A Major Project Report on

DESIGN AND FABRICATION OF DUAL EXTRUDER

WITH SINGLE NOZZLE FUSED DEPOSITION
MODELING MACHINE
Submitted in Partial Fulfilment of the Requirement
for the Award of the Degree
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
BY

P. HARISH G. SRINESH KUMAR R. KIRAN KUMAR

187R5A0313 187R5A0315 187R5A0321

Under the Supervision of

Ms. SK. ZAREENA
Assistant Professor

DEPARTMENT OF MECHANICAL
ENGINEERING
CMR TECHNICAL CAMPUS
KANDLAKOYA (V), MEDCHAL (M), RANGAREDDY-501 401
JUNE – 2021
 DECLARATION

I hereby declare that the Major project entitled “Design and Fabrication of
Dual Extruder with Single Nozzle Fused Deposition Modeling Machine”
submitted under the supervision of Ms. SK. Zareena, Assistant Professor is a
record of bonafied work carried out for the partial fulfilment for the award of the
Degree of Bachelor of Technology in Mechanical Engineering.

I solemnly declare that to the best of my knowledge, no part of this report has
been submitted here or elsewhere in a previous application for award of degree. All
sources of knowledge used have been duly acknowledged.

……..……..……… …………….…………… .………………………

P. HARISH G. SRINESH KUMAR R. KIRAN KUMAR
187R5A0313 187R5A0315 187R5A0321

ii
 CERTIFICATE

This is to certify that the project titled “Design and Fabrication of Dual Extruder
with Single Nozzle Fused Deposition Modeling Machine” carried out by
Peddi Harish (187R5A0313), Gunda Srinesh kumar (187R5A0315), Ramola
Kiran Kumar (187R5A0321) has been read and approved for meeting part of the
requirements and regulations governing the award of the Bachelor of Mechanical
Engineering degree by Jawaharlal Nehru Technological University, Hyderabad,
Telangana State, India.

…………………… ...……………………
Ms. SK. Zareena External Examiner
(Project Supervisor)

………………………… .…………..................
Dr. D. Maneiah Dr. A. Raji Reddy
(Head of Department) (Director)

iii
 ACKNOWLEDGEMENT

The success and final outcome of this project required a lot of guidance
and assistance from many people and am extremely fortunate to have got this all
along the completion of my project work. Whatever I have done is only due to such
guidance and assistance and we would not forget to thank them.

I heartily thank Dr. D. Maneiah, Head of the mechanical Department

and & Ms. SK. Zareena, project guide for their cordial support, valuable information
and guidance, which helped me in completing this task through various stages.

I respect and thank our Director, Dr. A. Raji Reddy for providing constant
encouragement, support and guidance throughout our project. I am extremely grateful
to him for providing all the facilities to make our project successful, though he had
busy schedule managing the academic and administrative affairs.

Peddi Harish
Gunda Srinesh Kumar
Ramola Kiran Kumar

iv
 ABSTRACT

Fused Deposition Modeling (FDM) is an Additive Manufacturing Technology

for printing 3D objects layer by layer. The main purpose of this project is to develop a
low cost 3D Printer using easily available materials and conventional methods for
fabrication which can be used to print objects confined within 300 x 250 x 300 (in
mm) Printing Area. Many Industries uses traditional methods for developing
prototype for analysis rather than using technologies like 3D printing because it is
expensive.

After thorough market survey, we came to a conclusion that 3D Printers

available in the Indian market are priced around Rs. 50,000 to 60,000 due to type of
supporting material used. Initially we designed our 3D Printer completely in 3D
Modeling Software SOLIDWORKS and analysed each part and selected readily
available material appropriately so as to develop a cost effective printer. Main
objective of project is to develop a printer which is cost effective and to encourage
manufacturers to adopt the method of 3D Printing.

v
 CONTENTS
ABSTRACT v
LIST OF FIGURES x
ABBREVIATIONS xiii
CHAPTER Page No.
1. INTRODUCTION 1
1.1 Additive Manufacturing 1
1.2 Fused Deposition Modelling 3
1.3 Working of FDM 4
1.4 Applications 6
1.4.1 Education 7
1.4.2 Prototyping and manufacturing 8
1.4.3 Medicine 9
1.4.4 Construction 10
1.4.5 Art and jewellery 11
1.4.6 Domestic use 12
1.4.7 Apparel 12
1.4.8 Food 13

2. LITERATURE SURVEY 15
2.1 Block Diagram and Flow Chart 16

3. TYPES OF ADDITIVE MANUFACTURING 18

3.1 Various Techniques Developed for AM 18
3.1.1 Photopolymerization 18
3.1.2 Material jetting 19
3.1.3 Binder jetting 20
3.1.4 Material extrusion 21
3.1.5 Powder bed fusion 22
3.1.6 Sheet lamination 23
3.2 Motion Configuration in 3D printers 24
3.2.1 Cartesian configuration 25
3.2.2 Delta configuration 26

vi
 3.2.3 SCARA configuration 27
3.2.4 Polar configuration 28
3.3 Materials Used in FDM 3Printing 29
3.3.1 PLA-Polyactic acid 29
3.3.2 ABS-Acrylonitrile butadiene styrene 30
3.3.3 Nylon 31
3.3.4 PET-Polyethylene terephthalate 31
3.3.5 TPU-Thermoplastic polyurethane 32
3.3.6 PC-Polycarbonate 32
3.3.7 ASA-Acrylonitrile styrene acrylate 33
3.3.8 ULTEM 33

4. METHODOLOGY 34
4.1 Flow Chart 34
4.2 Selection of Process 34
4.3 Selection of Mechanism 35
4.4 Software 36
4.4.1 CAD tools 36
4.4.2 CAM tools 37
4.4.3 Firmware 37

5. DESIGN AND FABRICATION 38

5.1 Conceptual Design 38
5.2 Bearings 39
5.2.1 Linear bearings 39
5.2.2 Ball bearings 40
5.3 Belts 40
5.3.1 Belt drive 41
5.3.2 Law of belting 42
5.3.3 Timing belt 42
5.4 Pulley 42
5.5 Aluminium Slots 44
5.6 PTFE Tube 45
5.7 Electronics 45

vii
 5.8 Controller Board 46
5.8.1 Arduino due 46
5.8.2 Beagle bone printer board 47
5.8.3 Azteeg x5 48
5.8.4 Smoothie board 49
5.8.5 Ramps 1.4 49
5.9 Stepper Motors 50
5.9.1 Selection of stepper motor 51
5.9.2 Stepper Motor Applications 52
5.10 Stepper Drives 53
5.11 LCD Controller 53
5.12 Thermistor 54
5.13 Limit Switches 55
5.13.1 Mechanical limit switches 56
5.13.2 Optical limit switches 56
5.13.3 Magnetic limit switches 57
5.13.4 Force sensitive limit switches 57
5.14 Heated Bed 58
5.15 Dual Extruder 58
5.16 Power Supply 59

6. FIRMWARE AND SOFTWARE 60

6.1 Introduction 60
6.2 List of Firmware 60
6.2.1 Marlin 60
6.2.2 Sprinter 63
6.2.3 Teacup 63
6.2.4 SJFW 64
6.2.5 Sailfish 64
6.3 Software 65
6.4 Software Used for Designing the 3D Printer 65
6.4.1 Solid works 65
6.4.2 Catia 66
6.5 Software Used for Printing the 3D Models 66

viii
 6.5.1 Cura 67
6.5.2 Repetier host 68
6.5.3 G-Code interpreter 69
6.5.4 Pronterface 69

7. CONCLUSION 71
7.1 3D Printed Models 72
7.2 Specifications 73
7.3 Future Scope 73

8. REFERENCES 76

ix
 LIST OF FIGURES

Figure No. Description Page No.

1.1 Subtractive & Additive manufacturing 2
1.2 Fused Deposition Modelling 3
1.3 Schematic of a typical FDM printer 4
1.4 FDM printing process 5
1.5 Applications of 3D printing 6
1.6 3D Printing in Education 7
1.7 3D Printed Gears 8
1.8 3D Printed Hand 9
1.9 3D Printed House 10
1.10 3D Printed Jewellery 11
1.11 3D Printed Clock 12
1.12 3D Printed Shoe 13
1.13 3D Printing of Chocolate 14
1.14 3D Printing of Food 14
2.1 System Block Diagram 17
2.2 Software Flow Chart 17
3.1 Additive Manufacturing Processes 18
3.2 Photopolymerization 19
3.3 Material Jetting 20
3.4 Binder Jetting 21
3.5 Material Extrusion 22
3.6 Powder bed fusion 23
3.7 Sheet lamination 24
3.8 Types of Motion Configuration 25
3.9 Cartesian configuration 26
3.10 Delta configuration 27
3.11 SCARA configuration 28
3.12 Polar configuration 28
3.13 3D Printing Material 29

x
3.14 PLA for 3D Printing 30
3.15 ABS for 3D Printing 30
3.16 Nylon Material Model 31
3.17 PET Material Model 31
3.18 TPU Material 32
3.19 Polycarbonate Model 32
3.20 ASA Material Model 33
3.21 Printed ULTEM Model 33
4.1 Functional block diagram 34
4.2 Cartesian type mechanism 36
5.1 CAD design 38
5.2 Linear bearings 39
5.3 Ball bearings 40
5.4 Belt 40
5.5 Timing belt 42
5.6 Pulleys 43
5.7 Aluminium slot 44
5.8 PTFE tube 45
5.9 Arduino Due Board 47
5.10 Beagle bone printer board 47
5.11 Azteeg X5 48
5.12 Smoothie Board 49
5.13 Ramps 1.4 50
5.14 Stepper drive 53
5.15 LCD Controller 54
5.16 Thermistor 55
5.17 Limit switches 55
5.18 Mechanical Limit Switch 56
5.19 Optical Limit Switch 57
5.20 Heated bed 58
5.21 Dual Extruder 59

xi
5.22 Power supply 59

6.1 Marlin firmware 61

6.2 Marlin configuration 62
6.3 Configuration of TEACUP 64
6.4 Design in Solidworks 66
6.5 Design in CURA 68
6.6 Design in Repetier Host 69
6.7 Pronterface Software 70
7.1 FDM Machine 71
7.2 3D Printed Models by FDM 72

xii
 ABBREVIATIONS

Abbreviation Description
CAD Computer Aided Design
CAE Computer Aided Engineering
CNC Computer Numerical Control
AM Additive Manufacturing
LM Layered Manufacturing
SFF Solid Freeform Fabrication
3DP Three Dimensional Printing
FDM Fused Deposition Modelling
DMD Direct Metal Deposition
SLS Selective Laser Sintering
IJM Ink Jet Modelling
SLA Stereo-Lithography
FFF Fused Filament Fabrication
UV Ultra Violet
DOD Drop on Demand
DMLS Direct Metal Laser Sintering
EBM Electron Beam Melting
SHS Selective Heat Sintering
SLM Selective Laser Melting
PBF Powder Bed Fusion
UAM Ultra Additive Manufacturing
LOM Laminated Object Manufacturing
Selective Compliance Assembly Robotic
SCARA
Arm
PLA Poly-Lactic Acid
ABS Acrlonitrile Butadiene Styrene
PET Polyethylene terephthalate
TPU Thermoplastic polyurethane
PC Polycarbonate

xiii
ASA Acrylonitrile Styrene Acrylate
PEI Polyetherimide
CAM Computer Aided Manufacturing
PTFE Polytetrafluoroethylene
LCD Liquid Crystal Display
RAMPS Reprap Arduino Mega Pololu Shield
PTC Positive Temperature Coefficient
NTC Negative Temperature Coefficient
LED Light Emitting Diode
FSR Force Sensitive Resitor
AC Alternating Current
DC Direct Current
ROM Read Only Memory
OS Operating System
CPU Central Processing Unit
Computer Aided Three Dimensional
CATIA
Interactive Application
USB Universal Serial Bulb
PC Personal Computer
UI User Interface
R&D Research & Development

xiv