PROJECT REPORT

on

DESIGN AND ANALYSN OF A 3D PRINTER

Submitted as partial fulfillment for the award
of

.BACHELOR OF TECHNOLOGY DEGREE

Session 2020-21

in

MECHANICAL ENGINEERING
by

SYED FOZAIL AHMAD (1703240141\

VIKAS YADAV (1703240155)
SURYANSH MTSHRA (17 03240140)
TUSTTAR RAJPUT (17 0324014s)

UNDER THE GUIDANCE OF

MR. ARUN PRATAP SINGH
(ASST. PROFFESOR)

ABES ENGTNEERTNG COLLEGE (032)

DR. ApJ ABDUL KALAM TECHNTCAL ffrUuR$-irV, LUCKNOW

 PROJECT REPORT
on
DESIGN AND ANALYSIS OF A 3D PRINTER
Submitted as partial fulfillment for the award
of

BACHELOR OF TECHNOLOGY DEGREE

Session 2020-21

in

MECHANICAL ENGINEERING
by

SYED FOZAIL AHMAD (1703240141)

VIKAS YADAV (1703240155)
SURYANSH MISHRA (1703240140)
TUSHAR RAJPUT (1703240145)

UNDER THE GUIDANCE OF

MR. ARUN PRATAP SINGH
(ASST. PROFFESOR)

ABES ENGINEERING COLLEGE (032)

AFFILIATED TO
DR. APJ ABDUL KALAM TECHNICAL UNIVERSITY, LUCKNOW
 ACKNOWLEDGEMENT
It gives us pleasure to submit our final year project report to the Department of Mechanical

Engineering, ABES Engineering College (032), Ghaziabad.

Our management deserves special thanks for their support and encouragement.
We would like to thank Dr. Rajendra Shukla, HOD, ABES Engineering College, for allowing
us to work on this project.
We express our gratitude to Prof. Arun Pratap Singh, Assistant Professor, Department of
Mechanical Engineering, for his unwavering support, insightful recommendations, and
direction by sharing his vast knowledge, all of which contributed to the project's successful
completion. Professors Dharmendra and Anuj Kr. Jain, Department of Mechanical
Engineering, are also to be thanked.
We owe him a great debt of gratitude for sharing his knowledge and providing us with
helpful advice and encouragement.
Our parents owe us the greatest debt of our lives for giving us with a decent education and
instilling in us good ideals in life.
Finally, we want to express our gratitude to everyone of the teaching and nonteaching staff at
ABES Engineering College's Department of Mechanical Engineering for their support and co
operation.

With due regards

Syed Fozail Ahmad
Vikas Yadav
Suryansh Mishra
Tushar Rajput

I
 ABSTRACT
3D printing, also known as additive manufacturing, is a process that involves depositing
material layer by layer to build an object. To begin 3D printing, we must first generate a 3D
model in CAD software. The model is then sliced or split into layers, which is called slicing.
Then, layer by layer, material is deposited to construct the model you require. Fused Deposition
Modelling (FDM), stereo-lithography (SL), Laser sintering (LS), high speed sintering (HSS),
and other 3D printing processes are available. After conducting a literature review, we decided
to use the FDM method for 3D printing and ABS as the printing filament.

In the designing part of the paper, we created the 3D Model of the various parts of 3D Printer
like Extruder, Printing Bed, Controller Board, Stepper Motors (NEMA 17 & NEMA 23)
and other parts in SolidWorks 2018 and assembled them to create a 3D Printer Model, then we
had done the thermal analysis on the Nozzle of the 3D Printer from where the filament is
extruded and the Future Scope of 3D Printing Technology is also discussed in this paper.

II
ACRONYMS
AM-Additive Manufacturing

FDM- Fused Deposition Modelling

SL- Stereolithography

LS- Laser Sintering

HSS- High Speed Sintering

CAD-Computer Added Graphics

STL- Standard Triangle Language

ABS- Acrylonitrile-butadiene styrene

PLA- Polylactic Acid

PETG- Polyethylene Terephthalate Glycol

III
LIST OF TABLES

Table Title Page No.

No.
Table.1 Showing the material properties of Brass 19
Table.2 Material properties of Acrylonitrile 20
Butadiene Styrene (ABS)

IV
LIST OF FIGURES

Fig. No. Title Page No.

Fig.1.1 3D Printing Applications 5

Fig.1.2 Two limited edition shoe models with 3D 5
printed midsoles designed by New Balance

Fig.1.3 Human Jaw prototype 6

Fig.1.4 3D printed spectacle 6
Fig.3.1 3D printer assembly in SolidWorks 10
Fig.3.2 Extruder Assembly 12
Fig.3.3 Exploded view of Extruder 13
Fig.3.4 Print Bed 13
Fig.3.5 Power Supply Unit (PSU) with controller 14
box
Fig.3.6 Polylactic acid 15
Fig.3.7 Acrylonitrile Butadiene Styrene 15
Fig.3.8 PGTG 16
Fig.3.9 NEMA-17 (SolidWorks) 17
Fig.3.10 Base Frame 18
Fig.3.11 CAD assembly of 3D printer 19
Fig.3.12 Analysis on Nozzle 20
Fig.4.1 Graph 21

V
CONTENTS
Sl. No. Title Page
No.
Acknowledgement
Abstract
Acronyms
List of Tables
List of Figures

CHAPTER-1 INTRODUCTION 1-6

1.1. 3D PRINTER
1.2. HISTORY OF 3D PRINTING

1.3 PRINCIPLE OF 3D PRINTING

1.4 APPLICATION OF 3D PRINTER

CHAPTER-2 LITERATURE REVIEW 7-9

CHAPTER-3 DESIGN OF 3D PRINTER AND THERMAL 10-20

ANALYSIS OF NOZZLE

3.1. PROCESS OF 3D PRINTING

3.2. DIFFERENT PARTS OF A 3D PRINTER
a. Extrude
b. Printing Bed
c. Controller Board
d. 3D printer filament
e. Stepper Motors (NEMA-17 & NEMA 23)
f. Base Frame
g. Motion Components
h. Threaded Rods
i. End Stops

VI
 3.3. CAD MODELS OF DIFFERENT PARTS OF A 3D
PRINTER
3.4. THERMAL ANALYSIS OF THE NOZZLE TIP OF
EXTRUDER ASSEMBLY
CHAPTER-4 RESULT & CONCLUSION 21
CHAPTER-5 FUTURE SCOPE 22-23
REFERENCE 24

VII
CHAPTER 1
INTRODUCTION
1.1 3D PRINTER
A 3D printer uses many layers of material to create 3D objects and parts i.e., additive
manufacturing. Rapid prototyping is another name for it. It is a mechanised process in which
3D things are swiftly created according to the needed size using a machine connected to a
computer that has blueprints for any object.

Additive manufacturing techniques comprises of Fused Deposition Modelling (FDM),

stereolithography (SL), Laser sintering (LS), high speed sintering (HSS) etc. 3D printing is
called as desktop fabrication. It is a rapid prototyping process whereby a real object can be
created from a 3D design. 3D printing, also known as additive manufacturing, is a technology
that will usher us away from the mass production lines of Henry Ford's age and into a new era
of customised, one-off manufacturing. For fast prototyping, a 3D printing machine makes use
of a CAD model.

In recent years, there has been a steady stream of news about 3D printing.
Scientists, for example, utilise 3D printers to create automobiles. Human skeletons are
printed using a 3D printer by doctors. Someone is printing living houses with a 3D printer.
The US has also launched a 3D printer to the International Space Station in space, according
to reports.The growth and importance of 3D printers are well beyond anyone's wildest
dreams.
In a 2012 article headlined "third industrial revolution," published in the British "Economist"
magazine, 3D printing technology was cited as the foundation of the third industrial revolution.
The author of this paper believes that social manufacturing, which is based on 3D printers, w
ould subvert the manufacturing process of modern industries.
The 3D printing business is expected to grow rapidly, and 3D printing will have a significant
impact on people's lives in the future.
When we design something in our CAD system, we convert it to a three
dimensional model, and then utilise the additive manufacturing (AM) method to recreate it as
a real life 3D object by depositing layer by
layer of material until the object is constructed. Subtractive processes are in which material

(usually metal) is removed from a crudely shaped initial part (perhaps a bar or slab, or a

1
forging ,casting with a more complex shape)to achieve the final shape and dimensions, where
as Additive Manufacturing is the technical name for the process popularly known as 3D Print
ing. Subtractive manufacturing creates parts by removing material layer by layer, whereas
additive manufacturing creates objects by adding material layer by layer.

The subtractive method, in which material is removed from a block by sculpting or drilling,
may differ from the additive method.
The primary objective for using a 3D printer is to maximise resource consumption, extend pr
oduct life, and make products lighter and stronger.
3D printing is widely used in a variety of industries, including aerospace, automotive,
medical, construction, and the manufacture of a wide range of consumer goods.

1.2 HISTORY

The 3D printing innovation is not a new concept many people think but it is not. When the
licences for FDM (fused deposition modelling) expired in 2009, 3D printing became a new
innovation area. Furthermore, as a result of the fact that it became more mainstream, people
believed that FDM was merely a single additional substance-producing system. Regardless,
the first 3D printing process was SLA, not FDM, and the first patent was filed in the 1980s.
From 1980 to the present, here is a timeline of 3D printing advancement.
Three primary 3D printing systems were introduced in the 1980s. Dr. Kodana was the first to
demonstrate a layer-by-layer technique to assembling, and he was also the first to develop a
quick prototyping strategy. He also created a progenitor for SLA. He attempted to polymerize
a photosensitive gum with UV light but was unsuccessful. Surprisingly, Dr. Kodana failed to
record the full patent details before the application's one-year deadline. The origins of 3D
printing technology can be traced back to 1983.
Charles Hull was the first person to patent stereo-lithography in 1983. In a patent application
titled "Contraption for creating 3 dimensional questions by stereo lithography" filed on August
8, 1984, Frame used the term stereo-lithography. In addition, he was the primary designer of
the SLA-1 (stereo-lithography) machine in 1987.
3D System Corporation was founded by Charles Hull (one of the biggest and more propel
association working in 3d printer division today). Stereolithography, according to Hull, is a
unique technology for printing consecutive layers of ultraviolet curable material on top of each
other to create solid objects. A focused light emission light is centred around the surface filled

2
with a fluid photopolymer in Frame's patent, he clarifies. Each layer of the model is drawn on
the liquid's surface by a computer-controlled light ray. The photopolymer polymerizes and
solidifies wherever intense light strikes the surface. Using the software CAD/CAM
mathematically slices (converts into layers) the models. then the process builds the models
layer by layer.
Other 3D printing innovations and technologies were introduced in the 1990s. In addition, new
3D printer makers and CAD tools are being introduced. 3D Systems sells their first
stereolithography (SLA) equipment commercially. Other emerging processes include William
Master's patented ballistic particle manufacturing (BPM) and Itzchak Pomerantz et
alpatented .'s solid ground curing (SGC).
Stratasys, EOS, and 3D systems are among the other developing companies seen between the
1990s and today. The first use of a 3D printer was in medical research in the 1990s, which
established the way of pharmaceutical and 3D printing and opened the doors to a wide range
of clients. Stratasys, which had produced many 3D printers for both professionals and amateurs,
received a patent on fused deposition modelling in 1992. 3D systems created the SLA
(Stereolithographic) equipment this year. The first SLA machine creates the thing layer by
layer using a UV laser hardening photopolymer and a liquid with the viscosity and colour of
honey. This was the first rapid prototyping technique, and it forever transformed the technical
world and design.
The key actors in the 3D printing sector, which had developed with varied methodologies, from
1993 to 1999. In terms of commercial operation, Sanders prototype (later Solidscape) and Z
Corporation were founded in 1996, while Arcam was founded in 1997.

RepRap, a self-replicating 3D printer, was launched in 2004. The RepRap project's open source
led to the widespread use of FDM 3D desktop 3D printers, and the popularity of 3D printers
grew from there.

The Z510 spectrum was introduced by Z-Corp in 2005. The world's first full-color, high-
definition 3D printer. In the year 2000, the first SLS machine became commercially
available, allowing the firm to produce industrial parts. Objet, a 3D printing start-up,
developed a machine that could print several materials, allowing a single part to be created
and fabricated with a variety of material properties.

In 2009, the FDM patents were released. In 2009, the FDM patents were released
into the public domain, ushering in a new era of FDM printer development, as well as a

3
decline in the price of desktop 3D printers, making the technology more accessible and
visible.

Sculpteo, a French firm, launched 3D printing cloud and online printing services using stereo
lithography or laser sintering this year.
This was another stride in the direction of 3D printing. A slew of comparable deposition print
ers have appeared, each with a marginally different selling point.
RepRap's approach revolves around opensource 3D printing developments that remain comm
ercially viable. As additive processes progressed, It is predicted that, in the not-too
distant future, metal removal will no longer be the only metal removal procedure carried out
by a moving head in a 3D work envelope, layer by layer, turning the bulk of raw material into
the desired shape.
Metal enduse parts such as engine brackets and huge nuts were printed instead of machined i
n the first decade of the twenty-first century.

1.3 PRINCIPLE OF 3D PRINTING

All 3D printing technologies are based on the same principle; A 3D printer takes a digital model
(as input) and turns it into a physical three-dimensional object by adding materials layer by
layer.

1.4 Application of 3D Printer

Rapid Prototyping: Helps industries to get imperative feedback, revise and can
bring more perfect or effective products to market faster. It allows for low-cost,
functional prototypes, allowing industries to test parts or products before introducing
to the market.
a. Functional prototyping
b. Concept Modeling
Production Parts: It build low-volume, durable production parts with different
engineering grade filaments like Nylon, ABS, PLA etc. prints parts efficiently and
precisely.
a. Anatomical Models
b. ECS ducting
c. Housings and Enclosures

4
Manufacturing Tooling: Complex designs of jigs, figures that required high
quality and efficiency can printed with 3D Printer.
a. Jigs and Fixtures
b. Forming tools
c. Composite Tooling
d. Investment Casting Patterns

Fig.1.1: 3D Printing Applications

Shoe Manufacturing: The sport-footwear industries are now adopting the technology
to optimize their products more effectively. The digital modeling gives them more
options in customization. The well-known brands in world like Nike, New Balance and
Adidas uses additive manufacturing for mass production of midsoles from 3D printed
materials.

5
Fig.1.2: Two limited edition shoe models with 3D printed midsoles designed by New Balance
3D printed using SLA 3D printing technology.

Dentistry: It has been one the leading users of 3D printing in healthcare. Dental 3D
printers use resin-based printing process to create dental models, dentures, jaws and
bridges in less time, with high accuracy and low cost. An 83-year-old British woman
recently underwent the first-ever custom transplant of a lower jaw made by a 3D printer.

Fig.1.3: Human jaw prototype

Glass and Eyewear: Getting eyewear printed with 3D printer benefits in limitless
capacity for customization. Also, the designs will intend more comfort, good quality
and at lower cost.

Fig.1.4: 3D printed spectacle

6
CHAPTER 2
LITERATURE REVIEW
Authors Lalit Kumar, Qamar Tanveer, Vineet Kumar [4] have stated in their paper titled
-
3D parts or new product within a limited time precisely and accurately. They have also stated
that it is totally different from conventional manufacturing i.e., subtractive manufacturing in
which parts or required object get manufactured by removal of material in form of chips where
as in additive manufacturing object or part is manufactured layer by layer that is removal of
chips is not required hence, no material wastage.
As this type of manufacturing has a problem i.e., cost of 3D printer. In this research authors
have developed a 3D printer basically for ABS material using different cost-effective parts
from market and they have successfully developed a printer of size (20*20*20) cm with
accuracy of 0.1mm in a competitive market price of 20763.

the Developm
marked it as third industrial revolution as published in British Economist magazine. From
meeting the needs of target audience and give support to their unique personality by providing
customized designs, and also save cost of various supply management process.
Towards the view to make the product more cost effective it shows a major cost cutting in the
process of transportation i.e., 20% to 30% of the price, in the sector of human resources like
less or no labour required and also assembling the product could be eliminated in some
processes. When these processes humanized enough, we will see more innovative designs. This
market could find some restrictions in the near future because of the limited 3D print material,
expensive setup as to be hold by an individual and most lacking in the field of time taking.

Authors Suraj Takale, Siddharth Singh, Gunjeet Singh, Nitin K. Kumar Anekar [6] had

used Additive Manufacturing technology for printing 3D Object Layer wise. They designed
and analyzed a cheap 3D Printer using available materials. They fabricated the 3D Printer to
print object confined within 200*200*200(in mm) Printing Area. They told that 3D Printers,
in Indian Market is around 50k to 60k due to difference in type of support material used. They

7
designed their model for 3D Printer in SOLIDWORKS and analyzed each part. They also told
that 3D Printing is rapidly evolving and many new methods will be discovered in future.

The authors Shishir Kumar Singh and Prof. Rajesh K Satankar [7] in their paper titled

has explained about the FDM (fused deposition modelling) as the prime method for additive
manufacturing process of 3D printing and the extrusion of PLA filament through the nozzle by
feed polymer filament mechanism, where the feed polymer acts as a plunger for the PLA
filament extrusion and this feed polymer filament should be in solid form to act as a plunger,
for this to happen the author decided to keep the temperature of the heat block (where the
filament is melted) at a temperature lower than the melting temperature of the feed polymer
filament. To obtain this the surface area of heat block is increased by adding fins.The author in
the paper has also taken different geometries of fins like triangular, circular, elliptical and
rectangular fins having elliptical perforations and analysed their thermal behaviour that helps
in design of extruder geometry. Through this the author concluded that the rectangular fins
with elliptical perforations has least temperature distribution and also that temperature
distribution inside the extruder plays crucial role in 3D printing.

The authors of the research work named Analysis in the Fused Deposition Mod
elling Yong Zhou, Gang Xiong, Timo Nyberg, and Dan Liu [9], state that fused dep
osition modelling (FDM) is one of the most appealing 3D printing item producing measures.

Extruding a semi-molten polymer fibre through a pre-heated nozzle in a prescribed design onto
a print bed is how FDM generates models.
The material cools, hardens, and binds with the surrounding components as it is deposited.

The holding quality and mechanical qualities of the generated models are determined by the t
emperature distribution among polymer filaments in the FDM measure.
In his paper, he constructed a thermal model of FDM.
Temperature fluctuations and phase transitions create the nonlinear profile of thermal conduct
ivity and specific heat.
In this paper, a finite element analysis method based on the continuous medium hypothesis is
used to investigate temperature advancement and the growth of the model of various compon
ents.
The effect of model on thermal development by modifying the thermal characteristics of the

8
material is demonstrated by the evaluation of models using acrylonitrile butadiene styrene (A
BS) co-polymer.
Extruding a semi-molten polymer fibre through a pre-heated nozzle in a prescribed design onto
a print bed is how FDM generates models

9
CHAPTER 3

DESIGN OF 3D PRINTER AND THERMAL ANALYSIS OF

THE NOZZLE

3.1 Process of 3D Printing

3.1.1 Modelling

The different parts of the 3D printer that are to be made before the assembly has to be designed
or modelled using a CAD (computer added drawing) software such as AutoCAD, SolidWorks
etc. The parts of 3D printer that would be further fabricated are created with the help of CAD,
which results in finding errors and rectifying it before the actual fabrication.

After the modelling of different parts of the 3D printer in CAD tool (SolidWorks) the model
often be in different formats (such as-. skp, .dae, .3ds or some other format), needs to be
converted to either a .STL or .OBJ format, to allow the printing software to be able to read it.

In the below fig. (Fig.-3.1) we have shown an assembled 3D printer made on the SolidWorks
by simulation of different parts of the printer.

Fig.3.1: 3D printer assembly in SolidWorks

10
3.1.2 Conversion to STL Format

The different parts of a CAD model use different methods to present it. So, to have consistency
in 3D printing industry the stereo-lithography format is followed [3].

3.1.3 Slice the STL File

A computer software is used to prepare the STL format that will be created. In light
of the construction approach, the pre-processing application slices the Stereo
lithography model into several layers ranging in thickness from 0.01 mm to 0.7 mm.
In addition, the software creates a support framework for the model to use while it
is being built. Auxiliary support is inevitable in more complicated systems [3].

3.1.4 Layer by Layer Construction

This is the last step where the actual construction of a model takes place by the help of any
rapid prototyping (RP) techniques. The machine use any one of the RP technique where one
layer is deposited at a time and the layer can be of polymer filaments, powdered Meta etc.

3.2 Different parts of 3D Printer

a. Extrude

b. Printing Bed

c. Controller Board

d. 3D printer filament

e. Stepper Motors (NEMA-17 & NEMA 23)

f. Base Frame

g. Motion Components

h. Threaded Rods

i. End Stops

11
3.3 CAD MODELS OF DIFFERENT PARTS OF A 3D PRINTER

Extruder

Extruder is a very essential part of FFF/FDM 3D printer that hold and eject the thermoplastic
material in a semi liquid form in order to deposit it in a layer-by-layer formation to produce the
resultant 3D product.

Fig.3.2. Extruder Assembly

A feed tube/thought guides the filament from the extruder through the heat sink and thermal
barrier tube (change in the cross-sectional areas of the tubes in order to regulate the
temperature before the heat block).

Heating Block is the part which is connected with the thermal barrier and nozzle on the other
end. This part is made of aluminium and its function is to melt the filament which is further
passing through the nozzle.

Nozzle is an integral part of extruder, which help to extrude the melted thermoplastic material
coming out of the heating block on to the printing bed.

12
 Fig.3.3 Exploded View of Extruder

Printing Bed

It is a flat and levelled platform in the 3D printer, where the extruded semi liquid material
landed in the controlled or pre planed manner to produce the required 3D print according to the
data present in the controller unit.

Fig.3.4 Print Bed

Controller Boards

It is called the brain of 3D Printer, controller boards coordinate the all moving parts of printer
resulting in 3D print from molten filament/plastic.

What it can do?

13
Like CPU has motherboard that deals with all the functions of a computer. Similarly, controller

For example: means

Processors

All the computing is done by chip installed on the controller board called processor. Different
type of bit processors are used, some of them are 8-bit, like the ATmega2560 and others are
32-bit like ARM processors.

Features
Connectors
Capabilities
Stepper Drivers
Communication

Fig.3.5: Power Supply Unit (PSU) with Controller Box

14
3D Printer Filament

It is a printing material used in Fused Deposition Manufacturing (FDM) type of printer. The
filament is heated to its melting point and flowed through the throat to the nozzle. It is then
squirted in a very controlled manner along an accurate and precise shape and thickness.

Types of Filaments

1. Polylactic Acid (PLA)- PLA filament is the most common 3D printing material
because it is easy to use and is made from renewable resources and thus,
biodegradable. It is easy to print and always reliable with 3D printer. The printed
parts using PLA have an extraordinary surface finish and are higly precise.

Fig.3.6

The chemical formula for PLA is (C3H4O2)n

The extruder temperature for PLA is 205±15°C and bed temperature is 40±15°C.
Advantages
a. Widely available
b. Easy to print
c. Lots of good colour available
2. Acrylonitrile Butadiene Styrene (ABS): ABS is very reliable and durable, also can
withstand a different range of temperatures, and tends to be more flexible than PLA.
It has different negative aspects also like need more heat, more bed adhesion etc.

Fig.: 3.7

15
 The chemical formula for ABS is
The extruder temperature for melting ABS is 230±10°C and bed temperature
required is 90±10°C.
Advantages
a. Has good blend of strength & flexibility
b. Easy post processing i.e., sanding, vapour polishing, solvent welding etc.
c. Used as a structural opinion.

3. Polyethylene Terephthalate Glycol (PETG): PETG filament is an industrial

filament with different great features. It is known for its clarity and is also very good

wraps, and produces no fumes when printed. PET filament is not biodegradable, but
it is 100% reclaimable. PET is available in 1.75mm and 2.85mm.

Fig.:3.8

The chemical formula for PETG is

The extruder temperature for melting PETG is 250±10°C and bed temperature
required is 90±10°C.
Advantages
a. Cost effective
b. Availability of colours
c. Modification is easy

Stepper Motor: It is a kind of electric motor that is used in robotics industry. The difference
is that stepper motor moves a known interval for each pulse of power. These pulses are given

16
by stepper driver which is installed in controller boards. This device helps in repeatable
movement or positioning of extruder or print bed.

Properties

Step angle
Micro stepping
Bipolar
Unipolar
Holding torque
Size

3D Printer usually uses NEMA (National Electrical Manufacturers Association) motors that
generally standardise the frame size of motor.

NEMA 17: This motor has twice the step accuracy of any other motor.

Fig.3.9: NEMA -17 (SolidWorks)

Specifications

Motor type - Bipolar

Step Angle -1.8°
Holding Torque - 59±5 N-cm

17
 Frame size - 42*42
Body length - 47 mm
Shaft diameter - 5mm
Shaft Length 16.5 mm
Number of leads - 4
Lead length - 225 mm

Base Frame: The frame is heart and soul of 3D Printer. It may looks simple but it is very
important and design can actually be quite complex.

Fig:3.10: Base Frame

The importance of 3D Printer frame are:

It gives the printer a great look as well as aesthetic appearance
Supports all the components i.e., mechanical or electrical that carry out actual printing
work
It determines the build volume of 3D printer
The materials generally used for making frame is aluminum, acrylic and plywood.

18
3.3 Assembly of part

Fig.3.11: CAD assembly of 3D printer

3.4. THERMAL ANALYSIS OF THE NOZZLE TIP OF EXTRUDER

ASSEMBLY

a. Material selection for nozzle-

Brass is the most common and widely used material for nozzle due to its high thermal
conductivity, easy manufacturing etc. The thermal properties of the brass are taken from the
literature survey, the thermal conductivity of the alloy is 109W/m-k and is likely high thermal
conductivity in its competition [7].

The various thermal properties of the brass are presented in tabular form below-

Table 1: showing the material properties of Brass [7]

Thermal property Value

Thermal conductivity (K) 109 W/m-k

Specific heat ( ) 380 J/kg-k

Density ( ) 9490 kg/ 3

19
 b. Material selection for the polymer filament-
The filament we chose is Acrylonitrile Butadiene Styrene (ABS) & its chemical formula is
presented as- [4]
The glass transition temperature of the ABS is 108°C, it is amorphous by nature [4]. The
ABS requires a heated bed with the temperature range of (80 -130)°C, this is required due
to the high glass transition temperature of ABS (100°C) [8].
The thermal properties of ABS are presented in tabular form below-
Table-2: Material properties of Acrylonitrile Butadiene Styrene (ABS) [8]

Properties Value

Diameter 1.75mm-2.83mm
Weight 1 kg
Glass Transition Temperature 108°C
Resistance Temperature -20°C to 80°C
Melting Temperature 200°C
Extrusion Temperature 230°C-260°C
Bed Temperature 80°C-130°C

The thermal analysis of the nozzle tip is presented below on working on SolidWorks for the
analysis with nozzle tip diameter of 0.4mm [4] and the extrusion temperature of the filament
taken as ABS to be 235°C [8] with the filament diameter to be 1.75mm [4].

Fig.3.12 Analysis on Nozzle

20
CHAPTER-4

Result and Conclusion:-

Fig: 4.1

This Graph is plotted by taking 20 nodes on nozzle in a line. Temperature Drops from 508K to
416K.

Material for Nozzle is Brass. Solid Type Meshing is Used. Total Number of nodes formed in
Nozzle is 14445. SI(MKS) Unit System is used for calculations putting values in Simulation.

Deformation will take place in Nozzle after a very long time cause the melting temperature of
Brass is 1205 K. If any deformation takes place in Nozzle, it will be at the tip of the Nozzle
from where Melted filament (ABS or any other material) will come out layer by layer for
printing objects.

From the above graph we can finally conclude that the temperature distribution inside the
nozzle plays an important role in the print or extruded materials quality and its strength. Also
the importance of the heated bed for the filament deposition on it to avoid the mistakes or
deformation in the printed 3D object.

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CHAPTER-5

FUTURE SCOPE

Aircrafts and Aerospace: Aircraft manufacturers nowadays are looking towards 3D

printing to improve the performance by creating an adequate reduction in the
maintenance required and consuming less fuel with lighter parts (they are 65% lighter
than traditional aircraft parts but just as strong).
How much cost cutting can be done by this? To put this thing into perspective, per
Kg reduction in weight, airlines save around Thirty-Five Thousand Dollar in fuel costs
spanning the lifetime of the aircraft. Aircraft designers/manufacturers already have in
their sights to manufacture whole plane by 3D printing in next 20-30 years.
Components such as ECDs which need different parts to be assembled due to its
complex structure are now being manufactured in a single job. Industries are also using
it as a privilege of cutting down on a supply chain using 3D printers by making a printed
products or replacements. Some companies are developing tools that can also
manufacture in space in 0 gravity conditions as needed.

Defence: 3D printing has already been utilized to make parts that are strong, durable
and reliable as needed in the battlefield, at lower prices comparatively. As in defence
system it is highly needed to maintain the inventory and this dependency of inventory
cost a major budget so 3D printing can help this system to make most of the inventory
on the spot. As well as the usage of 3D printing in military to make 3D prints of their
mission for the better understanding. It is also helpful to understand the geographic
situation of the sites in case of natural disaster to initiate the rescue operation.

Automotive: 3D printing is already being used in this industry to create sophisticated

parts and accessories. Engineers have employed 3D printing to create lighter versions
of their assembly equipment, increasing worker productivity even more. Furthermore,
3D printing will elevate vehicle marketing to a whole new level, resulting in more
visually detailed initiatives. It will assist the manufacturing behemoth in producing
accessories such as custom interiors, motorbike seats, and helmets, among other things,
in order to avoid discomfort.

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Healthcare: The most thrilling use of 3D print is in medical and healthcare field. As
this technology will make the medical solutions more customised for individual
requirements. From the zone of making artificial body part to the area of regenerate
medicine will be a great advantage.

Education: As sufficient work has been done by the photographic, video graphic
illustrations in several courses but to get a hands-on experience or knowledge we erg
the need of 3D prints to get and actual idea instead of imagination. Thus, the use of 3D
printing will further increase the quality of the education system,

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REFERENCES:
1. Ian Hutchings, Philip Shipway, in Tribology (Second Edition), 2017
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3. Hota, S. (2015). Study, Design and Fabrication of a 3D Printer (Doctoral dissertation).
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cost 3 D printer. Int J Appl Sci Eng Res, 5(6), 433-447.
5. Yuan, Li Mei. "Analysis on the Development of 3D Printer", Applied Mechanics and
Materials, 2015
6. Singh, G., Singh, S., Patel, M., Takale, S., & Anekar, N. K. K. Design and Analysis of FDM
based 3D Printer.
7. Shishir Kumar Singh, Prof. Rajesh K Satanka, Numerical and Analytical analysis
of 3D printer extruder in Fused Deposition Modelling
8. Properties of the ABS filament, www.3Dnatives.com
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fused deposition modeling process. In 2016 3rd international conference on information
science and control engineering (ICISCE) (pp. 678-682). IEEE.
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