SVKM’S NMIMS Deemed-to-be-University

Mukesh Patel School of Technology Management and Engineering

Experiment No: 6
Aim: To study the operating principle and workflow of a Fused Deposition Modeling (FDM) 3D
Printing machine
Apparatus: FDM desktop 3D Printing machine
Procedure:
1) Observe and understand various key features of Creality Ender3 Max 3D Printing machine
2) Observe the work volume, working principle and other hardware components of the machine

Theory:

Fused deposition modeling (FDM) 3D printing, also known as fused filament fabrication (FFF),
is an additive manufacturing (AM) process within the realm of material extrusion. FDM builds parts
layer by layer by selectively depositing melted material in a predetermined path, and
uses thermoplastic polymers that come in the form of filaments.
An FDM 3D printer works by depositing melted filament material over a build platform layer
by layer until you have a completed part. FDM uses digital design files that are uploaded to the
machine itself and translates them into physical dimensions. Materials for FDM include polymers such
as ABS, PLA, PETG and PEI, which the machine feeds as threads through a heated nozzle.
To operate an FDM machine, you first load a spool of this thermoplastic filament into the
printer. Once the nozzle hits the desired temperature, the printer feeds the filament through an
extrusion head and nozzle. This extrusion head is attached to a three-axis system that allows it to
move across the X, Y and Z axes. The printer extrudes melted material in thin strands and deposits
them layer by layer along a path determined by the design. Once deposited, the material cools and
solidifies. You can attach fans to the extrusion head to accelerate cooling in some cases.
Warping is one of the most common defects in FDM. When extruded material cools during
solidification, its dimensions decrease. Since different sections of the printed part cool at different
rates, their dimensions also change at different speeds. Differential cooling causes the buildup of
internal stresses that pull the underlying layer upward, causing it to warp.

Fig. Schematic of a typical FDM printer

 SVKM’S NMIMS Deemed-to-be-University
Mukesh Patel School Of Technology Management and Engineering

Identify and name the key components of desktop 3D printing machines:

Hot and cooling

fan

Extruder and
nozzle

Build plate

Controller
display

3D printing workflow

Brian Evens. Practical 3D Printers The Science and Art of 3D Printing

 SVKM’S NMIMS Deemed-to-be-University
Mukesh Patel School Of Technology Management and Engineering

Sr. No. Machine Specifications Comments

1 Build volume 200 200 200

2 No. of nozzles 1

3 Minimum layer thickness 0.3

4 Material which can be used PLA

5 Interface software used Repetier host

6 Slicer used Cura engine

7 Maximum temperature of nozzle 210

8 Maximum temperature of bed 60

Name the following features

Skirt Raft Brim

 SVKM’S NMIMS Deemed-to-be-University
Mukesh Patel School Of Technology Management and Engineering

Concept Questions:

State three pros and cons of the 3D printing machine studied.

Pros:

1. Customization : 3D printing allows for highly customizable designs. Users can create unique shapes, sizes, and
configurations to meet specific needs.

2. Rapid Prototyping : 3D printing accelerates the prototyping process by enabling quick iteration and testing of designs.
This can significantly reduce product development time and costs.

3. Reduced Waste : Traditional subtractive manufacturing methods often generate a lot of waste material. 3D printing, on
the other hand, is an additive manufacturing process, which means it only uses the material necessary to build the object,
minimizing waste.

Cons:

1. Limited Material Selection : While 3D printing has expanded its material options, the selection is still somewhat limited
compared to traditional manufacturing methods. Some materials may not be suitable for certain applications or may be
more expensive.

2. Layered Structure : Objects printed with 3D printers often have a layered structure, which can result in visible layer
lines and reduced strength compared to objects made using other manufacturing methods.

3. Speed : Although 3D printing is efficient for prototyping and small-scale production, it can be relatively slow compared
to other manufacturing processes, especially for larger and more complex objects. Printing large objects can take hours or
even days, depending on the size and complexity of the design.

What is warping? Why is it more significant in ABS as compared to PLA? How to overcome it?

Warping is a common issue in 3D printing where the corners or edges of a printed object lift or curl upwards during the
printing process, causing distortion or detachment from the print bed. This occurs due to uneven cooling and contraction
of the material as it cools down after being deposited onto the print bed.

Warping is more significant in ABS (Acrylonitrile Butadiene Styrene) compared to PLA (Polylactic Acid) due to several
factors:

1. Shrinkage : ABS tends to shrink more than PLA as it cools down, which increases the likelihood of warping.

2. Higher Printing Temperature : ABS typically requires a higher printing temperature than PLA. The higher temperature
exacerbates the thermal stresses and increases the likelihood of warping.

3. Adhesion to Print Bed : ABS has poorer adhesion to the print bed compared to PLA, making it more prone to
detachment and warping during the printing process.

To overcome warping in ABS and other materials, several techniques can be employed:

1. Use of a Heated Print Bed : Heating the print bed helps to reduce the temperature gradient between the bottom layers
of the print and the ambient environment, minimizing warping. For ABS, a heated bed temperature of around 90-100°C is
recommended.

2. Enclosed Printing Environment : Keeping the printing environment enclosed helps to maintain a consistent
temperature throughout the printing process, reducing thermal stresses and minimizing warping.
 SVKM’S NMIMS Deemed-to-be-University
Mukesh Patel School Of Technology Management and Engineering

3. Printing on a Surface with Good Adhesion : Using materials such as Kapton tape, PEI sheets, or applying a layer of glue
stick or hairspray on the print bed surface can improve adhesion and reduce the likelihood of warping.

4. Applying Rafts or Brims : Printing a raft or a brim around the object can provide additional support and improve
adhesion to the print bed, reducing the chances of warping.

5. Optimizing Cooling Settings : Controlling the cooling settings in the slicer software can help to minimize rapid cooling
and thermal stresses, reducing the risk of warping.

By employing these techniques, it is possible to mitigate warping issues in ABS and other materials, improving the overall
quality of 3D printed objects.

State at least four characteristics of fused deposition modeling.

Fused Deposition Modeling (FDM) is a popular 3D printing technology known for its simplicity, reliability, and
accessibility. Here are four key characteristics of FDM:

1. Layer-by-Layer Deposition : FDM builds objects layer by layer by extruding thermoplastic filament through a heated
nozzle. The nozzle moves along the X, Y, and Z axes, depositing material according to the 3D model's specifications. This
layering process enables the creation of complex geometries and intricate designs.

2. Wide Material Compatibility : FDM supports a variety of thermoplastic materials, including PLA (Polylactic Acid), ABS
(Acrylonitrile Butadiene Styrene), PETG (Polyethylene Terephthalate Glycol), TPU (Thermoplastic Polyurethane), and
others. Each material offers different properties such as strength, flexibility, durability, and temperature resistance,
allowing for versatility in applications.

3. Support Structures : FDM printers often use support structures to stabilize overhanging features and complex
geometries during printing. These supports are typically made of the same material as the object and are designed to be
easily removable after printing. They help prevent drooping or sagging of features that would otherwise be unsupported
during the printing process.

4. Post-Processing Flexibility : FDM-printed objects can undergo various post-processing techniques to enhance surface
finish and mechanical properties. Common post-processing methods include sanding, painting, vapor smoothing (for ABS),
acetone polishing (for ABS), and annealing (for certain materials). This flexibility allows users to achieve desired aesthetics
and functional characteristics tailored to specific applications.

Overall, FDM is valued for its affordability, ease of use, and versatility, making it a popular choice for hobbyists,
professionals, and manufacturers alike.