FACULTY OF INNOVATIVE DESIGN TECHNOLOGY

UNIVERSITI SULTAN ZAINAL ABIDIN

Kampus Gong Badak, Kuala Nerus Terengganu

LAB SHEET 1: 3D FUSED DEPOSITION MODELLING APPLICATION

DEPARTMENT POLYMER TECHNOLOGY DR ROSLAN A/0845

COURSE RAPID PROTOTYPING AND REVERSE 0139214100
ENGINEERING
CODE NO TPP31604 096688410
CREDIT THREE (3) roslanawang@unisza.edu.my

1.0 Introduction

Figure 1.0: Fused Deposition Modelling (FDM)

Fused Deposition Modelling (FDM), often referred to as 3D printing, represents a prevalent

and widely embraced technology in contemporary times. This methodology is commonly
associated with additive manufacturing machines, renowned for their ability to create
objects layer by layer. FDM boasts numerous merits, including the utilization of robust
materials, the enduring stability of their mechanical properties, and the high-quality
components they produce. The production-grade thermoplastic materials employed in
FDM are well-suited for intricate functional prototypes, the crafting of resilient
manufacturing tools, and the fabrication of low-volume manufacturing parts. The CAD data
is seamlessly translated into an STL file through the utilization of CURA software, which
also automates the generation of G-Code for seamless 3D printing.

A wide variety of polymers, including ABS, PLA, PETG, PEI, and PEEK, are employed
in the 3D printing process. These polymers are extruded as plastic filaments from a coil and
pass through a nozzle. The filaments are melted and then deposited onto a substrate,
referred to as a build platform or heat bed. Both the base and the nozzle are meticulously
controlled by a computer. Each layer deposited is approximately 0.1mm in thickness. The
computer operates by translating the object's dimensions into coordinates, enabling precise
control of the nozzle and base. As the nozzle traverses the base, the molten plastic cools
and solidifies, creating a strong bond with the preceding layer. Subsequently, the print head
moves upward to facilitate the deposition of the next layer of plastic.

1
2.0 Objectives.

By the conclusion of this session, students will be able to:

a. Recognize and name each component of the FDM machine.

b. Explain the specific role and function of each component mentioned in objective a.
c. Convert a model from a CAD file to an STL file and create G-Code.
d. Independently operate the FDM machine.

3.0 FDM/3D Printer Main Components:

a) Heat bed

Heat beds are utilized to enhance the print quality

of 3D printed objects by raising their temperature.
The bed is heated to match the glass transition
temperature of the filament in use, facilitating a
gentle melting of the model layers, enabling them
to adhere securely to the heated bed.

b) Extruder

Extrusion involves guiding the filament into the

hot end of the 3D printer, driven by a stepper
motor. Conversely, retraction entails retracting
the molten filament from the hot end, primarily
controlled through the g-code, preventing the
unintended creation of filament bridges between
two distinct regions.

c) Fixed rod axes

The 3D printer relies on the Cartesian

coordinate system (X, Y, Z) for its three axes,
each corresponding to a linear fixed rod set at
right angles to one another. The motion of the
hot end is facilitated by timing belts and pulleys.

2
 d) Hot end

The hot end is heated to temperatures ranging

from 160 C to 250 C, depending on the type of
filament to be used. The hot end melts the
filament and pushes the melted filament
through the nozzle. The hot end needs to be
b. Extruder thermally insulated from the other components
of the 3D printer to prevent any damage.

e) LCD Menu

LCD menu have the control menu and reset

button. From the control menu select the
temperature needed, layer thickness and
others. Please refer to instructor.

e) Filament

Filament is a consumable used by the 3D printer to

print layers. Filament comes in a variety of
materials and colours. Filament can be composed
of metal, wood, clay, biomaterials, carbon fibre,
etc.
ABS: - thermoplastic (temperatures from 210C to
250C.)
PLA: - thermoplastic (160C to 220C). PLA is
biodegradable and emits slight odours. PLA is most
frequently used in the Innovation Lab on all 3D
printers.

3
4.0 Materials required
a. Fused Deposition Modelling (FDM) Machine Model: Prusa MK 3
b. CURA software build in
c. 3D model scanned (Lab 1 and Lab 2) saves in STL file.

5.0 Procedure
a. This exercise is the continues from the Lab 1 and 2 which is the application using
the 3D scanner (desktop and handheld) method.
b. The model that has been modified using the CAD software is transferred to STL
file.
c. From the STL file will auto generate the G-Code by using the CURA software
which is built in FDM.
d. Printing the 3D object

6.0 Generate G-Code Using Cura Software Application

The next step is to prepare the design in the 3D printer slicing software. Cura software will
be used for orienting parts on the printer build plate and selecting the colour of each object.
It also generates a code for the toolpath that the printer will read and follow to print the
objects. For further information you may also could follow the link instruction below

https://youtu.be/KDDfhqc57BI

6.1 Open Cura software, if a menu pops up prompting for the printer, select the
Ultimaker 3. If a menu does not pop up, make sure the printer currently selected
is Ultimaker 3 at the top left corner.

6.2 To load the model files from above, select File > Open File(s) at the top left of
the window and open the STL files containing the base of the model selected
insert as Figure 6.1. In Cura, right click and drag to pan around, middle click
and drag to move your frame of view, and scroll up and down to zoom in and
out.

Figure 6.1: The base of selected product to print

4
6.3 Select the model base and click the rotate tool from the toolbar on the left side
of the window. Use the red, blue, and green hoops to rotate the base so that the
front of your model is facing upward as Figure 6.2.

Figure 6.2: The base of rotation

6.4 Select the rectangle insert, and using the Move tool on the left, enter 0.15 mm
as the Z value to raise it vertically. If the insert does not move, go to Preferences
>> Configure Cura and ensure the setting "automatically drop down to the build
plate" is unchecked.

Figure 6.3: Move tool

Figure 6.3: The Move Tool

6.5. Having the model insert selected, select the Move tool on the left-hand toolbar.
Using the red and green arrows, drag the insert piece and align it in the model
base as Figure 6.4. Finally, click Slice, then click Save to File in the bottom
right of the window. Save the file as a GCODE file

Figure 6.4: Align Tool

5
 7.0. 3D Printing Process
After generate the g-code format then follow the instruction below.

• Switch on the 3d printer.

• Place your pen drive/memory card in USB.
• Clean your surface bed plate.
• Load your filament into the required extruder as per the requirement.
• Wait until the nozzle & bed plate comes into the required temperature.
• Setting the extruder height from bed plate in XYZ axes (follow instruction given).
• Open the file from the USB storage and select the Print option

4.0 Answer ALL the question given

a) List THREE (3) advantages using FDM in Rapid Prototyping.

i …………………………………………………….
ii …………………………………………………….
iii …………………………………………………….

b) List THREE (3) types of polymers used for FDM in Rapid Prototyping.
i …………………………………………………….
ii …………………………………………………….
iii …………………………………………………….

c) Draw a schematic diagram of FDM and list the components.

d) List ALL the process flow taken to print the object from save in STL file until finish
product.

Reminder: Please keep your product output for a presentation.

PLEASE SUBMIT YOUR LAB REPORT ON 1 Nov23