DESIGN AND FABRICATION OF FDM BASED

PORTABLE 3D PRINTER
A PROJECT REPORT

Submitted By

P.RAJA (821116114050)

R.RAGUL KANNA (821116114305)

E.BAZEER (821116114502)

S.ARUNPANDIYAN (821116114503)

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING

in

MECHANICAL ENGINEERING

KINGS COLLEGE OF ENGINEERING

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2020

i
 BONAFIDE CERTIFICATE

Certified that this project “DESIGN AND FABRICATION OF FDM

BASED PORTABLE 3D PRINTER” is the bonafide work of “P.RAJA
(821116114050), R.RAGUL KANNA (821116114305), E.BAZEER
(821116114502), S.ARUNPANDIYAN (821116114503) who carried out the
project under my supervision.

SIGNATURE SIGNATURE

Dr.T.PUSHPARAJ,M.E.,Ph.D., Mr.S.KARTHI,M.E.,(Ph.D).,

Head of the Department,Professor, Assistant Professor,

Department of Mechanical Engg, Department of Mechanical Engg,

Kings College of Engineering, Kings College of Engineering,

Pudukkottai – 613 303. Pudukkottai – 613 303.

Submitted for the ANNA UNIVERSITY examination held on

INTERNAL EXAMINER EXTERNAL EXAMINER

ii
 ACKNOWLEDGEMENTS

We would like to convey our sincere thanks to our respected Secretary

Dr.R.Rajendran, M.A., M.Phil., Ph.D., for giving us the opportunity to display
our professional skills through this project.

We would like to thank our Principal Dr.J.Arputha Vijaya Selvi, M.E.,

Ph.D., and our respected Head of the Department of Mechanical Engineering
Dr.T.Pushparaj, M.E., Ph.D., for motivating us to reveal our innovative skills.

We express our deep sense of gratitude to our project guide

Mr.S.Karthi,M.E.,(Ph.D)., Assistant professor, Department of Mechanical
Engineering and project coordinator Mr.V.Vijayakumar,M.E., Assistant
professor, Department of Mechanical Engineering for their valuable guidance
and motivation, which helped us to complete this project.

We thank all our teaching and non-teaching staff members of the

Mechanical engineering department for their passionate support, for helping us to
identify our mistakes and also for the appreciation they gave us in achieving our
goal. We heartily thank our library staff and management for their extensive
support by providing the information and resources that helped us to complete
the project successfully. Also, we would like to record our deepest gratitude to
our parents for their constant encouragement and support which motivated us to
complete our project on time.

iii
 ABSTRACT

3D printing is a form of additive manufacturing technology where a three

dimensional object is created by laying down successive layers of material. It is
also known as rapid prototyping, is a mechanized method whereby 3D objects are
quickly made on a reasonablysized machine connected to a computer containing
blueprints for the object. The 3D printing concept of custom manufacturing is
exciting to nearly everyone.

This revolutionary method for creating 3D models with the use of inkjet
technology saves time and cost by eliminating the need to design; print and glue
together separate model parts .Now, you can create a complete model in a single
process using 3D printing. The basic principles include materials cartridges,
flexibility of output, and translation of code into a visible pattern.

Additive manufacturing process or 3D printing process is now becoming more

popular because of its advantages over conventional processes. A 3D printer is a
machine that create objects out of plastic, nylon like many other materials.3D
printers now days available are not so portable and also they are very costly. By
analyzing this problem, we are trying to make a portable 3D printer The cost of
this printer will be very less compared to other 3D printers. Making low cost 3D
printer with price 15% lower than market

iv
 TABLE OF CONTENTS

CHAPTER TITLE PAGE NO

NO

ABSTRACT Iv

TABLE OF CONTENTS ⅴ

LIST OF TABLES ⅶ

LIST OF FIGURES Viii

1 INTRODUCTION 1

1.1 3D printer 2

1.2 History 2

1.3 Application 7

2 LITERATURE REVIEW 11

3 PROBLEM IDENTIFICATION & 16

OBECTIVES 18

4 METHODOLOGY 19

4.1 Flow Chart 20

4.2 Selection Of Process 21

4.3 Selection of Mechanism 22

v
 4.4 Software 23

4.5 Working Principle Of Fdm Based 3d Printer 25

5 DESCRIPTION OF COMPONENTS 27

5.1 Mechanical Components 28

5.2 Electronic Components 34

6 DESIGN CALCULATION 42

6.1 Conceptual Design 43

6.2 Detail Design 44

6.3 Bearings 48

6.4 Belts And Pulley 50

7 FIRMWARE AND SOFTWARE 57

7.1 Introduction 58

7.2 List Of Firmware 58

8 FABRICATED MODEL 72

9 FUTURE PERSPECTIVE 77

10 COST ESTIMATION 80

11 CONCLUSION 83

REFERENCES 84

vi
 LIST OF TABLES
TABLE NO TITLE PAGE NO

5.3 PART LIST 41

6.6 PULLEY SPECIFICATIONS 56

8.1 MACHINE SPECIFICATIONS 76

10.1 COST ESTIMATION 81

vii
 LIST OF FIGURES

FIGURE NO TITLE PAGE NO

1.1 EVALUATION OF 3D PRINTER 6

1.2 APPLICATION 7

1.3 APPLICATION OF 3D PRINTER 10

4.1 FLOW CHART 20

4.2 CARTESIAN TYPE MECHANISM 23

4.3 FIRMWARE 24

4.4 FDM METHODOLOGY 26

5.1 SMOOTH ROD 27

5.2 LEAD SCREW 29

5.3 COUPLER 29

5.4 TIMING BELT 30

5.5 PULLEY 31

5.6 ALUMINIUM FRAME 31

5.7 HOTEND 32

5.8 MK8 EXTRUDER 33

5.9 PLA FILAMENT 34

5.10 STEPPER MOTOR 35

5.11 ARDUINO MEGA 2560 35

5.12 RAMPS 1.4 36

5.13 A4988 DRIVER 37

viii
 5. 14 END STOPS 38

5.15 SMPS 39

5.16 HEAT BED 39

6.1 CAD DESIGN 44

6.2 DETAILING OF NEMA 17 45

6.3 X-AXIS CAD DESIGN 46

6.4 Y-– AXIS MOVEMENT 48

6.5 LM8UU BALL BEARINGS 49

7.1 ARDUINO IDE 59

7.2 MARLIN FIRMWARE 61

7.3 ARDUINO SETUP 1 62

7.3.1 ARDUINO SETUP DONE 64

7.4 MARLIN FIRMWARE 65

7.5 SOLIDWORKS 3D MODEL 66

7.7. CURA SLICED IMAGE 69

7.8 PRONTERFACE 70

8.1 FABRICATED MODEL 73

8.2 ASSEMBLY OF 3D PRINTER 74

8.3 WORKING MODEL 1 75

1 ix
 CHAPTER 1
INTRODUCTION

1
1.1 3D PRINTER

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

parts are made by the addition of multiple layers of material. It can also be called
as rapid prototyping. It is a mechanized method where 3D objects are quickly
made as per the required size machine connected to a computer containing
blueprints of any object.

The additive method may differ with the subtractive process, where the
material is removed from a block by sculpting or drilling. The main reason to use
3d printer is for 90% of material utilization, increase product life, lighter and
stronger. 3D printing is efficiently utilized in various fields such as aerospace,
automobile, medical, construction and in manufacturing of many household
products.

1.2 HISTORY

The 3D printing innovation is not a new concept as many think. When FDM
(fused deposition modeling) licenses had expired in 2009, the 3D printing became
a new innovation topic. What's more, because of which it turned out to be more
mainstream, individuals envisioned that FDM was the just a single added
substance producing system. Be that as it may, the initial 3D printing procedure
was SLA not FDM, and its first patent was recorded in 1980's. Here is the
historical backdrop of 3D printing innovation, from 1980 to today.

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

Dr.Hideo Kodama was the first person to present layer by layer approach for
assembling and furthermore he was the principal individual to create fast

2
prototyping strategy. What's more, he made a progenitor for SLA. He polymerized
a photosensitive gum with the assistance of UV light, however, did not succeed.
Shockingly for Dr. Kodama, the full patent detail was not recorded by him before
the one-year due date after the application. the causes of 3d printing innovation can
be followed from 1983.

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

Frame designed the term stereolithography in august 8, 1984 patent application for
"Contraption for creation of 3 dimensional questions by stereolithography".
Furthermore, was the main individual to make SLA-1 (stereolithography) machine
in 1987.

Charles hull was the founder 3D system Corporation (one of the biggest and
more propel association working in 3d printer division today). Hull characterized
stereolithography as the unique technique which is used for making solid objects
by printing successive layers of ultraviolet curable material on top of other. In
frame's patent, he clarifies, a concentrated light emission light is centered around
the surface loaded with a fluid photopolymer. The light ray which is controlled by
a computer draws each layer of the model on the surface of the liquid. wherever
the bright light strikes the surface, the photopolymer polymerizes and changes to
solid. Using the software CAD/CAM mathematically slices (converts into layers)
the models. then the process builds the models layer by layer.

During the year 1990’s the other 3D printing innovation and processes were
emerged during this year. And the introduction of new 3D printer manufacturers
and cad tools. 3D systems make their first commercial sale of stereolithography
(SLA) system. And the other emerging processes were ballistic particle

3
manufacturing (BPM) patented by William masters, solid ground curing (SGC)
was been patented by Itzchak Pomerantz et al.

Furthermore, other developing organizations saw amid the nineties till today -
Stratasys, EOS, and 3D systems. The 1990's were the time of first use of the 3D
printer in medical researchers, who consolidated the way of pharmaceutical and 3D
printing and opening the chances to numerous clients. In 1992 the patent done on
fused deposition modeling was issued to Stratasys, who had developed may 3D
printers both for professional and for individuals. The SLA (Stereolithographic)
apparatus was made in this year by 3D systems. The first SLA machine uses a UV
laser solidifying photopolymer, and a liquid with the viscosity and color of honey
that makes the object layer by layer. This was the first rapid prototyping form that
had changed the engineering world and design for ever.

From 1993-1999, the main actors of the 3D printing sector, which had
emerged with various techniques. Sanders prototype (later Solidscape) and Z
Corporation were set up in 1996 in terms of commercial operation, Arcam was
established in 1997.

During that time where these 3D printing sector had started to begin the
demonstrate distinct diversification with these two very specific regions emphasis
that is clearly defined today. They were very high end 3D printing and still they are
very expensive which were geared up towards the par production for high value
and complex parts. This are growing rapidly and ongoing but the results are now
visible in production applications across the automotive, aerospace, medical and in
jewelry sectors. And at the other end, some of the 3D printing system
manufacturers were developing and advancing the “concept modelers”, they were
called at that time. These 3D printers kept on focusing on overall development and

4
improvement of these functioning prototyping that were being developed on
specifically as these offices and user friendly and the cost effective systems.
However, these systems were very much useful in industrial applications.

At the lower end of market, the 3D printers that today are been seen. During
this term there, price was a war between the 3D printing companies with the
increase in improvement, accuracy, speed and materials. In 2007 the market saw
the first system under 10,000$ from 3D systems but it never hit the market as
supposed to be. This was due to the market influence of other companies.

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

lower-priced models with multiple features. In 2003 there was the new invention
that 3D printer was used to construct cells when Thomas Boland of Clemson
university patented for the use of inkjet printers for printing of cells. To modify
these spotting systems for deposition of the cells into the very much organized 3D
matrices placed on a substrate this process were used. The printing of biological
structures is known as Bioprinting. The millennium saw the first 3D printed kidney
working. Additionally, more techniques for printing came into action, such as
extrusion bioprinting, have been researched and introduced as a means of
production. Due to which the organs may be printed using bioprinting and can be
transplanted.

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

printer. This open source of the RepRap project led to spreading of FDM 3D
desktop 3D printers and popularity of 3D printers begins from here.

In 2005, Z-Corp launched the spectrum Z510. The first color and high
definition 3D printer. The first SLS machine commercially accessible in 2000,
which gave opportunities to the manufacturer to build industrial parts. A 3D

5
printing startup company Objet built a machine that could print more than one
material, which allowed a single part that can be manufactured and fabricated with
different material properties.

In 2009, was the year where the FDM patents fell into the public domain,
giving an expansive wave for the development in FDM printers and due to the drop
of the price of desktop 3D printers, the technology was more accessible and
increased visibility. A French company named Sculpteo was started in this year
which had offered 3D printing cloud and online printing services using stereo
lithography or laser sintering. which was another step towards 3D printing
technology. A host of similar deposition printers have emerged with marginal
unique selling point and they continued to do so. The ethos of RepRap is all about
open source developments of 3D printing and keep it commercialize.

As the various additive processes developed. It is said that soon metal removal
will no longer be the only metal removal process done through a moving head
through a 3D work envelope converting the mass of raw material into desired
shape layer by layer.

Fig 1.1 Evaluation of 3D printer

6
1.3 APPLICATION

Fig 1.2 Application

1.3.1 EDUCATION

New learning material: often you must want new teaching materials but may
not be able to afford to budget for them. Now their resources can be made using a
3D printer, saving money on your department budget. When we will be Printing
our own learning, materials is not only cheaper but it will be almost always quicker
too. Even though students are traditionally taught through books and theory,
kinesthetic learners prefer to learn through using aids and materials. 3D printing
which also allows you to bring any of the subject matter to life as the physical aid
to engage all of your students for a very long period of time increasing that their
learning and improving their problem solving and critical thinking capabilities.

7
1.3.2 AEROSPACE

NASA engineers drew on ingenuity and advanced technology. About 70 of the

parts that make up the rover were built digitally, directly from computer designs, in
the heated chamber of a production-grade Stratasys 3D Printer. The process, called
Fused Deposition Modeling (FDM) Technology or additive manufacturing, creates
complex shapes durable enough for Martian terrain .For its 3D-printed parts,
NASA uses ABS, PCABS and polycarbonate materials. FDM, patented by
Stratasys, is the only 3D-printing method that supports production-grade
thermoplastics, which are lightweight but durable enough for rugged end-use parts.

1.3.3 ARCHITECTURE INDUSTRY

Poly-Jet 3D printing technology produces astonishingly smooth, detailed

architectural models in an array of materials, including rigid photopolymers ready
for painting. For models that must bear loads or take abuse, FDM Technology
builds strong parts in production-grade thermoplastics.

1.3.4 AUTOMOBILE INDUSTRY

One of Ducati’s key challenges is to reduce time-to-market for new products

by reducing the design cycle. To help meet this challenge, the entire design process
is validated using FDM prototyping systems from Fortus. FDM (fused deposition
modeling) enables Ducati to build both concept models and functional prototypes
from ABS, polycarbonate and poly-phenylsulfone.

1.3.5 CONSUMER PRODUCTS

Consumer electronics: Poly-Jet technology can produce models with

exceptionally thin walls — 0.6mm or less — ideal for small devices densely

8
packed with minute components. Smooth finish and realistic colors make these
models virtually indistinguishable from the end product.

Sporting goods: Prototypes often require a combination of rigid and flexible

materials. Think of a helmet's hard shell and padded interior, or a pair of ski
goggles with tinted lenses and rubber over molding. Only Poly-Jet technology can
produce prototypes with multiple materials and colors in a single, automated build,
so it's ideal for sporting goods designers with an eye for aesthetics. FDM
Technology works with production-grade thermoplastics to produce parts with
high impact strength and great durability. It's perfect for components that need to
withstand tough and repeated functional testing.

Toys: To capture the look and feel of your future products, only Poly-Jet can
deliver fine details, smooth surfaces, playful textures, varied materials and vivid
colors in a single, automated build process.

1.3.6 DENTAL INDUSTRY

APEX Dental Milling Center was one of the early adopters of CAD/CAM
technology for producing dental parts straight from CAD design imagery. Instead
of outsourcing production to CNC traditional milling techniques, the company then
switched to inhouse 3D printing. Having brought digital dentistry into the heart of
its business, APEX Dental Milling Center has discovered that in addition to
lowering prices, it can provide faster delivery times while maintaining its high
quality standards. For APEX Dental Milling Center, any worthwhile 3D printing
solution had to provide one or more business advantages, such as better products,
shorter processing times or more accuracy. The company found all of these
advantages, and more, with the Objet 3D Printer. APEX Dental Milling Center was
impressed with the ease and speed of the Objet Eden260V 3D Printing System.

9
The printed models produced on the Objet Eden260V delivered exceptionally fine
details and an outstanding surface finish – all necessary for ensuring the high
accuracy required by the lab’s team and its dentist customers.

1.3.7 JIGS AND FIXTURES

Inkjet-based technology and FDM Technology, both available from

Stratasys, provide fast and accurate methods to produce and manufacture tools. 3D
printing jigs and fixtures with inkjet or FDM can help reduce the backlog for an in-
house machine shop and be used as a bridge-to-tooling solution.

1.3.8 MEDICAL INDUSTRY

3D Printer Creates Multi-Material Respirator. Design reality, a UK based

design consultancy, uses the Objet260 Connex1 multi-material 3D printer; to
prototype gas mask respirators for the UK Ministry of Defense and US Fire
Services –reducing a 5- 6 day prototyping process to just hours

Fig 1.3 Application of 3D printer

10
 CHAPTER 2

LITERATURE REVIEW

11
2.1 Mechanical properties of FDM and SLA low-cost 3Dprints

[1] Ksawery Szykiedansa et al 2015 ,A recent development of the 3-D

printers, has made them readily available to the public at low costs. In order to
make 3-D printed parts to be more useful for engineering applications the
mechanical properties of printed parts must be known. This paper quantifies the
basic tensile strength and elastic modulus of printed components produced with
application of FDM and SLA printers. Tests have been conducted using ABS,
fiberglass reinforced polyethylene terephthalate glycol (Z-Glass) and a Nobel
printer photoresistive resin. The collected data show some distinctions between
tensile modulus of 3-D prints and its base materials, i.e. Z-ABS prints Young
modulus have mean value of 1.12 GPa and the encyclopedic value is between 1.7
up to 2.1 GPa. For other tested materials tensile modulus was appointed as 1.43
GPa for Z-Glass and 246 MPa for a Nobel printer photopolymer resin.

HIGHLIGHTS: 3-D prints; tensile modulus; Zortrax filaments; XYZprinting

photopolymer resin; FDM mechanical properties. A recent development of the 3-D
printers, has made them readily available to the public at low costs. Most of the
low-cost printers fabricate objects primarily from acrylonitrile butadiene styrene
(ABS) or polylactic acid (PLA). There are also low-cost printers that employ
stereo-lithography technology (SLA), which uses a laser to polymerize
photosensitive resin, producing higher-resolution printed objects of more complex
geometry. In order to make 3-D printed parts to be more useful for engineering
applications the mechanical properties of printed parts must be known .

2.2 Importance and Utilization of 3D Printing in Various Applications

12
 [2] CH. Venu Madhav et al,3D printing is one of the most important
technological advancement in Additive manufacturing which has been
Implemented and recognized as a part of modern industry . Development of
various components ranging from simple structures used in everyday life to
complicated Components in aerospace applications, 3D printing Provides many
advantages few are Simplicity, Reliability and Precision etc this makes it one of
the most widely used for making components which can be used as concept.
Components.3D printing is the most widely used additive manufacturing processes
in the current industry not only limited to Engineering. This paper presents an
overview of Additive Manufacturing and Various applications o f engineering

HIGHLIGHTS: Rapid Prototyping, Fused Deposition Modeling, 3D Printing,

Applications. The concept of Additive manufacturing was utilized in the
development of 3D printing which is the deposition of liquid material layer by
layer to get the final component according to given design. In today's
manufacturing industry 3D printing is a very important part because of its
simplicity and reliability to produce very complex and precise component.

2.3 Design and Development of FDM Based Portable 3D Printer

[3] Ashish Patil et al, Additive manufacturing process or 3d printing process

is now becoming more popular because of its advantages over conventional
processes. A 3d printer is a machine that create objects out of plastic, nylon like
many other materials.3D printers now days available are not so portable and also
they are very costly. By analyzing this problem, we are trying to make a portable
3D printer which we can take anywhere easily because of it's briefcase like design.
The cost of this printer will be very less compared to other 3D printers. In this

13
printer we are also providing more interfacing options like we can control it
through computer or we can send G-codes directly from SD card.

HIGHLIGHTS: FDM,G-Code,STL File. 3D printers use a variety of very

different types of additive manufacturing technologies, but they all share one core
thing in common: they create a three dimensional object by building it layer by
successive layer, until the entire object is complete. It’s much like printing in two
dimensions on a sheet of paper, but with an added third dimension. In the 3D
world, a 3D printer also needs to have instructions for what to print. It needs a file
as well. The file, a Computer Aided Design (CAD) file is created with the use of a
3D modelling program, either from scratch or beginning with a 3D model created
by a 3D scanner. Either way, the program creates a file that is sent to the 3D
printer. Along the way, software slices the design into hundreds, or more likely
thousands, of horizontal layers. These layers will be printed one atop the other until
the 3D object is done.

2.4 Utility and challenges of 3D Printing

[4] Aman Sharma et al , This paper is all about the advanced technology of
3D printing, their implementation in the respective fields and its significant
contribution in the global world of science and medical. In this paper we will deal
with the term Additive Manufacturing or 3D Printing and a little bit of its history.
Its various applications along with the type of materials used in the 3-D are also
described. We shall also throw some light on the numerous opportunities provided
by this emerging technology as well as the risks and challenges related to it. Its
environmental aspects are also shown in the paper. Lastly the scope and scenario in
future potential of 3D printing is also evaluated

14
HIGHLIGHTS: 3D Printing; Additive Printing; Fused Deposition Modeling
(FDM); Stereo-lithography; ABS Plastics. The different types of materials used are
FDM Thermoplastics, Polyjet Photopolymer, WDW materials etc. Recently
chocolate has also been used as a material in 3D printer. Other materials such as
carbon compounds and combination of different element are also being tested.
Nowadays 3D printers are also used in the field of medical science to repair tissue
cells and to replicate the body organs. Ears, kidney and heart vessels have already
been made and in near future it may be possible to print a real 3D printed heart
working on its own. 3D printers were earlier used by the engineers to make only
the prototypes but with the betterment of the technology, these are now used to
print finished products. Around 28% of the output of 3D printers is now the final
product which is expected to rise to 50% by 2016 and to 80% by the year 2020.

2.5 Metallic 3D Printer- New Era In Printing

[5] Orugonda Ravali et al, This paper aimed at Design and Development of
metallic 3D printer. The main focus is design of metallic 3D printer and its
applications. The study on design of 3D printer involves the basic analysis of
present 3D printers, their parts and mechanism. The requirements that are suitable
for working of 3D printer. 3D printing machine is designed and developed with
different parts like extruders, nozzle, stepped motors, Teflon tube etc which are
assembled, tested and also printed some objects. The development involves the
preparation of the filament that could print the metallic objects. Trials were made
on different filaments and conclusions are drawn. Betterments are made to improve
the performance of the filament in all the aspects required

15
 CHAPTER 3

PROBLEM IDENTIFICATION

&
OBECTIVES

16
3.1 PROBLEM IDENTIFICATION

Mastering FDM 3D printing requires a lot of tinkering and patience. There

are many print quality issues common to FDM such as warping, step lines,
stringing, under/over extrusion, layer shifting, and many, many more. While there
are solutions to all of these problems, it can take multiple attempts in order to get
the desired finished look. FDM machines have a lot of moving parts and settings
which need to be adjusted according to the geometry of the part, the environment
the printer is in, and the expected print quality.

 Not Extruding at Start of Print. Printer does not extrude plastic at the
beginning of the print.

 Not Sticking to the Bed.

 Under-Extrusion.

 Over-Extrusion.

 Gaps in Top Layers.

 Stringing or Oozing.

 Overheating.

 Layer Shifting

 Cost of Buying and Setting up A 3D Printer Is Very High.

17
3.2 OBECTIVES

The objectives of our present work are as follows:

 Additive manufacturing process or 3D printing process is now becoming

more popular because of its advantages over conventional processes. A 3D
printer is a machine that create objects out of plastic, nylon like many other
materials.3D printers now days available are not so portable and also they
are very costly. By analyzing this problem, we are trying to make a portable
3D printer The cost of this printer will be very less compared to other 3D
printers.
 Making low cost 3D printer with price 15% lower than market
 To print complex and intricate parts
 To build large printing volumes accurately
 To solve the problems of bed leveling

18
 CHAPTER 4

METHODOLOGY

19
4.1 FLOW CHART

The following flow chart shows the methodology used by us in

construction of 3D printer. The first step is to select one of the additive
manufacturing process among many process explained in chapter 2. Then an
appropriate mechanism is selected for X, Y and Z axis movements, considering
various factors such as cost of fabrication, simplicity of design, synchronization,
accuracy etc. Once the mechanism is selected the next step is integration of
electronics and software then the machine is designed and fabricated. The last
step is, synchronization of mechanical, electrical and software elements of the
machine.

Fig 4.1 flow chart

20
4.2 SELECTION OF PROCESS

The rundown of 3D printing innovations and procedures keeps on

developing as 3D printing is continually evolving. The 3D printing industry
continues upgrading its hardware and the materials and strategies to make protest
or parts. Contingent upon numerous factors, for example, spending plan, outline
or capacity, picking the fitting 3D printing process and also the correct material is
imperative.

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

stable. Complex shapes and intricate parts can be printed. FDM is at the very
entry of the market as it mainly used by individuals. FDM is an affordable 3D
printing process compared to other 3D printing technologies.

FDM starts with a product procedure which forms an STL file

(stereolithography file format), scientifically cutting and situating the model for the
building procedure. In the event that required, support structures might be created.
The machine may apportion numerous materials to accomplish diverse objectives.
The model or part is created by extruding little amount of thermoplastic material to
the desired shape layers as the material solidifies promptly after expulsion from the
nozzle. A plastic filament or metal wire is loosened up from a loop and supplies
material to an extrusion nozzle which can turn the flow on and off. There is
commonly a worm drive that pushes the filament into the nozzle at a controlled
rate. The nozzle is warmed to soften the material. The thermoplastics are warmed
past their glass change temperature and are then saved by an expulsion head.

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

numerically controlled component. The nozzle takes an instrument way controlled

21
by a PC helped producing (CAM) programming bundle, and the part is developed
from the last, one layer at any given moment. Stepper engines or servo engines are
commonly utilized to move the expulsion head. The system utilized is frequently
an X-Y-Z rectilinear outline, albeit other mechanical plans have been utilized. In
spite of the fact that as a printing innovation FDM is exceptionally adaptable, and
it is fit for managing little shades by the help of bringing down layers

4.3 Selection of Mechanism

Presently mechanisms such as, for example, SCARA, Cartesian, Polar, Delta
and so on are utilized as a part of development of FDM 3D Printers. We have
chosen cartesian arrangement of developments, where the bed moves in the
vertical heading i.e., in Z pivot bearing and the extruder spout moves horizontal
way i.e., both in X and Y hub course. Z hub development on such a 3D printer is
extremely exact and requires low increasing speeds, however the bed should be
lightweight with a specific end goal to look after precision, which makes it harder
to include a completely programmed bed leveling framework. Controlling a
straight Cartesian framework like this is mechanically straightforward and
furthermore generally simple from a product point of view, which is the reason
most 3D printers available today utilize this kind of plan. The Cartesian arrange
frameworks has for quite some time been utilized for instruments like plotters,
CNC processing machines, and 2D printers

22
 Fig 4.2 Cartesian Type Mechanism

4.4 SOFTWARE

4.4.1 CAD Tools

Computer Aided Design are used to design 3D parts for printing. Computer
aided design (CAD) is where we use the computer system to assist in the creation
modification analysis or optimization of a design. Computer aided design
software is utilized to expand the efficiency of the creator, enhance the nature of
configuration, enhance interchanges through documentation, and to make a
database for manufacturing.Computer-aided design files in the most genuine
sense are intended to enable you to effectively change and control parts in view of
parameters. Now and then CAD files are alluded to as parametric records. The
parts which are being represented as a tree of Boolean operations which are
performed on primitive shapes such as cubes, spheres, cylinders, pyramids.

23
4.4.2 CAM Tools

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

of translating CAD files into a machine-friendly font used for our 3D printer
electronics. Here we will be using a software which will be an integration of
object slicing, Generation of G codes and M codes, Object Placement and other
printer settings. Usually to turn a 3D part into a machine format, CAM software
needs a STL file. The machine friendly format that is used for printing is called
G-code.

4.4.3 Firmware

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

Atmel AVR processor. Atmel processors are what Arduino-based
microcontrollers use. These processors are exceptionally weak contrasted with
even the normal laptop you find in the landfill these days. However, so they do
run primitive software. This primitive software they run is the firmware. The
entire software chain that makes the 3D Printer work, the firmware portion of it is
the closest you get to actual programming. In fact, the term for what you are
doing with firmware is called cross compiling.

Fig 4.3 firmware

24
4.5 WORKING PRINCIPLE OF FDM BASED 3D PRINTER

FDM 3D printing is a technology that works both horizontally and vertically,

where an extrusion nozzle moves over a build platform. The process involves the
use of thermoplastic material that reaches melting point and is then forced out, to
create a 3D object layer by layer. As the design takes shape, it is clear to the see
each layer as a horizontal cross section. Following the completion of one layer, the
nozzle of the printer is lowered in order for the next layer of plastic to be added to
the design

When the FDM printer begins printing, the raw material is extruded as a thin
filament through the heated nozzle. It is deposited at the bottom of the printer
platform, where it solidifies. The next layer that is extruded fuses with the layer
below, building the object from the bottom up layer by layer.
Most FDM printers first print the outer edges, the interior edges next and lastly the
interior of the layer as either a solid layer or as a fill in matrix.

In some objects / models, there are fragile ‘overhangs’ that will droop unless
they are given some support. FDM printers incorporate a mechanism whereby
these support structures (called struts) are printed along with the object. They are
later removed once the build is complete. These struts are usually of the same
material as the object. Some printers have a second extruder to specifically deposit
soluble thermoplastic struts when there is a need to prevent the overhangs from
drooping. These struts may be of a different composition than the thermoplastic
used for the 3D model. They are later dissolved by an appropriate solvent.

25
1-Nozzle ejecting molten material, 2-Deposited material (modeled part),

3-Controlled movable table

Fig 4.4 extrusion nozzle

Fig 4.5 FDM methodology

26
 CHAPTER 5
DESCRIPTION OF COMPONENTS

27
5.1 MECHANICAL COMPONENTS
5.1.1 Smooth Rod M8 500 mm

Fig 5.1 smooth rod

These are the smooth rods used for 3D printer kits. They’re made of chrome-
plated high-carbon steel and provide smooth, consistent motion when paired with
linear bearings. These smooth rods are manufactured for use in 3D printers,
Hydraulics as well as in CNC / linear motion applications, are stand up to frequent
use without a problem.

In the robotics field, these smooth metal rods are usually used on the axis for 3D
printers or CNC engraving machines to slide on. This rod comes in various lengths
and body diameters

5.1.2 T8 Trapezoidal Lead Screw 8mm

The 500mm Trapezoidal 4 Start Lead Screw 8mm Thread 2mm Pitch Lead
Screw with Copper Nut used for general machine tools such as 3D printing

28
 Fig 5.2 lead screw
5.1.3 Flexible Coupling Coupler

Fig 5.3 coupler

This flexible type motor coupling can connect your driving shaft with the
driven shaft while it is very efficient in eliminating any misalignment to the
possible extent. Minimum backlash is another great advantage of this Aluminium
Flexible Coupling Coupler Helical Shaft 5mm x 8mm

29
5.1.4 LM8UU 8 mm Linear Ball Bearing

The LM8UU 8MM Linear Motion Bearing gives you very precise, safe and
reliable linear motion system. Such linear motion bearings are mostly used in 3D
printers and CNC(Computer Numerical Control) machines. An LM8UU 8 MM
Linear Motion Bearing can provide low friction motion along a single axis, hence
find a wide range of applications in DIY and robotics prototyping.

5.1.5 GT2 6MM Open Timing Belt

The Timing Belt is also called as the synchronous belt is popularly known for
its non-slipping mechanical drive belt. It is composed of the flexible belt which
contains a row of teeth embedded on the inner surface of the belt. Timing
Pulley and belt works when the toothed parts become compatible with each other.

Fig 5.4 Timing belt

30
5.1.6 Teeth Pulley

Fig 5.5 Teeth pulley

The GT2 series of belts and pulleys are designed 20 teeth 5mm bore
specifically for linear motion. They use a rounded tooth profile that guarantees that
the belt tooth fits smoothly and accurately in the pulley groove, so when you
reverse the pulley direction, there is no room for the belt to move in the groove

5.1.7 Aluminium channel frame

Fig 5.6 aluminium frame

31
 The most common uses for these types of channels include framing, tracks,
slides, protective edges, railings, rails, rims, and decoration

5.1.8 V6 J-Head Hotend Bowden Extruder

The hotend is the set of elements intended to melt and extrude the filament,
before depositing it in the construction space. The hotend always works in
conjunction with the extruder, either in direct or indirect mounting
(bowden). Simplifying its operation, it consists in the extruder pushing the filament
into a small chamber where it melts and by the pressure generated the molten
material comes out through a small hole where it solidifies when deposited on the
base of construction or the piece. Because the filament is pushed, it is necessary to
maintain maximum rigidity before reaching the melting zone. To do this, in the
hotend there must be two clearly differentiated parts: a cold zone and a hot
zone, with a transition between them as short as possible.

Fig 5.7 Hotend

32
5.1.9 MK8 Extruder Aluminium Block DIY Kit

This single head Complete Kit of Assembled MK8 Extruder has

outstanding quality and the best performance for DIY and professional systems.
With a 5.5kg (torque) stepper motor and all metal parts, you will find it easy to
solve the problems of uneven extrusion, jamming of hotend and filament
loading/unloading.

Fig 5.8 MK8 extruder

5.1.10 PLA 1.75 mm filament

PLA plastic or polylactic acid is a vegetable-based plastic material, which

commonly uses cornstarch as a raw material. ... PLA is a fully biodegradable
thermoplastic polymer consisting of renewable raw materials. Among all 3D
printing materials, PLA is part of the most popular materials used for additive
manufacturing.

33
 Fig 5.9 PLA filament

5.2 ELECTRONIC COMPONENTS

5.2.1 NEMA 17 Stepper Motor

The stepper motors move in precisely repeatable steps, hence they are the
motors of choice for the machines requiring precise position control. The
NEMA17 4.2 kg-cm Stepper Motor can provide 4.2 kg-cm of torque at 1.2A
current per phase.

The motor’s position can be commanded to move or hold at one position with
the help of Stepper Motor Drivers. The NEMA17 4.2 kg-cm Stepper Motor
provides excellent response to starting, stopping and reversing pulses from stepper
motor driver. They are very useful in the various application, especially which
demands low speed with high precision. Many machines such as 3D Printers, CNC
Router and Mills, Camera Platforms, XYZ Plotters etc

34
 Fig 5.10 stepper motor

5.2.2 Arduino Mega 2560

The Arduino Mega 2560 is a microcontroller board based on the

ATmega2560. It has 54 digital input/output pins (of which 15 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

Fig 5.11 Arduino mega 2560

35
5.2.3 Ramps1.4 Shield

Ramps is short for reprap Arduino mega pololu shield, it is mainly designed
for the purpose of using polo stepper driven board (similar to 4988 driven board).
Ramps can only work when connected to its mother board Mega 2560 and
4988/DRV8825. Owning to its stability in operation and great compatibility with
most 3Dprinter (all reprap-model such as pursa i2 and i3). The combination of
Ramps1.4+MEGA2560+A4988/DRV8825 is becoming a mainstream of DIY 3D
printer control board.\

Fig 5.12 RAMPS 1.4

5.2.4 A4988 Stepper motor Drivers

The A4988 driver Stepper Motor Driver is a complete micro-stepping motor

driver with built-in converter, easy to operate. It operates from 8 V to 35 V and can
deliver up to approximately 1 A per phase without a heat sink or forced air flow (it
is rated for 2 A per coil with sufficient additional cooling).

36
 Fig 5.13 A4988 driver

A4988 driver Stepper Motor Driver includes a fixed off-time current regulator,
the regulator can be in slow or mixed decay mode. The converter is the key to the
easy implementation of the A4988.

5.2.5 End stop switch

3D Printer Mech Endstop Switch uses a lever switch to detect when it is

activated. The switch is wired up so that when activated, it pulls the signal to
LOW. There is also an LED on the board that will light up when the switch is
activated. It uses a standard 4 pin 100″ pitch header and accepts a standard, old-
style CD-ROM audio connector cable.

The mechanical endstop is a simple solution to a simple problem. We want to be

able to detect when an X/Y/Z stage has reached its minimum or maximum. Instead
of messing with flags or complicated light beam interruption, we use a mechanical
switch.

37
 Fig 5.14 end stops

5.2.6 12 Volt 20 amp DC power supply

The term SMPS is defined as when the power supply is involved with the
switching regulator to change the electrical power from one form to another form
with required characteristics is called SMPS. This power supply is used to achieve
regulated DC output voltage from the DC input voltage (or) unregulated AC.
SMPS is a complex circuit such as other power supplies, it provides the supply
from a source to the loads. SMPS is very important for different appliances which
consume power and also for making electronic projects.

38
 Fig 5.15 smps

5.2.7 Heat bed

Heat beds are used because they dramatically improve print quality by keeping the
extruded plastic warm and thus preventing warping. Warping is a common
condition caused by plastic on the edges of the part cooling down at an uneven rate
when compared to the plastic inside of the part.

Fig 5.16 heat bed

39
5.3 PART LIST

S.NO DESCRIPTION QTY

1 NEMA 17 Stepper Motor 5

2 Arduino Mega 2560 1

3 Ramps1.4 Shield 1

4 A4988 Stepper motor Drivers 5

5 V6 J-Head Hotend Bowden Extruder 1

6 Mk8 Extruder Aluminium Block DIY 1

Kit

7 Smooth rod m8 500 mm 6

8 T8 Trapezoidal Lead Screw 8MM 2

9 Flexible Coupling Coupler 2

10 LM8UU 8 mm Linear Ball Bearing 12

11 End stop switch 3

40
12 GT2 6MM Open Timing Belt 2m

13 20 Teeth Pulley 5mm Bore 2

14 12 Volt 20 amp DC power supply 1

15 PLA 1.75 mm filament 100m

16 Aluminium channel -

Table 5.3

41
 CHAPTER 6
DESIGN CALCULATION

42
6.1 Conceptual Design

The design of the model has to be done in software where the actual model
with the required dimensions is developed so that it can be used to print the model.
To develop and fabricate thmodel there are many process and parameters involved
mainly design of the model. The design process started by keeping the print
volume as a basic design parameter. As the objective of the project is the
construction of economical and sizable 3D Printer, a print volume of 200 x 180 x
180 mm3 is selected. The 3 – Dimensional motion is achieved by synchronization
of movements in X, Y and Z directions. Hence mechanism of our 3D Printer is Z
plus core XY. This mechanism uses 4 stepper motors, two for Y-axis movement
(to and fro movement), one for Z-axis movement (Vertical movement) and one for
Extruder filament. This mechanism uses the single motor to control lead screws to
which the print bed is connected to the movement in Z – direction. The lead screws
are driven by the motor which in turn moves the bed in the vertical direction. Two
motors have been used here because the print volume is large, there will be a
disruption in the movement if only a single motor is used. The conceptual design
has been initially visualized in Sketch-up software

43
 Fig 6.1 Cad design

6.2 DETAIL DESIGN

6.2.1 Selection of Motor for X and Y axis

Assumptions:

Constant speed of the motor = 400rpm=6.667rps v = r ω

= [2πN]/60

= 41.908rad/s

Therefore;

400 = r*41.908 r = 9.547mm Torque = Force*Radius

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

44
Conclusion for motor design

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

Fig 6.2: Detailing of NEMA 17

6.2.2 X – axis Movement

Figure 6.3 shows the rendered CAD model of the mechanism of Lateral
movement. It consists of the pulleys, timing belt ,carriage, cylindrical rods, and
extruder nozzle (used in FDM process) arranged as shown.

The rotary motion from the motor in the y-axis is converted into linear sliding
motion and this linear motion is transfer by flange bearing by timing belt- pulley
connection as shown. The extruder nozzle is the main printing part of the machine.
For its movement in a horizontal direction, the carriage is provided. The extruder
nozzle is mounted onto to the carriage on one side, this may result in imbalance

45
and failure of the machine. To avoid this, the carriage is mounted on two rods and
designed for balance.

The carriage slides in the horizontal direction over these two cylindrical rods
using linear bearings. These cylindrical rods are fixed rigidly into the holes present
in the carriages that move in the Y direction. The timing belt is mounted on the
pulley which is driven by the motor on one side and a support pulley on the other
side

Fig 6.3 X-Axis Cad Design

The carriage is fixed to the lower timing belt of the loop, such that the belt
movement results in the movement of the carriage. When the motor rotates in
clockwise direction, since the carriage is connected to the lower belt in the loop, it
moves from right to left. When the motor rotates in an anticlockwise direction, the
carriage moves from left to right. To design this mechanism for horizontal
movement, the carriage is designed first for balance, so that the weight of the

46
carriage and the extruder nozzle is distributed equally on both the rods Figure 6.
The weight of the extruder nozzle is found and accordingly, the carriage is
designed. The carriage is designed using the free body diagram of the carriage

6.2.3 Y – Axis Movement

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

connected to the bed by using flange nut and shaft coupler as shown. The torque
produced by the motor is transmitted to the lead screws by using shaft coupler and
flange nut. When the motor rotates, say in a clockwise direction, shaft coupler
rotates lead screws in the same direction, say in a clockwise direction. The bed is
connected to the lead screws using threaded couplers, this makes the bed move in
a vertical direction when the lead screw rotates .

These cylindrical rods are fixed rigidly to the frame. The timing belt is
mounted onto the pulley which is driven by the motor on one side and a support
pulley on the other side. The carriage is fixed to the lower timing belt of the loop,
such that the belt movement results in the movement of the carriage. When the
motor rotates in one direction, the carriages are connected to the lower belt in the
loop moves from front to back or in opposite direction depending on the motor
orientation. The two motors should be in perfect synchronization for high quality
printing.

To design this mechanism for Y – axis movement, first the carriages are
designed. The carriages are designed to mount the motor, pulley and to hold X –
axis rods. Since these carriages are symmetric there is no problem of imbalance
and hence the carriage dimensions are determined by the mounting area required
by the motor, supporting pulley and the holes to hold the X – axis rods rigidly.

47
 Fig 6.4 y-– axis movement

6.2.4 Z – axis Movement

The rotary motion of motor is converted into linear sliding motion by

timing belt – pulley connection as shown. The X – axis rods are fixed to the
carriages with the help of holes in side face of the carriages. The carriages will
slide along the Y – axis over the two cylindrical rods using linear bearings.

6.3 BEARINGS

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

sliding shaft, pivot or wheel. At whatever point a pole pivots, it needs a heading
for smooth, powerful activity. A heading is intended to:

 Reduce friction

48
 • Support a load
• Guide moving part – wheel, shaft, pivots
6.3.1 Linear ball bearing LM8UU

This linear bearing is sort of the opposite of the radial ball bearings you
may be familiar with. Its Intended to slide along a 16mm linear shaft, rather than
to rotate around it. We chose 16mm bearings because based on the diameter of the
rod design. Linear Bearings come in open and close package. The closed ones
have their own lubrication and no additional lubrication is needed while open
ones need additional lubrication.

Fig 6.5 LM8UU ball bearings

Bearing number: LM08UU

Size (mm): 8x15x24

Brand: CX

Bore Diameter (mm): 8

49
Outer Diameter (mm): 15

Width (mm): 24

Bearing dimensions and specification in brand catalogue:

d - 8 mm

D - 15 mm

B - 24 mm

B1 - 17,5 mm

D1 - 14,3 mm

W - 1,1 mm

Weight - 0,011 Kg

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

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

6.4 BELTS AND PULLEY

It is in the form of a loop. It connects mechanically two shafts for

transmitting power smoothly from one shaft to another.

6.4.1 Belt Drive and its Types

Belt drive consists of two shafts and a belt. One of this shaft is a motor
shaft on which electric motor is mounted. On the other shaft, the machine is
mounted to which power is transmitted by the belt drive. Normally speed of the
motor is high because high-speed motors are more efficient. Therefore motor

50
shaft is the driving shaft and the machine shaft is the driven shaft. There are two
types of belt drive, namely flat belt drive and V-belt drive.

In this drive, both drive and driven shafts keep running a similar way. For
smooth power transmission, belt on one side is tighter than the opposite side. In
an even drive, the fixed side is constantly kept in the lower side of two pulleys on
the grounds that the hang of the upper side marginally expands the edge of contact
of the belt on the two pulleys. More edge of contact implies more power
transmission

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

two turning shafts. regularly parallel. Belts might be utilized as a wellspring of
movement, to transmit control effectively. or then again to track relative
development. Belts are circled over pulleys and may have a curve between the
pulley. furthermore, the poles require not be parallel. In a two-pulley framework.
the belt can either drive the pulleys regularly one way (the same if on parallel
shafts). or on the other hand, the belt might be crossed. with the goal that the
heading of the determined shaft is (the other way to the driver if on parallel
shafts). As a wellspring of movement, a transport line is one application where the
belt is adjusted to ceaselessly convey a heap between two focuses.

Belts are the least expensive utility for control transmission between shafts
that may not be axially adjusted. Power transmission is accomplished by
extraordinarily outlined belts and pulleys. The requests on a belt drive
transmission framework are extensive and this has prompted numerous minor
departure from the topic.They run smoothly with little noise,

51
6.5 TIMING BELT

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

engine that synchronizes the rotation of the crankshaft and the camshaft(s) so that
the engine's valves open and closes at the correct circumstances during each
cylinder's intake and exhaust strokes

Design of timing belt for X and Y axis

D=d= Diameter of pulley = 2cm

C = Center distance between two pulleys = 700mm

L = Length of the timing belt

Fig 6.6 Timing belt

The ultimate strength of polyurethane = 20.77MPa

Considering FOS = 4

Force = 40N (From Motor)

52
Area = 7.703 mm2

Width=5.925mm

Standard width=6mm

Conclusion for timing belt selection

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

Design of timing belt for Z axis

D=d= Diameter of pulleys = 15mm

C = Center distance between two pulleys = 0.736

L = Length of the timing

T=Thickness of the belt = 1.3mm

L = 2 (D + d) + √4c2 + D2 + d2

L = 1.540 m

The ultimate strength of polyurethane = 20.77MPa

Considering FOS = 2

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

σ = AF

Area = 12.03mm2

Width=9.25mm

53
Standard width=10mm

Conclusion for Z axis belt

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

pitch of 5.08mm is selected for smooth movement.

6.6 PULLEY

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

alter of course of a link or belt along its outline. Pulleys are utilized as a part of an
assortment of approaches to lifting loads. apply powers, and to transmit control. In
nautical settings, the gathering of the wheel, pivot, and supporting shell is alluded
to as a "piece." A pulley may likewise be known as a sheave or drum and may have
a section between two ribs around its perimeter. The drive component of a pulley
framework can be a rope, link, belt, or chain that keeps running over the pulley
inside the section.

Fig 6.7 pulley

By and large talking, for best execution, you need no less than 6 teeth in
contact with the pulley at any given time. That limits the possibility of the belt

54
slipping, and decreases kickback significantly further. By and by that implies you
need at least a 12-tooth pulley. Past that base, fewer teeth are for the most part
superior to more teeth, since a little pulley gives both more torque and more
determination. You get more torque in light of the fact that the more drawn out
your "arm", the less torque you have (Imagine the heap is mounted on an arm the
length of the range of the pulley, the shorter that arm, the less demanding it is to
lift the heap), and you get higher determination, since you have a settled number
of steps per unrest, and a little pulley moves a shorter straight separation for every
progression. A wheel with a notched edge around which a string passes, which
acts to alter the course of a power connection to the string and is utilized to raise
substantial weights.

For the most part talking, for best execution you need no less than 6 teeth in
contact with the pulley at any given time. That limits the shot of the belt slipping,
and decreases kickback significantly further. By and by that implies you need at
least a 12-tooth pulley. Past that base, fewer teeth are for the most part superior to
more teeth, since a little pulley gives both more torque and more determination.
You get more torque on the grounds that the more drawn out your "arm", the less
torque you have (Imagine the heap is mounted on an arm the length of the range
of the pulley, the shorter that arm, the less demanding it is to lift the heap), and
you get higher determination, since you have a settled number of steps per
transformation, and a little pulley moves a shorter straight separation for each
progression.

Design of pulley for X and z axis

From section we have the radius of the pulley,

Radius = 9.55mm = 10mm

55
Diameter = 20mm

Pitch = 2mm

Circumference = 2πr

= 62.84mm

Number of teeth = [circumference/pitch]

=31.42

≈32 teeth

Parameter X axis Z axis

Inner diameter 5mm 5mm

Outer diameter 20mm 20mm

Pitch 2.032mm 2.032mm

Width 6mm 6mm

Thickness 1.3mm 1.3mm

Table 6.6 Pulley Specifications

56
 CHAPTER 7
FIRMWARE AND SOFTWARE

57
7.1 INTRODUCTION

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

the form of nonvolatile memory in a computer program that provides to control the
device in hardware. It can provide a standard operating environment to the devices
to more complex software that allows hardware to run on the operating system
(os), to perform various devices to complete all monitoring and other manipulation
functions. The firmware is used for different purposes like consumer appliances,
computer peripherals etc. 3D printer electronic devices are controlled by CPU such
as Intel processor and Based on Arduino microcontroller used in the 3D printer.
These processors are used in the computer to run the primitive software. The
firmware of entire software makes the 3D printer work, the firmware portion of it
is the closest you get to actual programming. Therefore, the term what you are
doing with firmware is called cross-compiling.

7.2 LIST OF FIRMWARE

 Arduino IDE
 Marlin firmware

7.2.1 Arduino IDE

Arduino is an open-source electronics platform based on easy-to-use

hardware and software. Arduino boards are able to read inputs - light on a sensor, a
finger on a button, or a Twitter message - and turn it into an output - activating a
motor, turning on an LED, publishing something online. You can tell your board
what to do by sending a set of instructions to the microcontroller on the board.

58
 Over the years Arduino has been the brain of thousands of projects, from
everyday objects to complex scientific instruments. A worldwide community of
makers - students, hobbyists, artists, programmers, and professionals - has gathered
around this open-source platform, their contributions have added up to an
incredible amount of accessible knowledge that can be of great help to novices and
experts alike.

Arduino was born at the Ivrea Interaction Design Institute as an easy tool for
fast prototyping, aimed at students without a background in electronics and
programming. As soon as it reached a wider community, the Arduino board started
changing to adapt to new needs and challenges, differentiating its offer from
simple 8-bit boards to products for IoT applications, wearable, 3D printing, and
embedded environments. All Arduino boards are completely open-source,
empowering users to build them independently and eventually adapt them to their
particular needs. The software, too, is open-source, and it is growing through the
contributions of users worldwide

Fig 7.1 Arduino IDE

59
7.2.2 MARLIN

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

replicate in Rapid prototyping and it is popularly known as a 3D printer. It was
obtained by Grbl and Sprinter and it became open source for all 3D printer. Marlin
is used for a respected 3D printers like ultimate, Prusa and Printrbot for just a few
of the vendors who ship a variant of marlin. Marlin runs in 8-bit micro-controllers
the chips are at the center of open source reference platform for marlin Arduino
Mega2560 with RAMPS 1.4.

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

like supporting for ultimaker, ramps, and several other Arduino2570-based on 3D
printers. It supports printing over USB or from SD cards with folders and uses
look-ahead trajectory planning. Marlin is licensed under the GNU GPL v3 or later.
It is based on sprinter firmware, licensed under GPL v2 or later. Marlin Firmware
runs through a 3D printer’s main board, to manage all the real-time activities on
the machine. It coordinates the heaters, buttons, sensors, steppers, LCD display,
lights and everything will be involved in the 3D printing operation. Marlin implies
on additive manufacturing process called as FUSED DEPOSITION MODELING.
In this process a motor pushes the thermoplastic filament into a hot nozzle which
melts and extrudes the material while the nozzle is moved under computer control.
After several minutes it start laying layer by layer to form a physical object. The
control-language for Marlin is used to derivative of G-code. G-code gives
commands about machine to do simple things like to “set heater 1 to 210°,” or
“move to XY at speed F.” To print a model through Marlin, it must be converted to
G-code using a program called a “slicer.” Since every printer is different, but we
won’t find G-code files from download we should need to slice by yourself. As
Marlin receives movement of all commands it allows themselves into a movement

60
queue to be executed in the order received. The stepper will interrupt the processes
for queue and they start converting linear movements into precisely-timed
electronic pulses to the stepper motors. Even at modest speeds Marlin needs to
generate thousands of stepper pulses every second. Since CPU speed limits how
fast the machine can be moved, we’re always looking for new ways to optimize the
stepper interrupt! Heaters and sensors are managed in a second interrupt that
executes at much slower speed, while the main loop handles command processing,
updating the display, and controller events. For safety purpose in Marlin firmware
it will actually reboot the CPU gets too overloaded to read the sensors.

Fig 7.2 marlin firmware

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7.3 STEPS TO INSTALL FIRMWARE

Step 1: The first step in firmware is to be download the Arduino IDE from the
Arduino website and install it following the usual procedure for your OS. Marlin
can be compiled in Linux, Windows, and Unix.

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

Step 3: See Configuring Marlin for an explanation of the configuration file format
and a synopsis of most of options in these files to specify which hardware is in use

Step 4: Verify/Compile the firmware using Arduino IDE

Step 5: connect the controller to PC via USB cable

Step 6: upload the firmware program to controller CPU

Fig 7.3 Arduino setup 1

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Fig 7.3.1 Arduino setup 2

Fig 7.3.2 Arduino setup 3

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Fig 7.3.3 Arduino setup done

Fig 7.3.4 Program Of Arduino

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 Fig 7.4 Marlin Firmware

7.4 SOFTWARE

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

data or computer instructions software is all information processed by computer
systems program and data. In the 3D printer, the software performs an important
role for sending the information from one place to another without software we
cannot perform any virtual object which is to be sliced and printed is not obtained.
The programming platform is an embedded C and C++ program where C++
program acts an important role in the 3D printer the specification required for
movement and parameter are directly calibrated and loaded on the controller. the
software is the platform where it can create any 3D model by using any 3D
software.

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7.5 SOFTWARE USED FOR DESIGNING THE 3D PRINTING PARTS

7.5.1 SOLIDWORKS

It was published by Dassault system. The solid works are used for solid
modeling computer-aided design (CAD). It runs on operating systems like
windows7 or 8 etc. the 3D printed parts were designed using solid works to
develop an assembly of a 3D printer with complete design with solid works you
can print directly to 3D printer, similar to how you would print a document to your
normal printer.it can also give different types of output like STL, IGES, VRML
and JPEG etc

Fig 7.5 solidworks 3d model

Most probably we are using STL file because it accepts the format of 3D printing
and there are many formats provide more information about the model being
printed. It does not require any post-processing to define data such as orientation,
color, material etc. solid works support any slicing software to produce any G-code

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for printing the 3D models, so we have preferred solid works 2015 for designing
complete model in this software

7.5.2 CATIA

It was also published by DASSAULT SYSTEM. CATIA stands Computer

Aided Three-dimensional Interactive Application. it can be used to create 3D CAD
models, but this cannot be used directly for input in a 3D printer.The 3D printer is
a layer-by-layer process, hence it does not support any slicing software. This
process cannot be done CATIA, whereas it does not have any STL file to convert
any G-code. this is problems faced while designing the 3D model in the catia

7.6 SOFTWARES USED FOR PRINTING THE 3D MODELS

7.6.1 CURA

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

face the slicing software so that many users don’t know how to realize what it’s
doing. Just load the cad model into the software, select the quality should be
printed by pressing the print option in the software. It’s as easy as traditional 2D
printing. Essentially that’s all Cura is print software can get a digital file from any
computer to the 3D printer in any format. so that the 3D printing can understand
itself for printing. Cura can be available free for you to download, but it is also
open source. It is the standard software of 3D slicers worldwide. If you compare
Cura to other 3D slicing software, it seems very simple in cura there are many
features available for slicing when compare to other software with limited options
and adjustments. But Cura’s has more complex settings are there if you need them;
it’s just been designed very neatly and user-friendly. Cura is developed by 3D
printer manufacturer Ultimaker and, as everyone is know from their hardware,
they’re perfectionists. In the Cura software are almost all those settings and options

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that can be seen in the majority of other slicing software. We can change setting
according to what we want to print by changing a few quality and speed options,
then in Cura, it’s all carefully laid out and ready to go. We’re only going to assume
that you’ve switched to the printer and loaded the filament. From that point, it can
help to guide operation in the ways of Cura 3D and getting started with 3D
printing. Cura which can be creates a seamless integration between hardware,
software and materials for best 3D printing experiencearound it support different
file formats such as STL, 3MF, AND OBJ. we are using in our 3D printer is STL
file format because the model is completely designed from solid works and the file
format is in STL. Every model we design for print it must be translated by cura
into instructions your ultimaker will understand. The first thing you will need is a
3D model just make sure export file is in STL file format so that cura understand it.
within moments, cura slices your models ready for print. You can do any changes
required for a 3D printer using printer setting

Fig 7.6 Cura

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 Fig 7.7 cura sliced image

7.7 PRONTERFACE

Pronterface is a GUI host for 3D printing: It can manage your printer as

well as prepare, slice, and print your STL files. As such, you can use its graphic
environment to easily configure and control your 3D printer through a USB cable.

Running on Python source code, Pronterface has become very popular since
it’s release thanks to the quick setup and easy-to-use interface. Despite looking
simplistic, with the bare minimum in graphics and UI, it’s still very useful and

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While we already have a detailed tutorial on using Pronterface within our article on
the Printrun Suite, in this article, we’re going to show you the steps for installation
and first use

Fig 7.8 pronterface

7.7.1 G-code interpreter

It is commonly used language to control CNC machines. In 3D printer

the designed to be able to run on modest hardware the Arduino loaded with the
firmware and is a file format that can be prepared in advance from design file like
CAD files. the G-code interpreter reads each line of the file that sends to actual
signals to the motor for moving the devices symmetrically. Firmware on a printer
electronic platform will be integrated into hardware interpreter

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7.7.2 G-code sender

It creates communication between computer and 3D printer and sends the

G-codes file to printer we need to generate the G-code from any slicing software
and after generating the G-code from slicing software then load the file on a
memory card if it can support or connect the USB connection via computer to 3D
printer with help of microcontroller it can understand the G-code language and can
connect program on your workstation

Fig 7.9 g code interpreter

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 CHAPTER 8
FABRICATED MODEL

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8.1 FABRICATED MODEL

Here are some images of a Fabricated portable 3D printer and its components
showes in the fig below

Fig 8.1 fabricated model

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 Fig 8.1.1 fabricated model

8.2 ASSEMBLY OF FABRICATED MODEL AND ELECTRONICS

Fig 8.2 assembly of 3d printer

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8.2.1 Portable 3d printer

Here is the some figures of our portable FDM based 3d printer

Fig 8.3 working model 1

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 Table 8.1: Machine Specifications

Specifications
Build Volume 200L x 180W x 180H mm3

Method Fused Deposition Modeling

Layer Resolution Height 55 microns

Number of Extruders One

Machine Size 380mm(L) x 550mm(W) x 610mm(H)

Machine Weight 8Kg

Power Supply DC 12V, 5amp

Power Consumption 250v, 50-60Hz, 5amp, 600W

Connectivitiey USB,

Filament Diameter 1.75mm

Nozzle Diameter 0.4mm

Filament Material PLA, ABS,

Print File Type Gcode, STL, Obj

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 CHAPTER 9
FUTURE PERSPECTIVE

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3D printing is a new and promising technology, and as with all
developing fields the Scope for improvement and advancement are
definitely infinite.

NASA

Nothing incorporates innovation and advancement like our space program. ,

NASA designed, printed, and tested rocket engine injectors by subjecting them to
challenging pressures and temperatures of over 6,000 degrees F. In fall , NASA
has devised to launch and deliver a 3-D printer to the International Space Station,
which will help astronauts to print replacement tools in space

BIOTECHNOLOGY

In 2012, an elderly woman in Belgium proclaimed a 3-D printed jawbone,

transplanted and specially tailored to her facial structure . This year, engineers at
Princeton were able to produce an ear imprint, applying a culture of animal cells
and silver nanoparticles; the experimental version was able to read audio beyond
the limit of human levels, making this a “bionic” ear . Using this method, leather
could be manufactured and even meat . Engineers are working on producing non-
perishable foods from powder (liquid-free) cartridges; imagine the effect that
developments like these could have on global sustainability process in the future .

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CHAPTER 10

79
 COST ESTIMATION
S.NO DESCRIPTION COST

1 NEMA 17 Stepper Motor 2600

2 Arduino Mega 2560 800

3 Ramps1.4 Shield 700

4 A4988 Stepper motor Drivers 400

5 V6 J-Head Hotend Bowden Extruder 875

6 Mk8 Extruder Aluminium Block DIY Kit 550

7 Smooth rod m8 500 mm 1050

8 T8 Trapezoidal Lead Screw 8MM 850

9 Flexible Coupling Coupler 300

10 LM8UU 8 mm Linear Ball Bearing &SK8 1000

11 End stop switch 360

12 GT2 6MM Open Timing Belt 180

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13 20 Teeth Pulley 5mm Bore 190

14 12 Volt 20 amp DC power supply 830

15 PLA 1.75 mm filament 450

16 Aluminium channel 300 -

17 Nut Bolt & screw 600

18 Fabrication Equppiment & Other electrocis cost 1500

TOTAL 13,535

Table 10.1

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CHAPTER 11

82
 CONCLUSION

The outcome of this project was to build a portable 3D Printer which

has been successfully completed. The design of the frame is made robust and
compact using aluminum sections. The material selection of the various elements
is economical. Using a double motor for vertical movement along with a proximity
sensor makes bed leveling easy and the bed movement is monitored with
resolution in microns. The drawback in few of the 3D Printer which uses bed
movement in Y axis has distortion of the printed layer at high rates of printing. To
overcome this drawback, a new mechanism has been developed which uses bed
movement in Z. The control synchronization can be achieved using this new 3D
printer technique

it was concluded that among various printing techniques available

for additive manufacturing like fused deposition modeling, selective laser
sintering, stereo lithography etc., fused deposition modeling is the most feasible
and can be easily implemented without much complexity. fdm method is
economical method to build a low cost 3D printer

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