d object to be created
from digital data.The technology is used to create a 3d model from a picture &allows users to
test a design before investing in a larger manufacturing program. The earliest 3D printing

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technologies first became visible in the late 1980’s, at which time they were called Rapid
Prototyping (RP)technologies. This is because the processes were originally conceived as a
fast and more cost-effective method for creating prototypes for product development within
industry. As an interesting aside, the very first patent application for RP technology was filed
by a Dr Kodama, in Japan, in May 1980. Unfortunately for Dr Kodama, the full patent
specification was subsequently not filed before the one year deadline after the application,
which is particularly disastrous considering that he was a patent lawyer! In real terms,
however, the origins of 3D printing can be traced back to 1986, when the first patent was
issued for stereolithography apparatus (SLA). This patent belonged to one Charles (Chuck)
Hull, who first invented his SLA machine in 1983. Hull went on to co-found 3D Systems
Corporation one of the largest and most prolific organizations operating in the 3D printing
sector today.

3D Systems’ first commercial RP system, the SLA-1, was introduced in 1987 and following
rigorous testing the first of these system was sold in 1988. As is fairly typical with new
technology, while SLA can claim to be the first past the starting post, it was not the only RP
technology in development at this time, for, in 1987, Carl Deckard, who was working at the
University of Texas, filed a patent in the US for the Selective Laser Sintering (SLS) RP
process. This patent was issued in 1989 and SLS was later licensed to DTM Inc, which was
later acquired by 3D Systems. 1989 was also the year that Scott Crump, a co-founder of
Stratasys Inc. filed a patent for Fused Deposition Modelling (FDM) — the proprietary
technology that is still held by the company today, but is also the process used by many of the
entry-level machines, based on the open source RepRap model, that are prolific today. The
FDM patent was issued to Stratasys in 1992. In Europe, 1989 also saw the formation of EOS
GmbH in Germany, founded by Hans Langer. . After a dalliance with SL processes, EOS’
R&D focus was placed heavily on thelaser sintering (LS) process, which has continued to go
from strength to strength. Today, the EOS systems are recognized around the world for their
quality output for industrial prototyping and production applications of 3D printing. EOS sold

‘Stereos’ system in 1990. The company’s direct metal laser sintering (DMLS) process
resulted from an initial project with a division of Electrolux Finland, which was later
acquired by EOS.Other 3D printing technologies and processes were also emerging during
these years, namely Ballistic Particle Manufacturing (BPM) originally patented by William
Masters, Laminated Object Manufacturing (LOM) originally patented by Michael Feygin,

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Solid Ground Curing (SGC) originally patented by Itzchak Pomerantz et al and ‘three
dimensional printing’ (3DP) originally patented by Emanuel Sachs et al. And so the early
nineties witnessed a growing number of competing companies in the RP market but only
three of the originals remain today 3D Systems, EOS and Stratasys. In 2007, the market saw
the first system under $10,000 from 3D Systems, but this never quite hit the mark that it was
supposed to. This was partly due to the system itself, but also other market influences. The
holy grail at that time was to get a 3D printer under $5000 this was seen by many industry
insiders, users and commentators as the key to opening up 3D printing technology to a much
wider audience. For much of that year, the arrival of the highly-anticipated Desktop Factory
which many predicted would be the fulfillment of that holy grail was heralded as the one to
watch. It came to nothing as the organization faltered in the run up to production. Desktop
Factory and its leader, Cathy Lewis, were acquired, along with the IP, by 3D Systems in 2008
and all but vanished. As it turned out though, 2007 was actually the year that did mark the
turning point for accessible 3D printing technology even though few realized it at the time
as the RepRap phenomenon took root. Dr Bowyer conceived the RepRap concept of an open
source, self-replicating 3D printer as early as 2004, and the seed was germinated in the
following years with some heavy slog from his team at Bath, most notably Vik Oliver and
Rhys Jones, who developed the concept through to working prototypes of a 3D printer using
the deposition process. 2007 was the year the shoots started to show through and this
embryonic, open source 3D printing movement started to gain visibility.

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1.2 TYPES OF PRINTING TECHNOLOGIES

There is a variety of printing technologies (processes) to create physical objects from digital
designs. The main differences between these processes are in the way layers are deposited to
create parts and in the materials that are used. Some methods melt or soften material to
produce the layers, while others cure liquid materials using different sophisticated
technologies. Each method has its own advantages and drawbacks. Here are some common
technologies:
1.2.1 Stereo lithography – (SLA): In this method position of a perforated platform just
below the surface of a vat of liquid photo curable polymer. A UV (Ultra Violate) laser beam then
traces the first slice of an object on the surface of this liquid, causing a very thin layer of
photopolymer to harden. The perforated platform is then lowered very slightly and another slice
is traced out and hardened by the laser. Another slice is then created, and then another, until a
complete object has been printed and can be removed from the vat of photopolymer, drained of
excess liquid, and cured.Figure 1.1 shows a process of steriolithography.

FIG 1.1 Steriolithography process

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1.2.2 Fused deposition modelling (FDM): Here a hot thermoplastic is extruded from
a Temperature-controlled print head to produce fairly robust objects to a high degree of
accuracy. Fig 1.2 shows Fused deposition modelling of 3D printing process.

FIG 1.2 Fused deposition modelling

1.2.3 Selective laser sintering (SLS): This builds objects by using a laser to
selectively use together successive layers of a cocktail of powdered wax, ceramic, metal,
nylon or one of a range of other materials. The fig 1.3 shows a process of selective laser
sintering.

FIG 1.3 Selective laser sintering

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1.2.4Multi-jet modelling (MJM): This again builds up objects from successive layers
of powder, with an inkjet-like print head used to spray on a binder solution that glues only the
required granules together. Fig 1.4 shows Multi jet modelling type of 3D printing processes.

FIG1.4 Multi jet modelling

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1.3 APPLICATIONS,ADVANTAGES & DISADVANTAGES

1.3.1Applications:

 It is used in architecture & construction to build beautiful & durable models for
conception & promotion of construction industry.
 In medical field it is used in making of education models,surgical guides & custom
prosthetics.
 In aeronautics and space it is used for building of parts for planes,drones & satellites.
 In optical field it is used for making of lens & wide variety of frames.
 In textile department new structures are designed by help of 3D printing.
 This process uses lesser energy and waste will be reduced to minimum so it is
environmental friendly.
 Food is one of fundamental ingredients of life which is at the base of the pyramid of
human needs. Bringing the food industry to the digital age is one of the essential
and revolutionary applications of 3D printing. Applying this technology enables fast
automated and repeatable processes, freedom in design, as well as allowing large
and easy variability of the cooking process which can be customized for each region
or individual. Using robotic layer based food printing systems allows the recipe of
the food to be digitized and saved in order to prepare very repeatable and high
quality dishes without any margin for operator error. Also, the shape and decoration
of the food can be individualized based on the customer or the occasion.
A company called Choc Edge is currently marketing "the world's first commercial 3D
chocolate printer", the Choc Creator. It uses a nozzle to dispense molten chocolate into any
pattern and shape. While the $3,500 price might be expensive

Shelter is another basic human necessity which can be an interesting application for 3D
printing. The building industry is one of the last remaining fields where human labor and
skills are the norm and mass manufacturing techniques and robots are considered science
fiction. Given that a large portion of world population is without permanent shelter or food, it
would be logical to think that these basic necessities should be top priority for robotized
manufacturing techniques yet both the construction and food industries remain labor
intensive. Conventional building methods are hazardous, time consuming, and expensive; 3D
printing of buildings can enable automated creation of variety of buildings quickly and

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efficiently.

 Dental industry has been using artificial material for dentures, orthodontics,
implants, crown, and bridges for many years. As these parts are custom made for
each person, the process is both time consuming and expensive. Direct and indirect
3D printing, namely printing the actual part or a mold, has been shown to be a
cheaper and faster alternative to conventional techniques.

FIG 1.4 Wax implant for indirect manufacturing

FIG 1.5CAD model of skull

1.3.2Advantages:
1.Time-to-Market : 3D printing allows ideas to develop faster. Being able to print a concept
on the same day it was designed shrinks a development process from what might have been
months to a number of days, helping companies stay one step ahead of the other.
2.Save Money : Prototyping injection mould tools and production runs are expensive
investments. The 3D printing process allows the creation of parts and/or tools through
additive manufacturing at rates much lower than traditional machining.
3.Mitigate Risk : Being able to verify a design before investing in an expensive moulding
tool is worth its weight in 3D printed plastic, and then some. It is far cheaper to 3D print a
test prototype than to redesign or alter an existing mould.

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4.Feedback : With a prototype, you can test the market by unveiling it at a tradeshow,
showing it to buyers or raising capital by pre-selling on Indigo or Kick-starter. Getting
buyer's response to the product before it actually goes into production is a valuable way to
verify the product has market potential.
5.Get the Feel : One thing you can't get a picture or virtual prototype on the computer screen
is the way something feels in your hand. If you want to ensure the ergonomics and fit of a
product are just right, you must actually hold it, use it and test it.
6.Personalize It : With standard mass-production, all parts come off the assembly line or out
of the mould the same. With 3D printing, one can personalize, customize a part to uniquely
fit their needs, which allows for custom fits in the medical industries and helps set people to
elaborate their idea in new world.
7.Build your Imagination : In the modern boom of digital art and design, the possibilities are
not only accelerating but limitless. One can now 3D prints almost everything they imagine
after drawing it up virtually or by other. In a relatively short time, an idea, concept, dream or
invention can go from a simple thought to a produced part.
8.Square Holes? No Problem : The limitations of standard machining have constrained
product design for years. With the improvements in AM, now the possibilities are endless.
Geometry that has been historically difficult to build; like holes that change direction,
unrealistic overhangs is now possible and actually simple to construct.
9.Fail Fast, Fail Cheap : 3D printing allows a product developer to make breakthroughs at
early stages that are relatively inexpensive leading to better products and less expensive dead-
ends.
1.3.3 Disadvantages
1.Intellectual property issues :
The ease with which replicas can be created using 3D technology raises issues over
intellectual property rights. The availability of blueprints online free of cost may change with
for-profit organizations wanting to generate profits from this new technology.
2.Limitations of size :
3D printing technology is currently limited by size constraints. Very large objects are still
not feasible when built using 3D printers.
3.Limitations of raw material:
At present, 3D printers can work with approximately 100 different raw materials. This is
insignificant when compared with the enormous range of raw materials used in traditional

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manufacturing. More research is required to devise methods to enable 3D printed products to

be more durable and robust.
4.Cost of printers :
The cost of buying a 3D printer still does not make its purchase by the average householder
feasible. Also, different 3D printers are required in order to print different types of objects.
Also, printers that can manufacture in colour are costlier than those that print monochrome
objects.
5.Fewer Manufacturing Jobs:
As with all new technologies, manufacturing jobs will decrease. This disadvantage can have
a large impact to the economies of third world countries especially China, that depend on a
large number of low skill jobs.
6.Unchecked production of danger items:
Liberator, the world’s first 3D printed functional gun, showed how easy it was to produce
one’s own weapons, provided one had access to the design and a 3D printer. Governments
will need to devise ways and means to check this dangerous tendency.

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CHAPTER 2
LITERATURE SURVEY

2.1 Literature review

Kaufui V Wong [1]: In has investigated about steriolithography process in his journal
ISRN Mechanical Engineering 2012, 2012 Additive manufacturing processes take the
information from a computer-aided design (CAD) file that is later converted to a
stereolithography (STL) file. In this process, the drawing made in the CAD software is
approximated by triangles and sliced containing the information of each layer that is going to
be printed. There is a discussion of the relevant additive manufacturing processes and their
applications. The aerospace industry employs them because of the possibility of
manufacturing lighter structures to reduce weight. Additive manufacturing is transforming
the practice of medicine and making work easier for architects. In 2004, the Society of
Manufacturing Engineers did a classification of the various technologies and there are at least
four additional significant technologies in 2012. Studies are reviewed which were about
strength of products made in.

Julie Marcoux & Kenneth-Roy Bonin[2] : They have found that Advancement in some of
the next great emerging technology to enjoy overwhelming market penetration, three
dimensional (3D) printing could have significant information implications, notwithstanding
limited coverage in the information science literature. This review of complementary material
from other sources provides the introductory definitions, technical descriptions and
indications of future developments relevant to information professionals.

Izabela Hager, Anna Golonka, Roman Putanowicz[3]: They have presented a paper on 3D
printing machines.The paper presents the state-of-the-art concerning the current achievements
in the field of 3D printing of buildings and building components. The 3D printing
technologies, comparing to traditional techniques of constructing the buildings, could be
considered as environmental friendly derivative giving almost unlimited possibilities for
geometric complexity realizations. Two kinds of technologies were described in this paper
with pointing to Contour Crafting as a promising technique that may be able to revolutionize
construction industry in near future. Numerous advantages of this technology, such as
reduction of the costs and time, minimizing the pollution of environment and decrease of

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injuries and fatalities on construction sites could be cited. Despite many advantages and
hopes, some concerns are summarized in the conclusions, as the technology still has many
limitations. A brief description of few examples of pioneering usage of 3D printing in
construction industry are presented (Canal House in Amsterdam, WinSun company and
printing application for building carried out by Skanska company). Creating a model that will
be appropriate for 3D printers is possible in many different modelling programs. One of the
most popular formats for sharing such models is STL format. In the paper sample models
crated in Autodesk Inventor are shown, but also other tools suitable for preparing models for
3D printing are briefly discussed.

Verfasser des Aufsatzes: Gebhardt, Andreas; Fateri, Miranda[4]: An increasing amount

of popular articles focus on making models and sculptures by 3D Printing thus making more
and more even private users aware of this technology.Unfortunately they mostly draw an
incomplete picture of how our daily life will be influenced by this new technology. Often this
is caused by a very technical point of view based on not very representative examples.This
article focuses on the peoples needs as they have been structured by the so-called Maslow
pyramid. Doing so, it underlines that 3D Printing (called Additive Manufacturing or Rapid
Prototyping as well) already touches all aspects of life and is about to revolutionize most of
them.

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2.2 Objectives

The objective of the project are as follows:

 To prepare a prototype of Fused deposition type 3d printing machine.

 To design different models in Fusion 360 software.

 Models are being produced using poly lactic acid(PLA) filament.

2.3 Methodology
 Work volume of the machine is 210*110*110 (in mm).

 For the heating purpose we are using extruder whose nozzle diameter 0.4mm.Nozzle
flow rate 24cc/hour,cooling fan of 40*40*10mm,Heating voltages of 12volts.

 We are using Poly lactic acid (PLA) filament of 1.75mm diameter .whose best print
temperatures is 210º c.

 For the X,Y & Z axes we are using Arduino software which requires Arduino mega
2560 whose input voltage is 7-12 volts,limit voltage 6-20volts,Flashmemory 260 kb
& clock speed of 16MHz.

 We are using pronterface software which is a graphical interface for the host software
supplied with our 3d printer.

 We are using Fusion 360 software to deign our own models in .stl format.

 3 stepper motors required whose step angle is 1.8 degree ,Holding torque is 5.5Kgcm.

 To control the temperature of hot end so that the filament gets melted properly.

 To inspect the proper deposition of molten filament equally in all 3 directions.

 To upload the designs of models and produce them from the same 3D printing
machine.

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2.4 FLOWCHART FOR WORKING OF 3D PRINTING MACHINE

FIG 2.1 Flowchart fir working of 3D printing machine

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CHAPTER 3

PARTS OF 3D PRINTING MACHINE

A 3D printer includes a set of components that operate simultaneously to produce the desired output
from the input digital file, the basic components of a 3D printer are listed below.

3.1 Print Bed (Tray)

This is the flat surface where the 3D models are layered during printing. The print bed may
be ambient or heated Depending on the filament types used in the printer. Heated print beds
are used to keep the printed section of the print warm during the layering process to prevent
warping. The figure 3.1 shows a print bed we are using in 3D printing machine.

FIG 3.1 Print bed

3.2 Extruder:
The extruder is the part that thrusts out and feeds the plastic filament (or any other filament)
into the ‘hot-end’. Extruders are typically incorporated into the hot-end, however in some
types it can be remote, pushing the filament through a tube, called a Bowden cable, into the
hot-end. In some types a dual extruder is used, which provides the ability to print two
different materials at the same time. This added feature result in increased price, as it requires
an extra extruder, and hot end. The figure 3.2 shows the extruder.

FIG 3.2 Extruder

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3.3 Hot-end:
The hot-end is composed of a heat source, a temperature sensor, and an extrusion tip where
plastic filament is fed though to deposit molten material, it is often confused with the
extruder. The hole in the slot may range in size, typically between 0.2mm and 0.8mm. The
smaller the nozzle, the more detailed the print, but the longer it takes for the thinner layers to
stack up. Fig 3.3 shows various types of extruders used in 3d printing machine. Fig 3.4 shows
a extruder we used for FDM type of 3d printer.

Fig 3.3 Various types of extruders

Fig 3.4 Hot end

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Important feature in a hot end:

 Maximum printing temperature
 Nozzle size and options to change it
 Active cooling
PEEK Based Hot Ends – max temperature 230°C.
While the old hot ends (PEEK based) were able to print only with one or two materials, the
new ones today can be used with variety of thermoplastics. PEEK based hot ends used to jam
a lot if not maintained properly and the maximum temperature limit was about 230°C.
All Metal Hot Ends – max temperature 320°C
 Prints with all materials available – While some great materials extrude at 230°C
or less, the most strong and durable materials for 3D printing (like Nylon, PET and
Polycarbonate) extrude at temperature above 240°C.
 Cleaner prints – The Hexagon all metal hot end has active cooling in order to isolate
the melt zone. A smaller melt zone means more control. Therefore cleaner retraction
and less oozing that results in overall better print quality.
 Easy to maintain (almost jam free) – Fewer parts and smaller size make it almost jam
free and easier to clean. Thus the focus is on printing, not on repairing. Very little
maintenance is required – mainly when changing between different kinds of filament.

3.4Filament
The filament is the input material whicj is formulated as a 3d solid object by the printer. Like
an inkjet ink ,a 3d printer emits melted filament. PLA is currently the most environmentally
friendly material used in desktop FDM 3D printing. It is made from renewable sources of
plant starch. The material is used in food packaging, bags, disposable tableware, feminine
hygiene products, and even in diapers. It doesn’t require a heated bed and is non-toxic. In
addition, for beginners PLA is considered as the easiest material to print with and it’s
available in almost any color. You can get a high definition prints, but they will not be as
strong or as durable as ABS products. Fig 3.4 shows Filament of PLA type.

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FIG 3.5 Filament

TABLE 3.1
PROPERTIES OF POLY LACTIC ACID AND ACRYLO NITRILE BUTADIENE

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3.5 Nozzle

The Nozzle is the tip of the Hot End where the plastics comes out. It needs to be
exchangeable when needed. The nozzle size is really important. It usually varies from
0.25mm to 0.75mm. The most common size is 0.5mm. The best practice is to change the
nozzle sizes depending on your design and desired results. Fig 3.5 shows various types of
diameters of nozzles used.

FIG 3.6 Nozzle

3.5.1Smaller Nozzle Size:

 Smoother finish – smaller nozzle means thinner lines extruded and smaller layer height
that will result in a smoother and better looking part overall.
 More ridge parts – Theoretically more and thiner lines resulting in more layers will
make them bond stronger than a bigger nozzle, which produces fewer layers. Practically
that is not always the case.
 More accurate prints – in general accuracy will depend mainly on your 3D printer
calibration and the settings of your slicing software. But with a smaller nozzle size you
should be able to get closer to the perfect dimensions of your model.
 More detailed prints – in case your design has a lot of small features, and you’d like to
put an accent on them, you will definitely want to downgrade the size of the nozzle.

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3.5.2Bigger Nozzle Size:

 Faster printing – bigger nozzle will result in thicker strings and will reduce the number
of layers. Therefore the 3D printer will make less movements and 3D printing time will
decrease dramatically.
 Better first layer adhesion – because of the thicker strings (bigger extrusion width) there
is more surface area for the plastic to stick to the bed for the rest layer.
 Less supports (in some cases) – Bigger nozzles can handle overhangs better than smaller
nozzle sizes because the ratio between the layer height and the extrusion width is greater.
But this will depend on your layer height, where the previous layer has greater surface
area to support the next layer.
 Better reliability – Theoretically there should be no difference, but practically there is!
Bigger nozzle means faster 3D printing and more room for error, thus the success rate is
higher. For example the filaments diameter has some variations and with a smaller nozzle
this could cause a over-extrusion that will cause a jamming problem or under-extrusion
that will weaken the bond between layers which is extremely important for parts where
structural integrity is our main priority.

3.6 Guide Rods

 Here we use 8mm chromium rod in Y directionfor the movement of extruder &
10mm chromium rod in Z axis for the movement of printbed .These rods are
supported by the bearings for the operation .
 Guide rods are also known as Chrome Rods(as they are made up of chromium) look
very attractive and serve heavy duty purposes.
 They are designed with the finest and advanced techniques of surface removal,
polishing, hard chrome plating etc.
 As they are made up of preprocessed materials and goes under extensive inspection,
you can save processing, time, money by purchasing them.
 Provides key performance benefits such as high load capacities, high speeds, and
design compatibility. They are well suited for long travel applications, minimizing
vibration and providing smooth and quiet travel over joined shafts

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FIG 3.7 Guide rods

TABLE 3.2 GUIDE RODS SPECIFICATIONS

TYPE SIZE QUANTITY
D10 460 2
D8 330 4

3.7 Lead screw

A lead screw also known as a power screw or translation screw, is a screw used as a
linkage in a machine, to translate turning motion into linear motion. Because of the
large area of sliding contact between their male and female members, screw threads
have larger frictional energy losses compared to other linkages. They are not typically
used to carry high power, but more for intermittent use in low power actuator and
positioner mechanisms.

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FIG 3.8 Lead screw

TABLE 3.3 SCREW ROD SPECIFICATION

TYPE SIZE QUANTITY
M8 300 2

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3.8Arduino mega 2560

The Arduino Mega 2560 is a microcontroller board based on the ATmega2560 (datasheet).
It has 54 digital input/output pins (of which 14 can be used as PWM outputs), 16 analog
inputs, 4 UARTs (hardware serial ports), a 16 MHz crystal oscillator, a USB connection, a
power jack, an ICSP header, and a reset button. It contains everything needed to support
the microcontroller; simply connect it to a computer with a USB cable or power it with a
AC-to-DC adapter or battery to get started. The Mega is compatible with most shields
designed for the Arduino Duemilanove or Diecimila.

FIG 3.9 Arduino mega 2560

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Specifications :
Input Voltage (recommended) 7-12V
Input Voltage (limits) 6-20V
Digital I/O Pins 54 (of which 14 provide PWM output)
Analog Input Pins 16
DC Current per I/O Pin 40 mA
DC Current for 3.3V Pin 50 mA
Flash Memory 256 KB of which 8 KB used by bootloader
SRAM 8 KB
EEPROM 4 KB
Clock Speed 16 MHz

FIG 3.10 Parts of Arduino mega 2560

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3.9 Ramps 1.4 shield

FIG 3.11 Ramps 1.4 shield

RepRap Arduino Mega Pololu Shield, known affectionately as RAMPS, is the brain for most
of the 3D printers. It is designed to fit the entire electronics needed for a RepRap in one small
package for low cost.

RAMPS interfaces an Arduino Mega with the powerful Arduino MEGA platform and has
plenty room for expansion. The modular design includes plug in stepper drivers and extruder
control electronics on a single Arduino MEGA shield. It uses Pololu Stepper Drivers
delivering up to 1/16 microstepping. Four drivers are needed to move most 3D printers, with
3 going to the axis & one driving the extruder. An optional fifth stepper driver socket has
been provided for additional applications.The board has 3 high power switched (By
MOSFETS) outputs fused to 5 A and 11 A outputs for printbed and extruder.

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The RAMPS board electronics package has following features:

Upto 5 stepper motor driver outputs
3 PWM controlled MOSFET powered outputs
Heated bed control and extruder control pins with 11A fuse
6 sets of Digital Pins in headers with VCC and GND for endstops
Extra pins broke out : PWM, digital, serial, SPI, I2C and analog

3.10 Bearings

Linear ball bearings are pretty sensitive to misalignment which iswhy most carriages only
use two bearings instead of three. Ifyou mount two bearings in a way where they are not
aligned or have no way of aligning themselves,one of the bearings will inevitably run noisier
or even jam. So either use precise mounts or provide a way for the bearings to align, for
example by using only 1zip tie per bearing
Comman linear guide design parameters include load capacity ,
accuracy,rigidity,smoothness of travel,speed & acceleration .They also include
sise,Environment and required thrust,lubrication ,temperature consideration ,and handling
precautions.
Each linear roller or ball bearing guide has unique specifications for velocity, acceleration,
tolerance, preload,and temperature range. These tools help determine static and dynamic load
moment capacities.
Catalogs and websites also includes graphs and equitation for determing bearing travel life
from the dynamic load rating and user specified operating parameter.
SC10UU
SC10UU Shaft ID:10mm Aluminum ball bearing box sliding unit with sealed ball bearings,
easy to install by bolt on a working platform, and to move through the design of compact
Aluminum, SBR, TBR series linear guide side rail alternatives, low cost, for linear motion
precision is not very high occasions. Ball in the cage loop to run a smooth ball guide surface
to ensure even if high-speed operation, low noise.
SK08
These shaft supports are used for mounting ground shafts. These are often used in the more
simpel CNC machine, or other automation applications. This type of shaft and shaft support
is not made for heavy loading. If you need heavy loading or high rigidity, we advise to use
HIWIN guides. The nice thing about this low cost shaft support and the shafts them self is

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that they are less critical in alignment than HIWIN or other linear guides. This is because
they are more flexible.

SC10UU Bearings SK08

FIG 3.12 Linear bearing

TABLE 3.4 BEARING SPECIFICATIONS

TYPE DIAMETER QUANTITY
SC10UU 10 4
SK08 8 8

3.11 Stepper motor :

A stepper motor or step motor or stepping motor is a brushless DC electric motor that
divides a full rotation into a number of equal steps. The motor's position can then be
commanded to move and hold at one of these steps without any position
sensor for feedback (an open-loop controller), as long as the motor is carefully sized
to the application in respect to torque and speed.

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FIG 3.13 Stepper motors

A stepper motor or step motor or stepping motor is a brushless DC electric motor that divides
a full rotation into a number of equal steps. The motor's position can then be commanded to
move and hold at one of these steps without any position sensor for feedback (an open-loop
controller), as long as the motor is carefully sized to the application in respect to torque and
speed.

 Full-step drive (two phases on)

This is the usual method for full-step driving the motor. Two phases are
always on so the motor will provide its maximum rated torque. As soon as one phase is
turned off, another one is turned on. Wave drive and single phase full step are both one and
the same, with same number of steps but difference in torque.

 Half-stepping

When half-stepping, the drive alternates between two phases on and a single
phase on. This increases the angular resolution. The motor also has less torque (approx 70%)
at the full-step position (where only a single phase is on). This may be mitigated by
increasing the current in the active winding to compensate. The advantage of half stepping is
that the drive electronics need not change to support it. In animated figure shown above, if we
change it to half-stepping, then it will take 8 steps to rotate by 1 teeth position. So there will
be 25×8 = 200 steps per full rotation and each step will be 360/200 = 1.8°. Its angle per step
is half of the full step.

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 Microstepping

Microstepping is often sine–cosine microstepping in which the winding

current approximates a sinusoidal AC waveform. Sine–cosine microstepping is the most
common form, but other waveforms can be used. Regardless of the waveform used, as the
microsteps become smaller, motor operation becomes more smooth, thereby greatly reducing
resonance in any parts the motor may be connected to, as well as the motor itself. Resolution
will be limited by the mechanical stiction, backlash, and other sources of error between the
motor and the end device. Gear reducers may be used to increase resolution of positioning.

Step size repeatability is an important step motor feature and a fundamental reason for their
use in positioning.

FEATURES OF NEMA 17 STEPPER MOTOR

4 Step angle:1.8 degree

5 Configuration: 4 Wire bipolar stepper motor

6 Holding torque: 5.5 kgcm bipolar mode

7 Current /phase: 1.68A

8 Rated voltage: 2.8v

9 Inductance /phase: 2.8mH

10 Resistance/Phase :1.65 ohm

11 Rotor inertia:: 68gcm2

12 Length : 48mm

13 Weight :360 grams

3.12 Pulley and Timing belts

A toothed belt ,Timing belt is a flexible beltwith teeth moulded onto it inner surfaces .It is
designed to run over matching toothed pulleys or sprockets. Toothe belts are used in a wide
array of in mechanical devices ,where high power transmission is desired.
When this timing pulley is correctly tensioned,These type of belts have no slippage,

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and are often used to transfer motion for indexing for timing purposes.So there is less noise
and lubrication bath is not necessary.

FIG 3.14Pulley and timing belts

3.13 Flexible aluminium copper

A coupling is a device used to connect two shafts together at their ends for the purpose of
transmitting power. Cou1plings do not normally allow disconnection of shafts during
operation, however there are torque limiting couplings which can slip or disconnect when
some torque limit is exceeded.

The primary purpose of couplings is to join two pieces of rotating equipment while
permitting some degree of misalignment or end movement or both. By careful selection,
installation and maintenance of couplings, substantial savings can be made in reduced
maintenance costs and downtime.

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FIG 3.15 Couplers

3.14 SMPS (SWITCHED MODE POWER SUPPLY)

Is an electronic power supply that incorporates a switching regulator to convert electrical
power efficiently.an SMPS transfers power from a DC or AC source to DC load,such as
personal computer.Linear power supply regulates output voltages by continuly dissipating the
power in the pass transistoa.This higher power conversion efficiency is an important
advantages of SMPS.

A High quality 12V 10A Industrial power supply with Aluminium casing. Best suitable for
Industrial Machines Applications
Features:
 High efficiency, long life, and high reliability
 Low dc ripple, high efficiency
 low operation temperature & long performance life
 Excellent insulation property, high dielectric strength
 100% full-load burning test
 Dimension: 200*95*45

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FIG 3.16 SMPS(Switched mode power supply)

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CHAPTER 4

FABRICATION AND ASSEMBLY

4.1Fabricated parts

4.1.1Extruder holder : Fig 4.1 shows Extruder holder we have used .it is made up of
acrylic material.Used for holding the extruder

FIG 4.1 Extruder holder

4.1.2 Side plates: Fig 4.2 Shows side plates of our machine which is used for holding the
Front plates

FIG 4.2 Side plate

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4.1.3 Bearing plate: It is made up of acrylic .It is used for holding the bearings
in Y direction.

FIG 4.3 Bearing plate

4.1.4 Screw& Chromium rods holder: The holes present in this plates are used to
hold the screw & chromium rods

FIG 4.4 Screw & Chromium rods holder

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4.1.5 Front plate: This shows front face of 3D printer.which holds the side plates &
Bearing plates. Fig4.5 shows Front plate .

FIG 4.5 Front plate

4.1.6 Main body of 3d printer: The figure 4.6 shows the main body of 3D printer

FIG 4.6 Main body OF 3D printer

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4.1 Specifications of 3D printer

Serial No. Components/Parts Specifications

1 Print Bed Power Input:12V or 24V
Dimensions: 214mm*214mm
Resistance: 1 & 1.2ohm
2 Filament PLA(Polylactic Acid)
Diameter:1.75mm
3 Nozzle Diameter:0.4mm
4 Extruder Nozzle Flow Rate:24cc/hr
Thermistor NTC 100K B=3950
Cartiridge Heater Voltage: 12V
Cooling Fan-Dimensions:40*40*10mm
Operating Voltage :12V
5 Ramps 1.4 Shield Upto 5 stepper motor driver outputs
3 PWM controlled MOSFET powered outputs
6 sets of Digital Pins
6 SMPS Power Supply: 12V ,10A
Dimensions: 200*95*45mm
7 Arduino mega 2560 Datasheet: ATmega2560
Digital I/O Pins :54(of which 14 provide PWM
output)
Clock Speed:16 MHz
8 Stepper Motor(NEMA Step Angle :1.8 degree
17) Holding Torque :5.5 kgcm bipolar mode
Curreent :1.68 A
Rated Voltage:2.8 V
Length:48mm
Weight:360 grams
9 Guide Rods Material:Chromium
Diameter:10 mm(of length 460 mm)
8 mm(of length 330mm)
10 Lead Screw Material:Stainless Steel & Brass
Diameter:8 mm(of length 300mm)
11 Bearings SC10UU Shaft ID:10mm
SK08 Shaft ID:8mm
12 Timing Belt Thickness :2mm
13 Coupler Material:Aluminium
Weight:0.05kg
14 Body Part Acrylic

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CHAPTER 5

EXPERIMENTATION

 We are using Acrylic sheets to make the body of 3d printing machine.

 Machining of acrylic has been done by laser cutting machine .
 Filament, Extruder,Hot End,Print bed Stepper motors,and Electronic devices like
Arduino ,RAMPS shield,Endstops, ,power supply can be ordered online.
 Assemblying of all the mechanical & electronic parts.
 Softwares like Marlin are used for controlling the speed and movement of nozzle,
and FUSION 360 are used for designing the part model..
 The movement of extruder,printbed in X & Z directions is completed and y movement
Y axis movement also possible

FIG 5.1 Complete assembly of 3d printer

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Development of models using FUSION 360 software

Fig 5.2 operation of FUSION 360 Software

Controlling the 3D printer operation through PRONTERFACE software

Fig 5.3 Operation of PRONTERFACE software

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5.1 Models created using 3D printing machine & their

Pronterface operation

Fig 5.5 Pronterface operation Hexagonal nut

Fig 5.6 Pronterface operation Rectangular plate

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Fig 5.7 Pronterface operation Cone

Fig 5.8 Pronterface operation Circular ring

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CHAPTER 6

CONCLUSION

3D Printing technology could revolutionize and re-shape the world. Advances in 3D printing
technology can significantly change and improve the way we manufacture products and
produce goods worldwide.
We are concluding that we have created the models using the 3D
printer with PLA as afilament and the models which are created by 3D printer are having a
very high strength and by the use of sand paper we have improved the surface finish of the
models. We have satisfactorily completed the project of fused deposition type of 3D printer.
The movementin X,Y, & Z axis is successfully provided with the help of pulley belt
mechanisms. The special electronic component we used here is that ramps shield . With help
of this component we have controlled the temperature of filament. Acrylic has provided very
good stiffness for the machine. Any type of components can be prepared within the work
volume.

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SCOPE FOR FUTURE:

 We can improve the accuracy by reducing the size of nozzle diameter.
 Even we can use other filaments like Acrylonitrile butadiene styrene (ABS) for the
same machine.
 We can use limit switches to stop the extruder from getting back to home position
without any requirements.
 It is possible to use 2 extruders in the same axis so that we can create two models at
a time.
 It is possible to introduce LCD screen so that we can control the operation
automatically.

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REFERENCES

1 . Kaufui V. Wong and Aldo Hernandez (2012), A Review of Additive

Manufacturing, International Scholarly Research Network, pp 1–10.
2 Julie Marcoux Bibliothèque Champlain Université de MonctonMoncton, Canada
Julie.Marcous@umcton.ca. Kenneth-Roy BoninSchool of Information Studies
University of OttawaOttawa, Canada Kenneth-Roy.Bonin@uottawa.ca.
3 Izabela Hager*, Anna Golonka, Roman PutanowiczCracow University of Technology,
International Conference on Ecology and new Building materials and products.
4 Verfasser des Aufsatzes: Gebhardt, Andreas; Fateri, Miranda: Fachhochschule
Aachen University, Aachen, Germany 2013 Andreas Gebhardt; Lizenznehmer
RTejournal, weitere Informationen sind zu finden unter:
5 C. Inacu, D. Inancu, and A.Stanciou, “From CAD Model to 3D Print Via 'STL' File
Format,” Fiabilite si Durabilite = Fiability & Durability, vol.1, 2010, pp. 73-80.
6 G. Lacey, “3d Printing Brings Designs to Life,” Technology Education, 2010, pp.
17-19.
7 H. Lipson and M. Kurman, Factory at Home: The Emerging Economy of Personal
Manufacturing. Washington: U.S. Office of Science and Technology, 2010, n.p.
8 E. Malone and H. Lipson, “The Factory in Your Kitchen,” 2007 World Conference
on Mass Customization & Personalization (MCPC), Cambridge, MA: MCPC
2007. Retrieved from

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