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Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical)
1
A Dissertation on
“Design and Manufacturing of
3D Printer”
By
Onkar Joshi B-121220880
Uday Rachewad B-121220895
Chaitanya Shinde B-121220912
Sohit Patil B-121220925
Under the Guidance of
Prof. Rupali Patil
Department of Mechanical Engineering
PCET’S
Pimpri Chinchwad College of Engineering &
Research,
[2017-2018]
Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical)
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PCET’S
Pimpri Chinchwad College of Engineering &
Research
CERTIFICATE
This is to certify that
Onkar Joshi,
Uday Rachewad,
Chaitanya Shinde,
Sohit Patil
have successfully completed their Dissertation entitled
“Design and Manufacturing of 3D Printer”
Under my supervision, in the partial fulfillment of Bachelor of Engineering-
Mechanical Engineering of University of Pune.
Date:
Place:
Prof. Rupali Patil External Examiner_________
(Guide)
Prof. Sham Mankar Dr. H.U. Tiwari
(Head of Department, Mechanical) (Principal)
Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical)
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Acknowledgement
It gives us great pleasure to present a project report on “DESIGN AND
MANUFACTURING OF 3D PRINTER”. In preparing this report number of hands
helped us directly and indirectly. Therefore, it becomes our duty to express our gratitude
towards them.
We are very much obliged to subject guide Prof. Rupali Patil in Mechanical Engineering
Department, for helping us and giving us proper guidance. We will fail in our duty if
we won’t acknowledge a great sense of gratitude to the Head of Department Prof. Sham
Mankar and the entire staff members in for their cooperation.
We are also thankful to our family for their whole-hearted blessings that are always for
our support and constant encouragement towards the fulfillment of the work. We wish
to record the help extended to be our friends in all possible ways and active support and
constant encouragement.
Chaitanya Shinde
Uday Rachewad
Onkar Joshi
Sohit Patil
Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical)
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INDEX
Sr no. Title Page no.
1 List Of :
(A) Figures
(B) Tables
5
6
2 Abstract 7
3 Introduction 8
4 Literature review 11
5 Methodology 13
6 Working 19
7 Design and calculations 23
8 Specifications 26
9 Cost estimation 28
10 Conclusion 29
11 References 31
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List of Figures
Sr no. Particulars Page no.
1 Representation of working of FDM 3d printer 9
2 Stepper motor 14
3 Lead screw 15
4 Extruder 16
5 Timing belt with pulley 17
6 Arduino Uno 18
7 Schematic diagram of FDM printer with various parts involved 19
Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical)
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List of Tables
Sr no. Particulars Page no.
1 Specifications of steppermotor 26
2 Specifications of lead screw 27
3 Specifications timing belt and pulley 27
4 Specifications of microcontroller 27
5 Costestimation 28
Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical)
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ABSTRACT
3D printing, also known as additive manufacturing (AM), refers to processes used to
create a three-dimensional object in which layers of material are formed under computer
control to create an object. Objects can be of almost any shape or geometry and are
produced using digital model data from a 3D model or another electronic data source
such as an Additive Manufacturing File (AMF) file. STL is one of the most common
file types that 3D printers can read. Thus, unlike material removed from a stock in the
conventional machining process, 3D printing or AM builds a three-dimensional object
from computer-aided design (CAD) model or AMF file by successively adding material
layer by layer.
3D printable models may be created with a computer-aided design (CAD) package, via
a 3D scanner, or by a plain digital camera and photogrammetry software. 3D printed
models created with CAD result in reduced errors and can be corrected before printing,
allowing verification in the design of the object before it is printed.
The manual modeling process of preparing geometric data for 3D computer graphics is
similar to plastic arts such as sculpting. 3D scanning is a process of collecting digital
data on the shape and appearance of a real object, creating a digital model based on it.
In the current scenario, 3D printing or AM has been used in manufacturing, medical,
industry and socio-cultural sectors which facilitate 3D printing or AM to become
successful commercial technology. The earliest application of additive manufacturing
was on the toolroom end of the manufacturing spectrum. For example, rapid prototyping
was one of the earliest additive variants, and its mission was to reduce the lead time and
cost of developing prototypes of new parts and devices, which was earlier only done
with subtractive toolroom methods such as CNC milling, turning, and precision
grinding.
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Chapter 1 - INTRODUCTION
Additive Manufacturing (AM) is a term to describe set of technologies that create 3D
objects by adding layer-upon-layer of material. Materials can vary from technology to
technology. But there are some common features for all Additive Manufacturing, such
as usage of computer together with special 3D modeling software. First thing to start
this process is to create CAD sketch. Then AM device reads data from CAD file and
builds a structure layer by layer from printing material, which can be plastic, liquid,
powder filaments or even sheet of paper.
The term Additive Manufacturing holds within such technologies like Rapid
Prototyping (RP), Direct Digital Manufacturing (DDM), Layered Manufacturing and
3D Printing. There are different 3d printing methods that were developed to build 3D
structures and objects. Some of them are very popular nowadays, others have been
dominated by competitors.
This article is focused at the following 3d printing technologies or some may call them
types of 3D printers:
● Stereolithography(SLA)
● Digital Light Processing(DLP)
● Fused deposition modeling (FDM)
● Selective Laser Sintering (SLS)
● Selective laser melting (SLM)
● Electronic Beam Melting (EBM)
● Laminated object manufacturing (LOM)
We are basically focusing on Fused deposition modeling (FDM) technique due to its
simplicity, ease of manufacturing and cheap parts involved. This technology was
developed and implemented at first time by Scott Crump, Stratasys Ltd. founder, in
1980s. Other 3D printing companies have adopted similar technologies but under
different names. A well-known nowadays company MakerBot coined a nearly identical
technology known as Fused Filament Fabrication (FFF).
With help of FDM you can print not only func1tional prototypes, but also concept
models and final end-use products. What is good about this technology that all parts
Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical)
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printed with FDM can go in high-performance and engineering-grade thermoplastic,
which is very beneficial for mechanic engineers and manufactures. FDM is the only 3D
printing technology that builds parts with production-grade thermoplastics, so things
printed are of excellent mechanical, thermal and chemical qualities.
3D printing machines that use FDM Technology build objects layer by layer from the
very bottom up by heating and extruding thermoplastic filament. The whole process is
a bit similar to stereolithography. Firstly, special software “cuts” CAD model into
layers and calculates the way printer’s extruder would build each layer. Along to
thermoplastic a printer can extrude support materials as well. Then the printer heats
thermoplastic till its melting point and extrudes it throughout nozzle onto base, that
can also be called a build platform or a table, along the calculated path. A computer of
the 3d printer translates the dimensions of an object into X, Y and Z coordinates and
controls that the nozzle and the base follow calculated path during printing. To support
upper layer the printer may place underneath special material that can be dissolved
after printing is completed.
When the thin layer of plastic binds to the layer beneath it, it cools down and hardens.
Once the layer is finished, the base is lowered to start building of the next layer.
Printing time depends on size and complexity of an object printed. Small objects can
be completed relatively quickly while bigger or more complex parts require more time.
Comparing to stereolithography this technique is slower in processing. When printing
is completed support, materials can easily be removed either by placing an object into
a water and detergent solution or snapping the support material off by hand. Then
objects can also be milled, painted or plated afterwards.
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Figure 1:- Representation of working of FDM 3d printer[6]
FDM technology is widely spread nowadays in variety of industries such as automobile
companies like Hyundai and BMW or food companies like Nestle and Dial. FDM is
used for new product development, model concept and prototyping and even in
manufacturing development. This technology is considered to be simple-to-use and
environment-friendly. With use of this 3d printing method it became possible to build
objects with complex geometries and cavities.
Pieces printed using this technology have very good quality of heat and mechanical
resistance that allows to use printed pieces for testing of prototypes. FDM is widely
useful to produce end-use products, particularly small, detailed parts and specialized
manufacturing tools. Some thermoplastics can even be used in food and drug
packaging, making FDM a popular 3D printing method within the medical industry.
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Chapter 2 - LITERATURE REVIEW
[1] OJAS DANDGAVAL, PRANITA BICHKAR Performed experiment on RAPID
PROTOTYPING TECHNOLOGY - STUDY OF FUSED DEPOSITION MODELING
TECHNIQUE i.e. FDM an additive manufacturing technology commonly used for
modeling, prototyping and production applications has 3 steps: pre-processing,
production, post-processing. In pre-processing, a CAD model is constructed which
converted into STL format for FDM process. In pre-processing, a CAD model is
constructed which converted into STL format for FDM process. FDM machine
processes. The layers are created until completion of the model. In postprocessing, the
model and any supports are removed by washing or stripping away. The surface of the
model is then finished and cleaned. FDM machine processes the layers are created until
completion of the model. In post-processing, the model and any supports are removed
by washing or stripping away. FDM uses two materials: modeling material and support
material.
[2] FAWAZ ABDULLAH published a research paper on FUSED DEPOSITION
MODELING (FDM) Mechanism in which he wrote FDM 3D printed models are created
with actual thermoplastics. It is a process using molten plastics or wax extruded by a
nozzle that traces the parts cross sectional geometry layer by layer. A plastic filament or
metal wire is unwound from a coil and supplies material to an extrusion nozzle which
turns the flow on and off. The nozzle is heated to melt the material and can be moved in
both horizontal and vertical directions by a numerically controlled mechanism which is
directly controlled by a computer-aided design software package. The model or part is
produced by extruding small beads of thermoplastic material to form layers as the
material hardens immediately after extrusion from the nozzle plant. In addition to the
heating element, there is usually a thermistor (temperature sensor) integrated into the
extruder assembly to control the required temperature for the specific material being
used. For example, one of the most common materials used in FDM is PLA (polylactic
acid) which has a melting temperature of around 160 degrees Celsius.
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[3] FRED FISCHER explained in “STRATSYS - Brochure Determining which
Technology is right for your Application”, that Fused Deposition Modeling TM
(FDM®) is the most advanced and effective additive manufacturing(AM) or 3D printing
technology available. Thermoplastic filament feeds through a heated head and exits,
under high pressure, as a fine thread of semi-molten plastic. In a heated chamber, this
extrusion process lays down a continuous bed of plastic to form a layer.
Ease of use: In addition to the simplicity of file setup, there are several other
factors that contribute to the ease of use of FDM.
• Material changeovers: Simply remove one material and slide a new material cartridge
into the 3D printer.
• Setup for a build: Insert a build sheet (FDM only), bring the system up to operating
temperature, push start and walk away.
• When complete: Open the door/hood and remove parts just seconds after a job
completes.
.
[4] JUSTIN LAN S.B. Mechanical Engineering Massachusetts Institute of Technology
submitted a paper on DESIGN AND FABRICATION OF MODULAR MULTI-
MATERIAL 3D PRINTER which features a low-cost high-performance design largely
using commercial off-the-shelf parts. Inkjet print heads from commercial desktop
printers allow the use of multiple materials within a single print. In addition, the
modular and open design of the printer allows the independent and continuing
development of print heads and print materials. 3D printing requires positioning a print
head in three dimensions relative to a build platform. Since the printer's motion control
system must be able to position the print head relative to the build platform, the
question becomes how best to distribute actuation in the X, Y, and Z directions
between the print head and the build platform. In order to position the carriage in 2
dimensions, the motions of the X-axis and the Y-axis must be combined. A typical
design uses the X-axis to move the carriage; the Y-axis in turn moves the entire X-
axis, supplying the second degree of freedom.
Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical)
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[5]BILL EARL Published a paper naming “ALL ABOUT STEPPER MOTORS”
Where he wrote about types and other technical aspects of stepper motors. according to
him, Stepper motors are DC motors that move in discrete steps. They have multiple coils
that are organized in groups called "phases". By energizing each phase in sequence, the
motor will rotate, one step at a time.
Driver Specifications:
The two most important parameters in the driver specifications are:
 Amps per phase - This is the maximum current that the motor windings can
handle without overheating.
 Resistance per phase - This is the resistance of each phase.
A Voltage rating is often stated. But some motors have very low coil resistance. Strictly
following those formulas, the drive voltage will be less than 5v and performance will
not be good. This type of motor is not a good match for a constant-voltage driver. These
steppers require a more specialized controller. The impedance limits the current flow
through the coil at the beginning of each step.
[6] 3D PRINTING AND ITS APPLICATIONS SIDDHARTH BHANDARI AND B
REGINA Dept. of CSE and IT, Saveetha School of Engineering, Saveetha University,
Chennai, INDIA reads that 3D printing, additionally referred to as additive
manufacturing, may be a method of basically making a three-dimensional object from a
package model. Charles a Hull was a pioneer of the solid imaging process known as
stereolithography and the STL (stereolithographic) file format which is still the most
widely used format used today in 3D printing. He is also regarded to have started
commercial rapid prototyping that was concurrent with his development of 3D printing.
Researchers at the European Space Agency have been able to create a 1.5 tonne building
block make of synthetic lunar soil. The result was a sturdy yet light material that the
astronauts can assemble themselves. It should be noted that, so far, these technologies
have been tested only on Earth. The real test will occur whenever the ESA decides that
it is ready for space launch.
Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical)
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[7] THE BACHELOR THESIS is a work of students of Institute of Industrial
Engineering, Barcelona (ETSEIB) explaining the design of Arduino micro-controller
and Power electronics. It pretends to do it at more affordable pricing to bring the new
technology to a large number of users and to everyday uses. Plastics used for the design
of the printer are the Acrylonitrile Butadiene Styrene (ABS) and polylactic acid (PLA).
Table 2, shows a comparative between each materialand emphasize some of their
properties.
Name SLA FDM SLS
Type of `material
Liquid
(photopolymer)
Solid (filament) Powder (polymer)
Max. size about
the piece
149,86 x 74,93 x
50,038 cm
91,44 x 60,96 x
91,44 cm
55,88 x 55,88 x
76,2 cm
Min. layer
thickness
0,0254 mm 0,127 mm 0,004 mm
Tolerance 0,127 mm 0,127 mm 0,254 mm
Surface Smooth Rough Medium
Construction rate Medium Slow Fast
Applications
Fit Tester
Functional Tests
Patterns of rapid
tooling
Very detailed
parts
High temperature
applications
Fit Tester
Functional Tests
Patterns of rapid
tooling
Very detailed
parts
High temperature
applications
Applications for
food and
Medicine
Fit Tester
Functional Tests
Patterns of rapid
tooling
Less detailed
parts
High temperature
applications
Parts with hinged
or pressure
settings
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[8] 3D PRINTING: THE NEXT REVOLUTION IN INDUSTRIAL ENGINEERING
by CONSUMER TECHNOLOGY ASSOCIATION reads that The technology for 3D
printing has roots that go back decades. 3D printing presents compelling business
opportunities. Companies that wait too long to explore the potential could be missing
out. Today, automotive manufacturers primarily use the technology for prototyping
rather than parts manufacturing. This is likely because automotive production volumes
are usually too high for 3D printing to be a viable manufacturing method for most
finished parts. Making parts cheaper, lighter and faster is often a key goal of the
automotive industry, indicating future opportunities for 3D printing in parts
manufacturing.
[9]3D PRINTING: A PATENT OVERVIEW, this report was prepared by the UK
INTELLECTUAL PROPERTY OFFICE PATENT INFORMATICS TEAM.
It reads 3D printing is presently gaining lots of attention in the press as a new technolog.
It is important to comprehend the fact that the term “3D printing” can be considered an
umbrella term for a number of related technologies that can be used to produce 3D
objects. A review of landscape maps of this technology reveals that key areas of interest
include biomedical applications, circuits and electrode fabrication. Future work could
take many forms given the diversity of the technologies contained within the dataset. It
would to interesting to look at Trade Mark filings in this area to see if there is a
relationship between this data and the current patent data. Further work would
encompass the analysis of particular parts of this dataset to provide analysis of patent
data relating to particular technology areas such as biotechnology. However it is evident
from the information in this report, that 3D printing is spreading across many
technologies and has the potential to disrupt many of them.
[10] EVALUATION OF 3D PRINTING AND ITS POTENTIAL IMPACT ON
BIOTECHNOLOGY AND THE CHEMICAL SCIENCES by BETHANY C. GROSS,
JAYDA L. ERKAL, SARAH Y. LOCKWOOD, CHENGPENG CHEN, AND DANA
M. SPENCE Department of Chemistry, Michigan State University, 578 South Shaw
Lane, East Lansing, Michigan 48824, United States. According to this the creation of
nearly any imaginable geometry can be made tangible using CAD software capable of
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producing. STL files to be read and fabricated by a 3D printer. Choosing the appropriate
printer type, SLA, inkjet, SLS, FDM, or LOM, depends on the design, materials, and
purpose of the device. Additive manufacturing has found widespread use as a tool to
bioengineer tissue, varying in composition from bone and teeth to vascular and organ
scaffolding. Major concerns when introducing a foreign scaffold to the body are the
ability of the material to be absorbed by the body (bioresorption) and whether or not it
will be rejected by the body (biocompatibility). For these reasons, scaffolds are
traditionally comprised of tissue taken from the individual in need (autogenous tissue).
In this respect, 3D printing has become an attractive avenue for the development of
biocompatible materials that are resorbable. Producing synthetic organs for organ
transplants is plausible when utilizing 3D tissue engineering. While the technology is
still far from achieving this ambitious goal, 3D printing allows for the printing of cells
and hydrogels, which are hydrated polymers that provide a biodegradable structure onto
which cells can adhere and grow.
[11] ASCENT THOUGHT, LEADERSHIP FROM ATOS, WHITE PAPER ON 3D
PRINTING. The aim of this paper is to analyze the impact that new 3D printing
technologies will have in the current product life cycle as well as the new opportunities
and challenges it will bring to the processes and the supply chain. It states that, “In the
coming years 3D printing technologies will be, in most cases, an alternative to current
manufacturing processes. According to it, in future, we will see three changes in the way
additive printing will change from the niche activity it is now. These changes will mainly
come from overcoming its current limitations: long processing time, limited materials
to be used and size of the manufactured parts, as well as from the reduction of the raw
materials and means of production. In-house printing and design is not yet optimized as
current CAD software is not affordable for non- specialized users (in terms of cost and
knowledge) and cheap and easy to use design tools should be developed. 3D scanning
and its link to the printer is also a functionality to be approached to the in-house printing
ecosystem. However, it’s expected that Open Source will be a clear alternative for mass
consumers. Open Source software and hardware are being developed and spreading 3D
Printing to the consumers (“prosumers”).
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[12] THE IMPACT OF USING 3D PRINTING ON MODEL MAKING QUALITY
AND COST IN THE ARCHITECTURAL DESIGN PROJECTS by DINA R.
HOWEIDY and ZAINA ARAFAT. The following advantages were evident after the
experiment like reduced time of creating a model for the course from weeks to few hours
and the learners can produce more professional and detailed models, which assets them
gain marks and efficiently test their model designs before the submission. The process
of using additives in order to form solid 3D objects of from a digital model is called
three-dimensional printing. 3D printing has worked into a number of markets that deals
with architecture and Interior Design with different kinds of applications in interior
design, architecture, building construction, automotive design, and so forth. In
conclusion, this paper’s results suggest the use of the new technological methods such
as the 3D printing in the design process to show better representation for the design idea,
this study explored the advantages of using the 3d printing in the teaching strategy for
learners in studios and design courses, in addition to other design considerations in the
educational process.
[13] A Review paper on 3D-PRINTING ASPECTS AND VARIOUS PROCESSES
USED in the 3D-Printing.This is a research paper on 3D printing and the various
materials used in 3D printing and their properties. Nowadays, rapid prototyping has a
wide range of applications in various fields of human activity: research, engineering,
medical industry, military, construction, architecture, fashion, education, the computer
industry and many others. 3D printable models can be created with the help of CAD
design packages or via 3D scanner. The manual modelling process of preparing
geometric data for 3D computer graphics is similar to method sculpting.
Before printing a 3D model from STL file, it must be processed by a piece of software
called a "slicer" which converts the 3D model into a series of thin layers and produces
a G-code file from “.stl” file containing instructions to a printer. The 3D printer follows
the G-code instructions to put down successive layers of liquid, powder, or sheet
material to build a model from a series of cross-sections of a model. The main advantage
of this technique is its ability to create almost any shape or geometric model. depending
on the type of machine used and the size and number of models being produced.
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[14] The Key Technology Research Based on DESKTOP 3D PRINTER OF
PARALLEL MECHANISM by LIU Yu-qing, ZHANG Chunyan,ZHANGQiu-jie,
XU Yao, YANG Liu-song and HUANG Xiao-fei School of Mechanical Engineering
Shanghai University of Engineering Science,Shanghai, China. The paper aims at
desktop 3D printer of parallel mechanism. It describes the performance requirements of
the 3D printer mechanism. It compares the common performance institutions, obtaining
the more suitable mechanism for 3D printer. It uses Solidworks to complete the overall
printer model design. Then analysis and compare the key technology 3D printer, motor
selection, positioning way and extrusion device obtaining for the suitable design
scheme. Complete 3D printer machine design and prototyping; finally use the prototype
to print out high-precision products. Computer controlled rapid prototyping machine
heating nozzle, basing on cross-sectional data for each layer of the x-y plane motion.
The wire feeder sent the wire to the nozzle, heated, melted and extruded adhesive from
the nozzle print material to the working platform, and then rapidly cooled and solidified.
This process is repeated until the completion of the entity.
[15] In a paper named THE IMPACT OF 3D PRINTING TECHNOLOGY ON THE
SOCIETY AND ECONOMY, Alexandru Pîrjan, Dana-Mihaela Petroşanu analysed that
the evolution of 3D printing technology, its applications and numerous social, economic,
geopolitical, security and environmental consequences.
The 3D printing technology consists of three main phases - the modelling, the printing
and the finishing of the product:
 In the modelling phase, in order to obtain the printing model, the machine uses
virtual blueprints of the object and processes them in a series of thin cross-
sections that are being used successively.
 In the printing phase, the 3D printer reads the design and deposits the layers of
material, in order to build the product. Each layer, based on a virtual cross
section, fuses with the previous ones and, finally, after printing all these layers,
the desired object has been obtained. Through this technique, one can create
different objects of various shapes, built from a variety of materials.
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 The final phase consists in the finishing of the product. In many cases, in order
to obtain an increased precision, it is more advantageous to print the object at a
higher size than the final desired one, using a standard resolution and to remove
then the supplementary material using a subtractive process at a higher
resolution.
[16] 3D PRINTING OF METALS by MANOJ GUPTA, Department of Mechanical
Engineering, National University of Singapore, 9 Engineering Drive 1, Singapore
117576, Singapore. 3D printing is an emerging technique of immense engineering
importance, capable of transforming the way we make components. It has been explored
worldwide for metals, ceramics and polymers. 3D printing offers several advantages
such as the following:
(a) Shorter lead time
(b) Low cost
(c) Small volume of parts without the need of tooling or fixture
(d) Capability to fabricate near net shapes
(e) Design freedom that allows the fabrication of simple and complex shapes
(f) Potential to handle conventional and specialized materials.
The current Special Issue was targeted at metal-based materials as 3D printing of metals
is particularly challenging due to a host of microstructural changes that are encountered,
especially when the metals and alloys are exposed to high temperatures. Control of the
dimensional accuracy and end properties is still being explored by researchers for
different types of metals and alloys as the results of one compositional system cannot
be translated to another compositional system. Overall, nine papers (one review and
eight research papers) have been published in this issue. The materials investigated were
the following:
a. Aluminium-based materials
b. Magnesium-based materials
c. Steels
d. Titanium-based materials
e. Oxide dispersion-strengthened aluminium-based composites
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This suggests that there is no preferred metal system that is targeted by researchers but
all important metallic materials are equally targeted. 3D printing techniques that were
utilized in the papers published in this issue included the following:
a. Micro-coating metal additive manufacturing (MCMAM)—new technique
b. Electron beam melting
c. Selective laser melting
d. Laser metal deposition
This suggests the main drivers of 3D printing in the research community. The present
Special Issue, in general, is very informative as the nine articles cover a variety of topics
and challenges and for different metallic materials (ferrous and non-ferrous) covering
four different types of 3D printing techniques and issues related to microstructure,
process defects, mechanical properties and heat treatments for a wide spectrum of
applications.
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Chapter 3 - METHODOLOGY
The 3D being designed as discussed above is of FDM (fused deposition
modelling) type and consists of stepper motors that controls the three axes namely X, Y
and Z axis making it possible to achieve stepped motion of various parts with respect to
time and achieve a slow but precise motion of extruder and printing plate respectively.
The whole process is a bit similar to stereolithography.
Firstly, special software “cuts” CAD model into layers and calculates the way
printer’s extruder would build each layer. Along to thermoplastic a printer can extrude
support materials as well. Then the printer heats thermoplastic till its melting point and
extrudes it throughout nozzle onto base, that can also be called a build platform or a
table, along the calculated path. A computer of the 3d printer translates the dimensions
of an object into X, Y and Z coordinates and controls that the nozzle and the base follow
calculated path during printing. To support upper layer the printer may place underneath
special material that can be dissolved after printing is completed. The parts involved in
making this printer are as follows.
● Stepper motor
● Lead screw
● Timing belt
● Timing pulleys
● Extruder
● Arduino Mega
● RAMPS 1.4 Shield
● PLA Filament
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3.1 Stepper motor: -
The stepper motor is used for actuating the components along various axes like x, y and
z these are the building block of an FDM 3D printer as these are needed for accurate
and precise deposition of plastic. These revolve in very small increments that is
converted into linear motion by using pulleys and lead screws giving small
displacements at a time. Brushed DC motors rotate continuously when DC voltage is
applied to their terminals. The stepper motor is known by its property to convert a train
of input pulses (typically square wave pulses) into a precisely defined increment in the
shaft position. Each pulse moves the shaft through a fixed angle.
Figure: - Stepper motor[5]
Stepper motors effectively have multiple "toothed" electromagnets arranged around a
central gear-shaped piece of iron. The electromagnets are energized by an external
driver circuit or a microcontroller. To make the motor shaft turn, first, one electromagnet
is given power, which magnetically attracts the gear's teeth. When the gear's teeth are
aligned to the first electromagnet, they are slightly offset from the next electromagnet.
This means that when the next electromagnet is turned on and the first is turned off, the
gear rotates slightly to align with the next one. From there the process is repeated. Each
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of those rotations is called a "step", with an integer number of steps making a full
rotation. In that way, the motor can be turned by a precise angle.
3.2 Lead screw: -
A lead screw drive provides exactly the required combination of features needed for this
task. The large mechanical advantage of the screw drive means even a modestly sized
motor will be able to move the weight of the build platform. Screw drives are non back
drivable, so the drive motor will not need to exert a large holding torque to maintain the
platform's position. The primary drawback of a lead screw, the slow movement speed,
is mostly irrelevant in this application because the build platform is not required to
translate, quickly or frequently. Finally, the backlash in the lead screw system is
eliminated because the weight of the build platform preloads the drive nut against the
lead screw.
Figure: - Lead screw [4]
3D printers feature a cantilevered build platform that is actuated by a single screw drive.
While this design is adequate for small prints, its low stiffness makes it unsuitable for
larger printers. An examination of existing industrial printers reveals that most feature
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two or more linear screw drives actuating the platform together, allowing multiple-point
support of the build platform. Due to the size and weight of the build platform in this
printer, two independent screw drives are used to control the Z-axis. The use of
additional screw drives provides more support for the platform, as well as the ability to
tilt the platform for leveling and calibration.
3.3 Extruder: -
Its job is to convert the solid coil of plastic material into the molten state by utilizing a
heating element within the extruder assembly. This heating element can be a vitreous
enamel resistor, a nichrome wire, or a cartridge heater. In addition to the heating
element, there is usually a thermistor (temperature sensor) integrated into the extruder
assembly to control the required temperature for the specific material being used. For
example, one of the most common materials used in FDM is PLA (polylactic acid)
which has a melting temperature of around 160 degrees Celsius. A 3D printer using
fused filament fabrication can make use of multiple materials if it has multiple extruder
Figure: - Extruder[6]
heads; most commercial printers do in fact feature multiple extruders to allow the
use of support material.
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3.4 Timing Belts and Pulleys: -
Timing belt is a flexible belt with teeth molded onto its inner surface. It is designed to
run over matching toothed pulleys or sprockets. Toothed belts are used in a wide array
of in mechanical devices, where high-power transmission is desired. with carefully
designed tooth profiles, backlash can be almost completely eliminated. The weaknesses
of a belt drive are exactly opposite those of a lead screw. As the mechanical advantage
of a belt drive is low, they can be easily back driven unless a holding force is applied to
the drive pulley. In addition, as the belt can stretch slightly, belt drives are much less
stiff than screw drives and can introduce some springiness into the system. In addition,
belt drives require a tensioning system to prevent over- or under-tightening of the belt
from degrading performance.
Toothed belts are made of a flexible polymer over a fabric reinforcement. Original ly
this was rubber over a natural textile, but developments in material science have had a
substantial effect in increasing the lifetime of these belts. This included changes from
natural to synthetic rubber and polyurethane and also the adoption of nylon, Kevlar, or
other aramid fibres and carbon fibers in their reinforcement.
Figure: - Timing belt with pulley[4]
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3.5 Micro-controller(Arduino Mega 2560):-
Arduino is an electronic platform that of the Open Source philosophy of both software
and hardware. This system was created for students, professionals, designers and / or
staff who were interested in creating interactive objects. For this reason, Arduino
software is very intuitive and easy.
Other aspects of the microcontroller are the memories; this contains different types and
each of these memories has characteristics and functions of which are described below:
● Memory FLASH: Is the memory for save the firmware.
● SRAM (Static Random-Access Memory): where the program stores and
manipulates variables to run.
● EEPROM (Electrically Erasable Programmable Read-Only Memory): is an area
of memory that could be used by programmers to store information of long-term
Figure: - Arduino Mega 2560[4]
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3.6 RAMPS 1.4 Shield: -
RepRap Arduino Mega Pololu Shield, or RAMPS for short. It is designed to fit the entire
electronics needed for a RepRap in one small package for low cost. RAMPS interface
an Arduino Mega with the powerful Arduino MEGA platform and has plenty room for
expansion. The modular design includes plug in stepper drivers and extruder control
electronics on an Arduino MEGA shield for easy service, part replacement, upgrade-
ability and expansion. Additionally, a number of Arduino expansion boards can be
added to the system as long as the main RAMPS board is kept to the top of the stack.
Figure: - RAMPS 1.4 Shield[13]
Features: -
 It has provisions for the cartesian robot and extruder.
 Expandable to control other accessories.
 3 mosfets for heater / fan outputs and 3 thermistor circuits.
 Fused at 5A for additional safety and component protection
 Heated bed control with additional 11A fuse
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3.7 Stepper MotorDriver (A4988): -
Figure: - Stepper Motor Driver A4988[5]
The A4988 is a stepper motor driver board that has on a A4988_chip that enables
control of stepper motors through arduino type programming firmware and software.
The A4988 is an utterly tested and proven solution to drive stepper motors in RepRap
3D printers, and this fact should not be overlooked. As long as the following three
conditions are met, these Made in China Allegro A4988 stepper driver boards seem to
be bullet-proof workhorses:
Features: -
1. The stepper driver boards should not be inserted backwards in their respective
slots on the controller board.
2. The stepper cables should not be disconnected from the boards while powered
on.
3. Proper airflow (i.e. active cooling or in other words, a fan) should be provided.
4. Simple step and direction control interface
5. Five different step resolutions: full-step, half-step, quarter-step, eighth-step,
and sixteenth-step
6. Adjustable current control lets you set the maximum current output with a
potentiometer, which lets you use voltages above your stepper motor’s rated
voltage to achieve higher step rates
7. Intelligent chopping control that automatically selects the correct current decay
mode (fast decay or slow decay).
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3.8 PLA Filament (Poly Lactic Acid): -
Polylactic Acid (PLA) is different than most thermoplastic polymers in that it is derived
from renewable resources like corn starch or sugar cane. Most plastics, by contrast, are
derived from the distillation and polymerization of nonrenewable petroleum reserves.
Figure: - PLA Filament[9]
Property Value
Technical Name Polylactic Acid (PLA)
Chemical Formula (C3H4O2)n
Melt Temperature PLLA: 157 - 170 °C (315 - 338 °F)
Typical Injection Molding Temperature PLLA: 178 - 240 °C (353 - 464 °F)
Heat Deflection Temperature (HDT) 49 - 52 °C (121 - 126 °F) at 0.46 MPa
Tensile Strength PLLA: 61 - 66 MPa
Flexural Strength PLLA: 48 - 110 MPa
Specific Gravity PLLA: 1.24
Shrink Rate PLLA: 0.37 - 0.41%
Currently, the SPI resin identification code 7 ("others") is applicable for PLA. In
Belgium, Galactic started the first pilot unit to chemically recycle PLA (Loopla).
Unlike mechanical recycling, waste material can hold various contaminants. Polylactic
acid can be recycled to monomer by thermal depolymerization or hydrolysis. When
purified, the monomer can be used for the manufacturing of virgin PLA with no loss
of original properties (cradle-to-cradle recycling).
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Chapter 4 - EXPERIMENTAL TRIAL
Fused deposition modeling, which is often referred as “FDM”, is a type of
fabrication commonly used within engineering design. Throughout the development and
manufacturing production cycle, FDM systems are invaluable every step of the way
including conceptual prototyping, design verification and direct digital manufacturing.
FDM is ideally suited for the designers who demand part stability and strength. Unlike
other additive processes, FDM 3D printed models are created with actual
thermoplastics. The result is a prototype that can endure exposure to chemicals,
mechanical stress, and a variety of climate extremes. Extruded prints are supported with
soluble enabling complex cavities and geometries. This also makes the process perfect
for jigs and fixtures. FDM is a process using molten plastics or wax extruded by a nozzle
that traces the parts cross sectional geometry layer by layer. FDM creates tough parts
that are ideal for functional usage. FDM works on an “additive” principle by laying
down material in layers. A plastic filament or metal wire is unwound from a coil and
supplies material to an extrusion nozzle which turns the flow on and off. The nozzle is
heated to melt the material and can be moved in both horizontal and vertical directions
by a numerically controlled mechanism which is directly controlled by a computer-aided
design software package. The model or part is produced by extruding small beads of
thermoplastic material to form layers as the material hardens immediately after
extrusion from the nozzle plant.
Figure: - Schematic diagram of FDM printer with various parts involved[1]
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The nozzle in a 3D printer has one of the most important jobs of all the
mechanical systems. It is the last mechanical device that is used to build up a 3D object
and its design and functionality is extremely important when it comes to the accuracy
and build quality of the printer. The biggest contributor to the performance of the nozzle
is its orifice size. Typically, the nozzle size used on many 3D printers is 0.4mm. This
size is small enough to produce high quality parts while maintaining reasonable build
times. Printers such as the Makerbot Replicator use this size nozzle. Depending on the
overall goal of the part being printed however, these nozzles can be changed to larger
diameters in order to increase the speed of the print job. While doing so will decrease
the horizontal accuracy, parts that will be used as rough drafts or that will be post
processed with fillers or paints will still perform as intended. It is important to never set
the layer height higher than the nozzle size. This will dramatically decrease the bond
strength between the layers and overall build quality.
For example, if a 3D printer is using a 0.6mm nozzle, then the maximum layer
height should not exceed 0.5mm. While the nozzle is used to direct molten plastics in a
precise manner, it’s other job is to convert the solid coil of plastic material into the
molten state by utilizing a heating element within the extruder assembly. This heating
element can be a vitreous enamel resistor, a nichrome wire, or a cartridge heater. In
addition to the heating element, there is usually a thermistor (temperature sensor)
integrated into the extruder assembly to control the required temperature for the specific
material being used. For example, one of the most common materials used in FDM is
PLA (polylactic acid) which has a melting temperature of around 160 degrees Celsius.
In contrast, another very popular material used is nylon. This material requires extrusion
between 240 and 270 degrees Celsius.
It is very important to use the correct extrusion temperature in order to minimize
the risk of the nozzle jamming and also maximize the bond between bead layers. The
design of the extruder is very important to not only the printing accuracy, but also to the
overall performance and maintenance of the printer. While the bottom end of the
extruder must be able to heat the material to a desired temperature within a few degrees,
the upper end must remain as cool as possible in order to avoid jamming. This is due to
the feed mechanism located above the extruder, which requires the filament material to
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be in a completely solid state in order to function properly. One way to decrease heat
transfer from the heating element to the feed mechanism and in turn decreasing the
chance of jamming, is to use fans to cool the top end of the extruder. Depending on the
type of model being printed, and the type of material being used, a heated bed may be
important to maintain the structure’s shape while it cools. Since plastics shrink as they
cool, a quick temperature drop could cause the corners of a part to curl up off of the
printer bed. To minimize this risk, some printers incorporate an electronically heated
bed that keeps the temperature steady. This allows the model to cool at a more even rate
and improve its overall dimensional accuracy.
There are many factors that contribute to the build quality of a 3D printed part.
As mentioned previously, the extruder assembly which includes the extruder, heating
element, & nozzle contribute greatly to the overall build quality. In this section,
additional factors that contribute to build quality will be discussed.
Because the melted filament is bounded by the bottom bead layer and the bottom surface
of the nozzle, the rest of the material flows to the sides. This causes any excess or
deficiency in the filament cross-section to greatly affect the width of the bead produced.
According to ProtoParadigm (a supplier of high quality filaments), it can be said that
the error amount in the width of the bead is about two times that of the error in the
filament cross-section.
Depending on the software being used to print an object, the user can utilize a
wide range of different tools to modify the method in which the model is printed. Many
basic printing machines ship with their own software. An example of this is the
MakerBot type printers. This printer ship with a basic software package that is designed
to be as simple as possible. This means that the user does not have as much control over
how the model is actually printed. Some users prefer to use their software of choice in
order to open up these additional options. One such software is called Slic3r, an open-
source software that provides users with additional features.
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ASSEMBLY: -
Our work started with manufacturing of a skeleton for our 3-D printer. The material
chosen for the same is mild steel due to its higher strength and good heat resistance
along with less cost. The frame has dimensions 320mm x 320 mm x 400mm. Thus, a
total of 4160mm or 4.160m of steel bar is used. The rod was cut into required dimensions
and then welded by using Metal Inert Gas Welding (MIG).
A net (320 mm x 320mm) is mounted on the frame, by MIG welding, at a height of 800
mm from the top surface of the base of frame. The purpose of the net is to support: -
 The stepper motors which are to be mounted for the movement of leadscrews,
 The base plate on which the final material will be printed,
A net was used instead of a sheet of metal to reduce the weight of the assembly.
Figure: - Manufacturing of Frame Figure: - Manufactured Frame
A Saddle was manufactured of aluminum (dimensions - 320mm x 200mm x 18mm).
The aluminum rod of was cut into required dimensions and the welded to form our
saddle with use of Tungsten Inert Gas Welding (TIG). For the movement of the print
head the saddle was mounted on two lead screws which in turn were coupled with two
stepper motors. The lead screws used have diameter 8mm, lead of 8mm (axial
advancement in one revolution of screw) and are of 2mm in pitch (distance between
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corresponding threads). The stepper motors are fitted into the net by using screw. The
motors rotate and the lead screws advance in Y-Direction.
Figure: - Manufacturing of saddle.
The Saddle has a belt-motor-pulley assembly. For the purpose of mounting the extruder
i.e. the printing head on the saddle an adhesive named ‘tight bond’ is used. To facilitate
movement of the print head in X-Direction a motor and a pulley (a dead motor in our
case) are used. A timing belt is used to transmit torque from the live motor to the dead
motor. The printhead is attached to the belt and for ease of translation of the extruder
i.e. its movement in X-Direction it is supported by four wheels. The extruder is supplied
with PLA Filament (Poly Lactic Acid) which melts when its is passed through hot end
and solidifies when its falls down on the base plate. A fan is provided for avoiding over
heating of the print head.
A similar arrangement is provided for the lateral movement (in Z-Direction) of the base
plate.
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Figure :- Final Assembly
For controlling the motion of the stepper motors all of them are plugged to Arduino
Mega 2560 microcontroller. This controller sits on shield called RAMPS 1.4 to reduce
the tediousness of the wire works. Use of RAMPS makes it easy to mount stepper motor
drivers (A4988) on Arduino as it has dedicated slots unlike Arduino which has pins and
requires a lot of wired connection if we want to run motors using it.
All of components are powered by an ATX DC power supply of 450 Watts operating
on 12 Volts.
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Chapter 5 - DESIGN AND CALCULATIONS
Motors are used to move the platform in required directions. For raising and lowering
the platform the calculations are:
For Raising,
Considering equilibrium of horizontal forces,
𝑃 = 𝜇𝑁 cos𝛼 + 𝑁sin 𝛼 …. (a)
Considering equilibrium of vertical forces,
𝑊 = 𝑁 cos𝛼 − 𝜇𝑁sin 𝛼 …. (𝑏)
Dividing expression (a) by (b),
𝑃 =
𝑊(𝜇𝑁 cos𝛼 + 𝑁 sin 𝛼)
𝑁 cos𝛼 − 𝜇𝑁 sin 𝛼
Dividing the Numerator and Denominator of the right-hand side by cos𝛼,
𝑃 =
𝑊(𝜇 + tan 𝛼)
(1 − 𝜇 tan 𝛼)
….(𝑐)
The coefficient of Friction µ is expressed as,
𝜇 = tan 𝜑
Where 𝜑 is the friction angle.
Substituting 𝜇 = tan 𝜑 in Eq. (c), we have
𝑃 =
𝑊(tan 𝜑 + tan𝛼)
(1 − tan 𝜑 tan𝛼)
Or,
𝑃 = 𝑊 tan(𝜑 + 𝛼)
The torque required to raise the load is given by,
𝑀𝑡 =
𝑃𝑑𝑚
2
𝑀𝑡 =
𝑊𝑑𝑚
2
tan(𝜑 + 𝛼)
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For Lowering,
Considering equilibrium of horizontal forces,
𝑃 = 𝜇𝑁 cos𝛼 − 𝑁sin 𝛼 …. (a)
Considering equilibrium of vertical forces,
𝑊 = 𝑁 cos𝛼 − 𝜇𝑁sin 𝛼 …. (𝑏)
Dividing expression (a) by (b),
𝑃 =
𝑊(𝜇𝑁 cos𝛼 − 𝑁 sin 𝛼)
𝑁 cos𝛼 + 𝜇𝑁 sin 𝛼
Dividing the Numerator and Denominator of the right-hand side by cos𝛼,
𝑃 =
𝑊(𝜇 −tan 𝛼)
(1 + 𝜇 tan 𝛼)
…. (𝑐)
The coefficient of Friction µ is expressed as,
𝜇 = tan 𝜑
Where 𝜑 is the friction angle.
Substituting 𝜇 = tan 𝜑 in Eq. (c), we have
𝑃 =
𝑊(tan 𝜑 − tan𝛼)
(1 + tan 𝜑 tan𝛼)
Or,
𝑃 = 𝑊 tan(𝜑 − 𝛼)
The torque required to lower the load is given by,
𝑀𝑡 =
𝑃𝑑𝑚
2
𝑀𝑡 =
𝑊𝑑𝑚
2
tan(𝜑 − 𝛼)
Torque required to overcome collar friction,
According to uniform pressure theory,
(𝑀𝑡)𝑐 =
𝜇𝑐𝑊
3
.
𝐷0
3
− 𝐷𝑖
3
𝐷0
2
−𝐷𝑖
2
According to the uniform wear theory,
(𝑀𝑡)𝑐 =
𝜇𝑐𝑊
4
. (𝐷0 + 𝐷𝑖)
Where,
𝜇𝑐= coefficient of friction at the collar
𝐷0= outer diameter of the collar (mm)
𝐷𝑖= inner diameter of the collar (mm)
(𝑀𝑡)𝑐= collar friction torque (N-mm)
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Total Torque Transmitted,
(𝑀𝑡)𝑡 = 𝑀𝑡 + (𝑀𝑡)𝑐
The torque generated by the motor is used to raise and lower the platform.
The parameters of the platform are:-
Material used: Aluminum
Density: 2700 kg/𝑚3
Total weight: 1 kg
The parameters of the Motor are:
Holding Torque = 300 × 103
Nm.
Cogging Torque = 12 × 103
Nm.
Pitch (P) = 1.25 mm
Mean diameter (𝐷𝑚) = 8 mm
Collar Diameter (𝐷𝑐) = 6.75 mm
Coefficient of friction (µ) = 0.15
Coefficient of collar friction (µ𝑐) = 0.17
Force (F) = 1 kg × 9.81 𝑚 𝑠2
⁄ = 9.81 N
Lead (L) = 8 mm
Applying Power screw equations,
The frictional angle (𝜑) = tan−1(𝜇)
Or,
(𝜑) = tan−1(0.15)
(𝜑) = 8.5307°
The pitch angle (𝛼) = tan−1(
𝐿
𝜋×𝐷𝑚
)
Or,
(𝛼) = tan−1(
8
𝜋×8
)
(𝛼) = 17.6567
Therefore,
Torque required to raise the load will be:
𝑀𝑡 =
9.81 × 0.008
2
.tan(17.6567 + 8.5307)
𝑀𝑡 = 0.0192 𝑁𝑚
(𝑀𝑡)𝑐=
9.81×0.17
2
.
0.008
2
(𝑀𝑡)𝑐 = 0.0033 𝑁𝑚
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(𝑀𝑡)𝑡 = 0.0192 + 0.0033
(𝑀𝑡)𝑡 = 0.0225 Nm
Therefore,
Torque required to lower the load will be:
𝑀𝑡 =
9.81 × 0.008
2
.tan(17.6567 − 8.5307)
𝑀𝑡 = 0.0063 𝑁𝑚
(𝑀𝑡)𝑐=
9.81×0.17
2
.
0.008
2
(𝑀𝑡)𝑐 = 0.0033 𝑁𝑚
Therefore,
Number of motors required to move the platform =
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑡𝑜𝑟𝑞𝑢𝑒 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑡𝑜𝑚𝑜𝑣𝑒 𝑡ℎ𝑒 𝑝𝑙𝑎𝑡𝑓𝑜𝑟𝑚
𝑇𝑜𝑟𝑞𝑢𝑒 𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑 𝑏𝑦 𝑜𝑛𝑒 𝑚𝑜𝑡𝑜𝑟
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑀𝑜𝑡𝑜𝑟𝑠 =
0.0225
0.012
= 1.875 ≈ 2
Minimum height oflayer produced ( 𝒕 ) =
𝐿𝑒𝑎𝑑 𝑜𝑓 𝑆𝑐𝑟𝑒𝑤
360°
×
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑎𝑛𝑔𝑢𝑙𝑎𝑟 𝑠𝑡𝑒𝑝 𝑜𝑓 𝑚𝑜𝑡𝑜𝑟
( 𝑡 ) =
8
360
× 1.8 = 0.04𝑚𝑚
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Chapter 6 - CONCLUSION
As the 3D printer is a device, it should be analyzed with the advantages
and disadvantages, how the device can change the society and engineering etc.
in mind. The very nature of 3D printing, creating a part layer by layer, instead of
subtractive methods of manufacturing lend themselves to lower costs in raw
material. Instead of starting with a big chunk of plastic and carving away (milling
or turning) the surface in order to produce your product. Additive manufacturing
only "prints" what you want, where you want it. Other manufacturing techniques
can be just as wasteful. 3D printing is the ultimate just-in-time method of
manufacturing. No longer do you need a warehouse full of inventory waiting for
customers. Just have a 3D printer waiting to print your next order. On top of that,
you can also offer almost infinite design options and custom products. It doesn't
cost more to add a company logo to every product you have or let your customers
pick every feature on their next order, the sky's the limit with additive
manufacturing.
Figure: 3D printing growth & cost projection
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Whether you are designing tennis shoes or space shuttles, you can't just
design whatever you feel like, a good designer always take into account whether
or not his design can be manufactured cost effectively. Additive manufacturing
open up your designs to a whole new level. Because undercuts, complex
geometry and thin walled parts are difficult to manufacture using traditional
methods, but are sometimes a piece of cake with 3D printing. In addition, the
mathematics behind 3D printing are simpler than subtractive methods. For
instance, the blades on a centrifugal supercharger would require very difficult
path planning using a 5-axis CNC machine.
With so many potential benefits of 3D printing, there’s no surprise that
this method is making its way through a diverse number of industries and quickly
becoming a favorite tool of progressive marketers. Comparing the numerous
advantages, applications and future scope, we can conclude that the 3D printer
and its technology is able to create next industrial revolution.
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Chapter 7 - REFERENCES
[1] Ojas Dandgaval, Pranita Bichkar: Rapid Prototyping Technology - Study of Fused
Deposition Modeling Technique.
[2] Fawaz Abdullah: Fused Deposition Modeling (FDM) Mechanism.
[3] Fred Fischer: FDM AND POLYJET 3D PRINTING.
[4] Justin Lan: Design and Fabrication of a Modular Multi-Material 3D Printer.
[5] Bill Earl: All About Stepper Motors.
[6] Siddharth Bhandari And B Regina: 3D Printing and Its Applications
[7] School of Industrial Engineering, Barcelona (ETSEIB) Bachelor Thesis- 3D Printer
Electronics Design
[8] 3D Printing: The Next Revolution in Industrial Engineering By Consumer
Technology Association
[9] 3D Printing: A patent overview, UK intellectual property office patent informatics
team.
[10] Bethany C. Gross, Jayda L. Erkal, Sarah Y. Lockwood, Chengpeng Chen, and Dana
M. Spence: Evaluation of 3D printing and its potential impact on biotechnology and the
chemical sciences.
[11] White paper on 3D printing.
[12] Dina R. Howeidy and Zaina Arafat: the impact of using 3D printing on model
making quality and cost in the architectural design projects
[13] 3D - printing aspects and various processes used.
[14] Liu Yu-Qing, Zhang Chunyan,Zhangqiu-Jie, Xu Yao, Yang Liu-Song and Huang
Xiao-Fei: Desktop 3D Printer Of Parallel Mechanism
[15] Alexandru Pîrjan, Dana-Mihaela Petroşanu: The Impact Of 3D Printing
Technology on The Society and Economy
[16] Manoj Gupta: 3D Printing of Metals

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3D_Printer - Report.docx

  • 1. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 1 A Dissertation on “Design and Manufacturing of 3D Printer” By Onkar Joshi B-121220880 Uday Rachewad B-121220895 Chaitanya Shinde B-121220912 Sohit Patil B-121220925 Under the Guidance of Prof. Rupali Patil Department of Mechanical Engineering PCET’S Pimpri Chinchwad College of Engineering & Research, [2017-2018]
  • 2. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 2 PCET’S Pimpri Chinchwad College of Engineering & Research CERTIFICATE This is to certify that Onkar Joshi, Uday Rachewad, Chaitanya Shinde, Sohit Patil have successfully completed their Dissertation entitled “Design and Manufacturing of 3D Printer” Under my supervision, in the partial fulfillment of Bachelor of Engineering- Mechanical Engineering of University of Pune. Date: Place: Prof. Rupali Patil External Examiner_________ (Guide) Prof. Sham Mankar Dr. H.U. Tiwari (Head of Department, Mechanical) (Principal)
  • 3. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 3 Acknowledgement It gives us great pleasure to present a project report on “DESIGN AND MANUFACTURING OF 3D PRINTER”. In preparing this report number of hands helped us directly and indirectly. Therefore, it becomes our duty to express our gratitude towards them. We are very much obliged to subject guide Prof. Rupali Patil in Mechanical Engineering Department, for helping us and giving us proper guidance. We will fail in our duty if we won’t acknowledge a great sense of gratitude to the Head of Department Prof. Sham Mankar and the entire staff members in for their cooperation. We are also thankful to our family for their whole-hearted blessings that are always for our support and constant encouragement towards the fulfillment of the work. We wish to record the help extended to be our friends in all possible ways and active support and constant encouragement. Chaitanya Shinde Uday Rachewad Onkar Joshi Sohit Patil
  • 4. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 4 INDEX Sr no. Title Page no. 1 List Of : (A) Figures (B) Tables 5 6 2 Abstract 7 3 Introduction 8 4 Literature review 11 5 Methodology 13 6 Working 19 7 Design and calculations 23 8 Specifications 26 9 Cost estimation 28 10 Conclusion 29 11 References 31
  • 5. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 5 List of Figures Sr no. Particulars Page no. 1 Representation of working of FDM 3d printer 9 2 Stepper motor 14 3 Lead screw 15 4 Extruder 16 5 Timing belt with pulley 17 6 Arduino Uno 18 7 Schematic diagram of FDM printer with various parts involved 19
  • 6. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 6 List of Tables Sr no. Particulars Page no. 1 Specifications of steppermotor 26 2 Specifications of lead screw 27 3 Specifications timing belt and pulley 27 4 Specifications of microcontroller 27 5 Costestimation 28
  • 7. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 7 ABSTRACT 3D printing, also known as additive manufacturing (AM), refers to processes used to create a three-dimensional object in which layers of material are formed under computer control to create an object. Objects can be of almost any shape or geometry and are produced using digital model data from a 3D model or another electronic data source such as an Additive Manufacturing File (AMF) file. STL is one of the most common file types that 3D printers can read. Thus, unlike material removed from a stock in the conventional machining process, 3D printing or AM builds a three-dimensional object from computer-aided design (CAD) model or AMF file by successively adding material layer by layer. 3D printable models may be created with a computer-aided design (CAD) package, via a 3D scanner, or by a plain digital camera and photogrammetry software. 3D printed models created with CAD result in reduced errors and can be corrected before printing, allowing verification in the design of the object before it is printed. The manual modeling process of preparing geometric data for 3D computer graphics is similar to plastic arts such as sculpting. 3D scanning is a process of collecting digital data on the shape and appearance of a real object, creating a digital model based on it. In the current scenario, 3D printing or AM has been used in manufacturing, medical, industry and socio-cultural sectors which facilitate 3D printing or AM to become successful commercial technology. The earliest application of additive manufacturing was on the toolroom end of the manufacturing spectrum. For example, rapid prototyping was one of the earliest additive variants, and its mission was to reduce the lead time and cost of developing prototypes of new parts and devices, which was earlier only done with subtractive toolroom methods such as CNC milling, turning, and precision grinding.
  • 8. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 8 Chapter 1 - INTRODUCTION Additive Manufacturing (AM) is a term to describe set of technologies that create 3D objects by adding layer-upon-layer of material. Materials can vary from technology to technology. But there are some common features for all Additive Manufacturing, such as usage of computer together with special 3D modeling software. First thing to start this process is to create CAD sketch. Then AM device reads data from CAD file and builds a structure layer by layer from printing material, which can be plastic, liquid, powder filaments or even sheet of paper. The term Additive Manufacturing holds within such technologies like Rapid Prototyping (RP), Direct Digital Manufacturing (DDM), Layered Manufacturing and 3D Printing. There are different 3d printing methods that were developed to build 3D structures and objects. Some of them are very popular nowadays, others have been dominated by competitors. This article is focused at the following 3d printing technologies or some may call them types of 3D printers: ● Stereolithography(SLA) ● Digital Light Processing(DLP) ● Fused deposition modeling (FDM) ● Selective Laser Sintering (SLS) ● Selective laser melting (SLM) ● Electronic Beam Melting (EBM) ● Laminated object manufacturing (LOM) We are basically focusing on Fused deposition modeling (FDM) technique due to its simplicity, ease of manufacturing and cheap parts involved. This technology was developed and implemented at first time by Scott Crump, Stratasys Ltd. founder, in 1980s. Other 3D printing companies have adopted similar technologies but under different names. A well-known nowadays company MakerBot coined a nearly identical technology known as Fused Filament Fabrication (FFF). With help of FDM you can print not only func1tional prototypes, but also concept models and final end-use products. What is good about this technology that all parts
  • 9. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 9 printed with FDM can go in high-performance and engineering-grade thermoplastic, which is very beneficial for mechanic engineers and manufactures. FDM is the only 3D printing technology that builds parts with production-grade thermoplastics, so things printed are of excellent mechanical, thermal and chemical qualities. 3D printing machines that use FDM Technology build objects layer by layer from the very bottom up by heating and extruding thermoplastic filament. The whole process is a bit similar to stereolithography. Firstly, special software “cuts” CAD model into layers and calculates the way printer’s extruder would build each layer. Along to thermoplastic a printer can extrude support materials as well. Then the printer heats thermoplastic till its melting point and extrudes it throughout nozzle onto base, that can also be called a build platform or a table, along the calculated path. A computer of the 3d printer translates the dimensions of an object into X, Y and Z coordinates and controls that the nozzle and the base follow calculated path during printing. To support upper layer the printer may place underneath special material that can be dissolved after printing is completed. When the thin layer of plastic binds to the layer beneath it, it cools down and hardens. Once the layer is finished, the base is lowered to start building of the next layer. Printing time depends on size and complexity of an object printed. Small objects can be completed relatively quickly while bigger or more complex parts require more time. Comparing to stereolithography this technique is slower in processing. When printing is completed support, materials can easily be removed either by placing an object into a water and detergent solution or snapping the support material off by hand. Then objects can also be milled, painted or plated afterwards.
  • 10. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 10 Figure 1:- Representation of working of FDM 3d printer[6] FDM technology is widely spread nowadays in variety of industries such as automobile companies like Hyundai and BMW or food companies like Nestle and Dial. FDM is used for new product development, model concept and prototyping and even in manufacturing development. This technology is considered to be simple-to-use and environment-friendly. With use of this 3d printing method it became possible to build objects with complex geometries and cavities. Pieces printed using this technology have very good quality of heat and mechanical resistance that allows to use printed pieces for testing of prototypes. FDM is widely useful to produce end-use products, particularly small, detailed parts and specialized manufacturing tools. Some thermoplastics can even be used in food and drug packaging, making FDM a popular 3D printing method within the medical industry.
  • 11. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 11 Chapter 2 - LITERATURE REVIEW [1] OJAS DANDGAVAL, PRANITA BICHKAR Performed experiment on RAPID PROTOTYPING TECHNOLOGY - STUDY OF FUSED DEPOSITION MODELING TECHNIQUE i.e. FDM an additive manufacturing technology commonly used for modeling, prototyping and production applications has 3 steps: pre-processing, production, post-processing. In pre-processing, a CAD model is constructed which converted into STL format for FDM process. In pre-processing, a CAD model is constructed which converted into STL format for FDM process. FDM machine processes. The layers are created until completion of the model. In postprocessing, the model and any supports are removed by washing or stripping away. The surface of the model is then finished and cleaned. FDM machine processes the layers are created until completion of the model. In post-processing, the model and any supports are removed by washing or stripping away. FDM uses two materials: modeling material and support material. [2] FAWAZ ABDULLAH published a research paper on FUSED DEPOSITION MODELING (FDM) Mechanism in which he wrote FDM 3D printed models are created with actual thermoplastics. It is a process using molten plastics or wax extruded by a nozzle that traces the parts cross sectional geometry layer by layer. A plastic filament or metal wire is unwound from a coil and supplies material to an extrusion nozzle which turns the flow on and off. The nozzle is heated to melt the material and can be moved in both horizontal and vertical directions by a numerically controlled mechanism which is directly controlled by a computer-aided design software package. The model or part is produced by extruding small beads of thermoplastic material to form layers as the material hardens immediately after extrusion from the nozzle plant. In addition to the heating element, there is usually a thermistor (temperature sensor) integrated into the extruder assembly to control the required temperature for the specific material being used. For example, one of the most common materials used in FDM is PLA (polylactic acid) which has a melting temperature of around 160 degrees Celsius.
  • 12. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 12 [3] FRED FISCHER explained in “STRATSYS - Brochure Determining which Technology is right for your Application”, that Fused Deposition Modeling TM (FDM®) is the most advanced and effective additive manufacturing(AM) or 3D printing technology available. Thermoplastic filament feeds through a heated head and exits, under high pressure, as a fine thread of semi-molten plastic. In a heated chamber, this extrusion process lays down a continuous bed of plastic to form a layer. Ease of use: In addition to the simplicity of file setup, there are several other factors that contribute to the ease of use of FDM. • Material changeovers: Simply remove one material and slide a new material cartridge into the 3D printer. • Setup for a build: Insert a build sheet (FDM only), bring the system up to operating temperature, push start and walk away. • When complete: Open the door/hood and remove parts just seconds after a job completes. . [4] JUSTIN LAN S.B. Mechanical Engineering Massachusetts Institute of Technology submitted a paper on DESIGN AND FABRICATION OF MODULAR MULTI- MATERIAL 3D PRINTER which features a low-cost high-performance design largely using commercial off-the-shelf parts. Inkjet print heads from commercial desktop printers allow the use of multiple materials within a single print. In addition, the modular and open design of the printer allows the independent and continuing development of print heads and print materials. 3D printing requires positioning a print head in three dimensions relative to a build platform. Since the printer's motion control system must be able to position the print head relative to the build platform, the question becomes how best to distribute actuation in the X, Y, and Z directions between the print head and the build platform. In order to position the carriage in 2 dimensions, the motions of the X-axis and the Y-axis must be combined. A typical design uses the X-axis to move the carriage; the Y-axis in turn moves the entire X- axis, supplying the second degree of freedom.
  • 13. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 13 [5]BILL EARL Published a paper naming “ALL ABOUT STEPPER MOTORS” Where he wrote about types and other technical aspects of stepper motors. according to him, Stepper motors are DC motors that move in discrete steps. They have multiple coils that are organized in groups called "phases". By energizing each phase in sequence, the motor will rotate, one step at a time. Driver Specifications: The two most important parameters in the driver specifications are:  Amps per phase - This is the maximum current that the motor windings can handle without overheating.  Resistance per phase - This is the resistance of each phase. A Voltage rating is often stated. But some motors have very low coil resistance. Strictly following those formulas, the drive voltage will be less than 5v and performance will not be good. This type of motor is not a good match for a constant-voltage driver. These steppers require a more specialized controller. The impedance limits the current flow through the coil at the beginning of each step. [6] 3D PRINTING AND ITS APPLICATIONS SIDDHARTH BHANDARI AND B REGINA Dept. of CSE and IT, Saveetha School of Engineering, Saveetha University, Chennai, INDIA reads that 3D printing, additionally referred to as additive manufacturing, may be a method of basically making a three-dimensional object from a package model. Charles a Hull was a pioneer of the solid imaging process known as stereolithography and the STL (stereolithographic) file format which is still the most widely used format used today in 3D printing. He is also regarded to have started commercial rapid prototyping that was concurrent with his development of 3D printing. Researchers at the European Space Agency have been able to create a 1.5 tonne building block make of synthetic lunar soil. The result was a sturdy yet light material that the astronauts can assemble themselves. It should be noted that, so far, these technologies have been tested only on Earth. The real test will occur whenever the ESA decides that it is ready for space launch.
  • 14. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 14 [7] THE BACHELOR THESIS is a work of students of Institute of Industrial Engineering, Barcelona (ETSEIB) explaining the design of Arduino micro-controller and Power electronics. It pretends to do it at more affordable pricing to bring the new technology to a large number of users and to everyday uses. Plastics used for the design of the printer are the Acrylonitrile Butadiene Styrene (ABS) and polylactic acid (PLA). Table 2, shows a comparative between each materialand emphasize some of their properties. Name SLA FDM SLS Type of `material Liquid (photopolymer) Solid (filament) Powder (polymer) Max. size about the piece 149,86 x 74,93 x 50,038 cm 91,44 x 60,96 x 91,44 cm 55,88 x 55,88 x 76,2 cm Min. layer thickness 0,0254 mm 0,127 mm 0,004 mm Tolerance 0,127 mm 0,127 mm 0,254 mm Surface Smooth Rough Medium Construction rate Medium Slow Fast Applications Fit Tester Functional Tests Patterns of rapid tooling Very detailed parts High temperature applications Fit Tester Functional Tests Patterns of rapid tooling Very detailed parts High temperature applications Applications for food and Medicine Fit Tester Functional Tests Patterns of rapid tooling Less detailed parts High temperature applications Parts with hinged or pressure settings
  • 15. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 15 [8] 3D PRINTING: THE NEXT REVOLUTION IN INDUSTRIAL ENGINEERING by CONSUMER TECHNOLOGY ASSOCIATION reads that The technology for 3D printing has roots that go back decades. 3D printing presents compelling business opportunities. Companies that wait too long to explore the potential could be missing out. Today, automotive manufacturers primarily use the technology for prototyping rather than parts manufacturing. This is likely because automotive production volumes are usually too high for 3D printing to be a viable manufacturing method for most finished parts. Making parts cheaper, lighter and faster is often a key goal of the automotive industry, indicating future opportunities for 3D printing in parts manufacturing. [9]3D PRINTING: A PATENT OVERVIEW, this report was prepared by the UK INTELLECTUAL PROPERTY OFFICE PATENT INFORMATICS TEAM. It reads 3D printing is presently gaining lots of attention in the press as a new technolog. It is important to comprehend the fact that the term “3D printing” can be considered an umbrella term for a number of related technologies that can be used to produce 3D objects. A review of landscape maps of this technology reveals that key areas of interest include biomedical applications, circuits and electrode fabrication. Future work could take many forms given the diversity of the technologies contained within the dataset. It would to interesting to look at Trade Mark filings in this area to see if there is a relationship between this data and the current patent data. Further work would encompass the analysis of particular parts of this dataset to provide analysis of patent data relating to particular technology areas such as biotechnology. However it is evident from the information in this report, that 3D printing is spreading across many technologies and has the potential to disrupt many of them. [10] EVALUATION OF 3D PRINTING AND ITS POTENTIAL IMPACT ON BIOTECHNOLOGY AND THE CHEMICAL SCIENCES by BETHANY C. GROSS, JAYDA L. ERKAL, SARAH Y. LOCKWOOD, CHENGPENG CHEN, AND DANA M. SPENCE Department of Chemistry, Michigan State University, 578 South Shaw Lane, East Lansing, Michigan 48824, United States. According to this the creation of nearly any imaginable geometry can be made tangible using CAD software capable of
  • 16. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 16 producing. STL files to be read and fabricated by a 3D printer. Choosing the appropriate printer type, SLA, inkjet, SLS, FDM, or LOM, depends on the design, materials, and purpose of the device. Additive manufacturing has found widespread use as a tool to bioengineer tissue, varying in composition from bone and teeth to vascular and organ scaffolding. Major concerns when introducing a foreign scaffold to the body are the ability of the material to be absorbed by the body (bioresorption) and whether or not it will be rejected by the body (biocompatibility). For these reasons, scaffolds are traditionally comprised of tissue taken from the individual in need (autogenous tissue). In this respect, 3D printing has become an attractive avenue for the development of biocompatible materials that are resorbable. Producing synthetic organs for organ transplants is plausible when utilizing 3D tissue engineering. While the technology is still far from achieving this ambitious goal, 3D printing allows for the printing of cells and hydrogels, which are hydrated polymers that provide a biodegradable structure onto which cells can adhere and grow. [11] ASCENT THOUGHT, LEADERSHIP FROM ATOS, WHITE PAPER ON 3D PRINTING. The aim of this paper is to analyze the impact that new 3D printing technologies will have in the current product life cycle as well as the new opportunities and challenges it will bring to the processes and the supply chain. It states that, “In the coming years 3D printing technologies will be, in most cases, an alternative to current manufacturing processes. According to it, in future, we will see three changes in the way additive printing will change from the niche activity it is now. These changes will mainly come from overcoming its current limitations: long processing time, limited materials to be used and size of the manufactured parts, as well as from the reduction of the raw materials and means of production. In-house printing and design is not yet optimized as current CAD software is not affordable for non- specialized users (in terms of cost and knowledge) and cheap and easy to use design tools should be developed. 3D scanning and its link to the printer is also a functionality to be approached to the in-house printing ecosystem. However, it’s expected that Open Source will be a clear alternative for mass consumers. Open Source software and hardware are being developed and spreading 3D Printing to the consumers (“prosumers”).
  • 17. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 17 [12] THE IMPACT OF USING 3D PRINTING ON MODEL MAKING QUALITY AND COST IN THE ARCHITECTURAL DESIGN PROJECTS by DINA R. HOWEIDY and ZAINA ARAFAT. The following advantages were evident after the experiment like reduced time of creating a model for the course from weeks to few hours and the learners can produce more professional and detailed models, which assets them gain marks and efficiently test their model designs before the submission. The process of using additives in order to form solid 3D objects of from a digital model is called three-dimensional printing. 3D printing has worked into a number of markets that deals with architecture and Interior Design with different kinds of applications in interior design, architecture, building construction, automotive design, and so forth. In conclusion, this paper’s results suggest the use of the new technological methods such as the 3D printing in the design process to show better representation for the design idea, this study explored the advantages of using the 3d printing in the teaching strategy for learners in studios and design courses, in addition to other design considerations in the educational process. [13] A Review paper on 3D-PRINTING ASPECTS AND VARIOUS PROCESSES USED in the 3D-Printing.This is a research paper on 3D printing and the various materials used in 3D printing and their properties. Nowadays, rapid prototyping has a wide range of applications in various fields of human activity: research, engineering, medical industry, military, construction, architecture, fashion, education, the computer industry and many others. 3D printable models can be created with the help of CAD design packages or via 3D scanner. The manual modelling process of preparing geometric data for 3D computer graphics is similar to method sculpting. Before printing a 3D model from STL file, it must be processed by a piece of software called a "slicer" which converts the 3D model into a series of thin layers and produces a G-code file from “.stl” file containing instructions to a printer. The 3D printer follows the G-code instructions to put down successive layers of liquid, powder, or sheet material to build a model from a series of cross-sections of a model. The main advantage of this technique is its ability to create almost any shape or geometric model. depending on the type of machine used and the size and number of models being produced.
  • 18. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 18 [14] The Key Technology Research Based on DESKTOP 3D PRINTER OF PARALLEL MECHANISM by LIU Yu-qing, ZHANG Chunyan,ZHANGQiu-jie, XU Yao, YANG Liu-song and HUANG Xiao-fei School of Mechanical Engineering Shanghai University of Engineering Science,Shanghai, China. The paper aims at desktop 3D printer of parallel mechanism. It describes the performance requirements of the 3D printer mechanism. It compares the common performance institutions, obtaining the more suitable mechanism for 3D printer. It uses Solidworks to complete the overall printer model design. Then analysis and compare the key technology 3D printer, motor selection, positioning way and extrusion device obtaining for the suitable design scheme. Complete 3D printer machine design and prototyping; finally use the prototype to print out high-precision products. Computer controlled rapid prototyping machine heating nozzle, basing on cross-sectional data for each layer of the x-y plane motion. The wire feeder sent the wire to the nozzle, heated, melted and extruded adhesive from the nozzle print material to the working platform, and then rapidly cooled and solidified. This process is repeated until the completion of the entity. [15] In a paper named THE IMPACT OF 3D PRINTING TECHNOLOGY ON THE SOCIETY AND ECONOMY, Alexandru Pîrjan, Dana-Mihaela Petroşanu analysed that the evolution of 3D printing technology, its applications and numerous social, economic, geopolitical, security and environmental consequences. The 3D printing technology consists of three main phases - the modelling, the printing and the finishing of the product:  In the modelling phase, in order to obtain the printing model, the machine uses virtual blueprints of the object and processes them in a series of thin cross- sections that are being used successively.  In the printing phase, the 3D printer reads the design and deposits the layers of material, in order to build the product. Each layer, based on a virtual cross section, fuses with the previous ones and, finally, after printing all these layers, the desired object has been obtained. Through this technique, one can create different objects of various shapes, built from a variety of materials.
  • 19. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 19  The final phase consists in the finishing of the product. In many cases, in order to obtain an increased precision, it is more advantageous to print the object at a higher size than the final desired one, using a standard resolution and to remove then the supplementary material using a subtractive process at a higher resolution. [16] 3D PRINTING OF METALS by MANOJ GUPTA, Department of Mechanical Engineering, National University of Singapore, 9 Engineering Drive 1, Singapore 117576, Singapore. 3D printing is an emerging technique of immense engineering importance, capable of transforming the way we make components. It has been explored worldwide for metals, ceramics and polymers. 3D printing offers several advantages such as the following: (a) Shorter lead time (b) Low cost (c) Small volume of parts without the need of tooling or fixture (d) Capability to fabricate near net shapes (e) Design freedom that allows the fabrication of simple and complex shapes (f) Potential to handle conventional and specialized materials. The current Special Issue was targeted at metal-based materials as 3D printing of metals is particularly challenging due to a host of microstructural changes that are encountered, especially when the metals and alloys are exposed to high temperatures. Control of the dimensional accuracy and end properties is still being explored by researchers for different types of metals and alloys as the results of one compositional system cannot be translated to another compositional system. Overall, nine papers (one review and eight research papers) have been published in this issue. The materials investigated were the following: a. Aluminium-based materials b. Magnesium-based materials c. Steels d. Titanium-based materials e. Oxide dispersion-strengthened aluminium-based composites
  • 20. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 20 This suggests that there is no preferred metal system that is targeted by researchers but all important metallic materials are equally targeted. 3D printing techniques that were utilized in the papers published in this issue included the following: a. Micro-coating metal additive manufacturing (MCMAM)—new technique b. Electron beam melting c. Selective laser melting d. Laser metal deposition This suggests the main drivers of 3D printing in the research community. The present Special Issue, in general, is very informative as the nine articles cover a variety of topics and challenges and for different metallic materials (ferrous and non-ferrous) covering four different types of 3D printing techniques and issues related to microstructure, process defects, mechanical properties and heat treatments for a wide spectrum of applications.
  • 21. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 21 Chapter 3 - METHODOLOGY The 3D being designed as discussed above is of FDM (fused deposition modelling) type and consists of stepper motors that controls the three axes namely X, Y and Z axis making it possible to achieve stepped motion of various parts with respect to time and achieve a slow but precise motion of extruder and printing plate respectively. The whole process is a bit similar to stereolithography. Firstly, special software “cuts” CAD model into layers and calculates the way printer’s extruder would build each layer. Along to thermoplastic a printer can extrude support materials as well. Then the printer heats thermoplastic till its melting point and extrudes it throughout nozzle onto base, that can also be called a build platform or a table, along the calculated path. A computer of the 3d printer translates the dimensions of an object into X, Y and Z coordinates and controls that the nozzle and the base follow calculated path during printing. To support upper layer the printer may place underneath special material that can be dissolved after printing is completed. The parts involved in making this printer are as follows. ● Stepper motor ● Lead screw ● Timing belt ● Timing pulleys ● Extruder ● Arduino Mega ● RAMPS 1.4 Shield ● PLA Filament
  • 22. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 22 3.1 Stepper motor: - The stepper motor is used for actuating the components along various axes like x, y and z these are the building block of an FDM 3D printer as these are needed for accurate and precise deposition of plastic. These revolve in very small increments that is converted into linear motion by using pulleys and lead screws giving small displacements at a time. Brushed DC motors rotate continuously when DC voltage is applied to their terminals. The stepper motor is known by its property to convert a train of input pulses (typically square wave pulses) into a precisely defined increment in the shaft position. Each pulse moves the shaft through a fixed angle. Figure: - Stepper motor[5] Stepper motors effectively have multiple "toothed" electromagnets arranged around a central gear-shaped piece of iron. The electromagnets are energized by an external driver circuit or a microcontroller. To make the motor shaft turn, first, one electromagnet is given power, which magnetically attracts the gear's teeth. When the gear's teeth are aligned to the first electromagnet, they are slightly offset from the next electromagnet. This means that when the next electromagnet is turned on and the first is turned off, the gear rotates slightly to align with the next one. From there the process is repeated. Each
  • 23. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 23 of those rotations is called a "step", with an integer number of steps making a full rotation. In that way, the motor can be turned by a precise angle. 3.2 Lead screw: - A lead screw drive provides exactly the required combination of features needed for this task. The large mechanical advantage of the screw drive means even a modestly sized motor will be able to move the weight of the build platform. Screw drives are non back drivable, so the drive motor will not need to exert a large holding torque to maintain the platform's position. The primary drawback of a lead screw, the slow movement speed, is mostly irrelevant in this application because the build platform is not required to translate, quickly or frequently. Finally, the backlash in the lead screw system is eliminated because the weight of the build platform preloads the drive nut against the lead screw. Figure: - Lead screw [4] 3D printers feature a cantilevered build platform that is actuated by a single screw drive. While this design is adequate for small prints, its low stiffness makes it unsuitable for larger printers. An examination of existing industrial printers reveals that most feature
  • 24. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 24 two or more linear screw drives actuating the platform together, allowing multiple-point support of the build platform. Due to the size and weight of the build platform in this printer, two independent screw drives are used to control the Z-axis. The use of additional screw drives provides more support for the platform, as well as the ability to tilt the platform for leveling and calibration. 3.3 Extruder: - Its job is to convert the solid coil of plastic material into the molten state by utilizing a heating element within the extruder assembly. This heating element can be a vitreous enamel resistor, a nichrome wire, or a cartridge heater. In addition to the heating element, there is usually a thermistor (temperature sensor) integrated into the extruder assembly to control the required temperature for the specific material being used. For example, one of the most common materials used in FDM is PLA (polylactic acid) which has a melting temperature of around 160 degrees Celsius. A 3D printer using fused filament fabrication can make use of multiple materials if it has multiple extruder Figure: - Extruder[6] heads; most commercial printers do in fact feature multiple extruders to allow the use of support material.
  • 25. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 25 3.4 Timing Belts and Pulleys: - Timing belt is a flexible belt with teeth molded onto its inner surface. It is designed to run over matching toothed pulleys or sprockets. Toothed belts are used in a wide array of in mechanical devices, where high-power transmission is desired. with carefully designed tooth profiles, backlash can be almost completely eliminated. The weaknesses of a belt drive are exactly opposite those of a lead screw. As the mechanical advantage of a belt drive is low, they can be easily back driven unless a holding force is applied to the drive pulley. In addition, as the belt can stretch slightly, belt drives are much less stiff than screw drives and can introduce some springiness into the system. In addition, belt drives require a tensioning system to prevent over- or under-tightening of the belt from degrading performance. Toothed belts are made of a flexible polymer over a fabric reinforcement. Original ly this was rubber over a natural textile, but developments in material science have had a substantial effect in increasing the lifetime of these belts. This included changes from natural to synthetic rubber and polyurethane and also the adoption of nylon, Kevlar, or other aramid fibres and carbon fibers in their reinforcement. Figure: - Timing belt with pulley[4]
  • 26. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 26 3.5 Micro-controller(Arduino Mega 2560):- Arduino is an electronic platform that of the Open Source philosophy of both software and hardware. This system was created for students, professionals, designers and / or staff who were interested in creating interactive objects. For this reason, Arduino software is very intuitive and easy. Other aspects of the microcontroller are the memories; this contains different types and each of these memories has characteristics and functions of which are described below: ● Memory FLASH: Is the memory for save the firmware. ● SRAM (Static Random-Access Memory): where the program stores and manipulates variables to run. ● EEPROM (Electrically Erasable Programmable Read-Only Memory): is an area of memory that could be used by programmers to store information of long-term Figure: - Arduino Mega 2560[4]
  • 27. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 27 3.6 RAMPS 1.4 Shield: - RepRap Arduino Mega Pololu Shield, or RAMPS for short. It is designed to fit the entire electronics needed for a RepRap in one small package for low cost. RAMPS interface an Arduino Mega with the powerful Arduino MEGA platform and has plenty room for expansion. The modular design includes plug in stepper drivers and extruder control electronics on an Arduino MEGA shield for easy service, part replacement, upgrade- ability and expansion. Additionally, a number of Arduino expansion boards can be added to the system as long as the main RAMPS board is kept to the top of the stack. Figure: - RAMPS 1.4 Shield[13] Features: -  It has provisions for the cartesian robot and extruder.  Expandable to control other accessories.  3 mosfets for heater / fan outputs and 3 thermistor circuits.  Fused at 5A for additional safety and component protection  Heated bed control with additional 11A fuse
  • 28. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 28 3.7 Stepper MotorDriver (A4988): - Figure: - Stepper Motor Driver A4988[5] The A4988 is a stepper motor driver board that has on a A4988_chip that enables control of stepper motors through arduino type programming firmware and software. The A4988 is an utterly tested and proven solution to drive stepper motors in RepRap 3D printers, and this fact should not be overlooked. As long as the following three conditions are met, these Made in China Allegro A4988 stepper driver boards seem to be bullet-proof workhorses: Features: - 1. The stepper driver boards should not be inserted backwards in their respective slots on the controller board. 2. The stepper cables should not be disconnected from the boards while powered on. 3. Proper airflow (i.e. active cooling or in other words, a fan) should be provided. 4. Simple step and direction control interface 5. Five different step resolutions: full-step, half-step, quarter-step, eighth-step, and sixteenth-step 6. Adjustable current control lets you set the maximum current output with a potentiometer, which lets you use voltages above your stepper motor’s rated voltage to achieve higher step rates 7. Intelligent chopping control that automatically selects the correct current decay mode (fast decay or slow decay).
  • 29. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 29 3.8 PLA Filament (Poly Lactic Acid): - Polylactic Acid (PLA) is different than most thermoplastic polymers in that it is derived from renewable resources like corn starch or sugar cane. Most plastics, by contrast, are derived from the distillation and polymerization of nonrenewable petroleum reserves. Figure: - PLA Filament[9] Property Value Technical Name Polylactic Acid (PLA) Chemical Formula (C3H4O2)n Melt Temperature PLLA: 157 - 170 °C (315 - 338 °F) Typical Injection Molding Temperature PLLA: 178 - 240 °C (353 - 464 °F) Heat Deflection Temperature (HDT) 49 - 52 °C (121 - 126 °F) at 0.46 MPa Tensile Strength PLLA: 61 - 66 MPa Flexural Strength PLLA: 48 - 110 MPa Specific Gravity PLLA: 1.24 Shrink Rate PLLA: 0.37 - 0.41% Currently, the SPI resin identification code 7 ("others") is applicable for PLA. In Belgium, Galactic started the first pilot unit to chemically recycle PLA (Loopla). Unlike mechanical recycling, waste material can hold various contaminants. Polylactic acid can be recycled to monomer by thermal depolymerization or hydrolysis. When purified, the monomer can be used for the manufacturing of virgin PLA with no loss of original properties (cradle-to-cradle recycling).
  • 30. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 30 Chapter 4 - EXPERIMENTAL TRIAL Fused deposition modeling, which is often referred as “FDM”, is a type of fabrication commonly used within engineering design. Throughout the development and manufacturing production cycle, FDM systems are invaluable every step of the way including conceptual prototyping, design verification and direct digital manufacturing. FDM is ideally suited for the designers who demand part stability and strength. Unlike other additive processes, FDM 3D printed models are created with actual thermoplastics. The result is a prototype that can endure exposure to chemicals, mechanical stress, and a variety of climate extremes. Extruded prints are supported with soluble enabling complex cavities and geometries. This also makes the process perfect for jigs and fixtures. FDM is a process using molten plastics or wax extruded by a nozzle that traces the parts cross sectional geometry layer by layer. FDM creates tough parts that are ideal for functional usage. FDM works on an “additive” principle by laying down material in layers. A plastic filament or metal wire is unwound from a coil and supplies material to an extrusion nozzle which turns the flow on and off. The nozzle is heated to melt the material and can be moved in both horizontal and vertical directions by a numerically controlled mechanism which is directly controlled by a computer-aided design software package. The model or part is produced by extruding small beads of thermoplastic material to form layers as the material hardens immediately after extrusion from the nozzle plant. Figure: - Schematic diagram of FDM printer with various parts involved[1]
  • 31. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 31 The nozzle in a 3D printer has one of the most important jobs of all the mechanical systems. It is the last mechanical device that is used to build up a 3D object and its design and functionality is extremely important when it comes to the accuracy and build quality of the printer. The biggest contributor to the performance of the nozzle is its orifice size. Typically, the nozzle size used on many 3D printers is 0.4mm. This size is small enough to produce high quality parts while maintaining reasonable build times. Printers such as the Makerbot Replicator use this size nozzle. Depending on the overall goal of the part being printed however, these nozzles can be changed to larger diameters in order to increase the speed of the print job. While doing so will decrease the horizontal accuracy, parts that will be used as rough drafts or that will be post processed with fillers or paints will still perform as intended. It is important to never set the layer height higher than the nozzle size. This will dramatically decrease the bond strength between the layers and overall build quality. For example, if a 3D printer is using a 0.6mm nozzle, then the maximum layer height should not exceed 0.5mm. While the nozzle is used to direct molten plastics in a precise manner, it’s other job is to convert the solid coil of plastic material into the molten state by utilizing a heating element within the extruder assembly. This heating element can be a vitreous enamel resistor, a nichrome wire, or a cartridge heater. In addition to the heating element, there is usually a thermistor (temperature sensor) integrated into the extruder assembly to control the required temperature for the specific material being used. For example, one of the most common materials used in FDM is PLA (polylactic acid) which has a melting temperature of around 160 degrees Celsius. In contrast, another very popular material used is nylon. This material requires extrusion between 240 and 270 degrees Celsius. It is very important to use the correct extrusion temperature in order to minimize the risk of the nozzle jamming and also maximize the bond between bead layers. The design of the extruder is very important to not only the printing accuracy, but also to the overall performance and maintenance of the printer. While the bottom end of the extruder must be able to heat the material to a desired temperature within a few degrees, the upper end must remain as cool as possible in order to avoid jamming. This is due to the feed mechanism located above the extruder, which requires the filament material to
  • 32. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 32 be in a completely solid state in order to function properly. One way to decrease heat transfer from the heating element to the feed mechanism and in turn decreasing the chance of jamming, is to use fans to cool the top end of the extruder. Depending on the type of model being printed, and the type of material being used, a heated bed may be important to maintain the structure’s shape while it cools. Since plastics shrink as they cool, a quick temperature drop could cause the corners of a part to curl up off of the printer bed. To minimize this risk, some printers incorporate an electronically heated bed that keeps the temperature steady. This allows the model to cool at a more even rate and improve its overall dimensional accuracy. There are many factors that contribute to the build quality of a 3D printed part. As mentioned previously, the extruder assembly which includes the extruder, heating element, & nozzle contribute greatly to the overall build quality. In this section, additional factors that contribute to build quality will be discussed. Because the melted filament is bounded by the bottom bead layer and the bottom surface of the nozzle, the rest of the material flows to the sides. This causes any excess or deficiency in the filament cross-section to greatly affect the width of the bead produced. According to ProtoParadigm (a supplier of high quality filaments), it can be said that the error amount in the width of the bead is about two times that of the error in the filament cross-section. Depending on the software being used to print an object, the user can utilize a wide range of different tools to modify the method in which the model is printed. Many basic printing machines ship with their own software. An example of this is the MakerBot type printers. This printer ship with a basic software package that is designed to be as simple as possible. This means that the user does not have as much control over how the model is actually printed. Some users prefer to use their software of choice in order to open up these additional options. One such software is called Slic3r, an open- source software that provides users with additional features.
  • 33. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 33 ASSEMBLY: - Our work started with manufacturing of a skeleton for our 3-D printer. The material chosen for the same is mild steel due to its higher strength and good heat resistance along with less cost. The frame has dimensions 320mm x 320 mm x 400mm. Thus, a total of 4160mm or 4.160m of steel bar is used. The rod was cut into required dimensions and then welded by using Metal Inert Gas Welding (MIG). A net (320 mm x 320mm) is mounted on the frame, by MIG welding, at a height of 800 mm from the top surface of the base of frame. The purpose of the net is to support: -  The stepper motors which are to be mounted for the movement of leadscrews,  The base plate on which the final material will be printed, A net was used instead of a sheet of metal to reduce the weight of the assembly. Figure: - Manufacturing of Frame Figure: - Manufactured Frame A Saddle was manufactured of aluminum (dimensions - 320mm x 200mm x 18mm). The aluminum rod of was cut into required dimensions and the welded to form our saddle with use of Tungsten Inert Gas Welding (TIG). For the movement of the print head the saddle was mounted on two lead screws which in turn were coupled with two stepper motors. The lead screws used have diameter 8mm, lead of 8mm (axial advancement in one revolution of screw) and are of 2mm in pitch (distance between
  • 34. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 34 corresponding threads). The stepper motors are fitted into the net by using screw. The motors rotate and the lead screws advance in Y-Direction. Figure: - Manufacturing of saddle. The Saddle has a belt-motor-pulley assembly. For the purpose of mounting the extruder i.e. the printing head on the saddle an adhesive named ‘tight bond’ is used. To facilitate movement of the print head in X-Direction a motor and a pulley (a dead motor in our case) are used. A timing belt is used to transmit torque from the live motor to the dead motor. The printhead is attached to the belt and for ease of translation of the extruder i.e. its movement in X-Direction it is supported by four wheels. The extruder is supplied with PLA Filament (Poly Lactic Acid) which melts when its is passed through hot end and solidifies when its falls down on the base plate. A fan is provided for avoiding over heating of the print head. A similar arrangement is provided for the lateral movement (in Z-Direction) of the base plate.
  • 35. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 35 Figure :- Final Assembly For controlling the motion of the stepper motors all of them are plugged to Arduino Mega 2560 microcontroller. This controller sits on shield called RAMPS 1.4 to reduce the tediousness of the wire works. Use of RAMPS makes it easy to mount stepper motor drivers (A4988) on Arduino as it has dedicated slots unlike Arduino which has pins and requires a lot of wired connection if we want to run motors using it. All of components are powered by an ATX DC power supply of 450 Watts operating on 12 Volts.
  • 36. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 36 Chapter 5 - DESIGN AND CALCULATIONS Motors are used to move the platform in required directions. For raising and lowering the platform the calculations are: For Raising, Considering equilibrium of horizontal forces, 𝑃 = 𝜇𝑁 cos𝛼 + 𝑁sin 𝛼 …. (a) Considering equilibrium of vertical forces, 𝑊 = 𝑁 cos𝛼 − 𝜇𝑁sin 𝛼 …. (𝑏) Dividing expression (a) by (b), 𝑃 = 𝑊(𝜇𝑁 cos𝛼 + 𝑁 sin 𝛼) 𝑁 cos𝛼 − 𝜇𝑁 sin 𝛼 Dividing the Numerator and Denominator of the right-hand side by cos𝛼, 𝑃 = 𝑊(𝜇 + tan 𝛼) (1 − 𝜇 tan 𝛼) ….(𝑐) The coefficient of Friction µ is expressed as, 𝜇 = tan 𝜑 Where 𝜑 is the friction angle. Substituting 𝜇 = tan 𝜑 in Eq. (c), we have 𝑃 = 𝑊(tan 𝜑 + tan𝛼) (1 − tan 𝜑 tan𝛼) Or, 𝑃 = 𝑊 tan(𝜑 + 𝛼) The torque required to raise the load is given by, 𝑀𝑡 = 𝑃𝑑𝑚 2 𝑀𝑡 = 𝑊𝑑𝑚 2 tan(𝜑 + 𝛼)
  • 37. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 37 For Lowering, Considering equilibrium of horizontal forces, 𝑃 = 𝜇𝑁 cos𝛼 − 𝑁sin 𝛼 …. (a) Considering equilibrium of vertical forces, 𝑊 = 𝑁 cos𝛼 − 𝜇𝑁sin 𝛼 …. (𝑏) Dividing expression (a) by (b), 𝑃 = 𝑊(𝜇𝑁 cos𝛼 − 𝑁 sin 𝛼) 𝑁 cos𝛼 + 𝜇𝑁 sin 𝛼 Dividing the Numerator and Denominator of the right-hand side by cos𝛼, 𝑃 = 𝑊(𝜇 −tan 𝛼) (1 + 𝜇 tan 𝛼) …. (𝑐) The coefficient of Friction µ is expressed as, 𝜇 = tan 𝜑 Where 𝜑 is the friction angle. Substituting 𝜇 = tan 𝜑 in Eq. (c), we have 𝑃 = 𝑊(tan 𝜑 − tan𝛼) (1 + tan 𝜑 tan𝛼) Or, 𝑃 = 𝑊 tan(𝜑 − 𝛼) The torque required to lower the load is given by, 𝑀𝑡 = 𝑃𝑑𝑚 2 𝑀𝑡 = 𝑊𝑑𝑚 2 tan(𝜑 − 𝛼) Torque required to overcome collar friction, According to uniform pressure theory, (𝑀𝑡)𝑐 = 𝜇𝑐𝑊 3 . 𝐷0 3 − 𝐷𝑖 3 𝐷0 2 −𝐷𝑖 2 According to the uniform wear theory, (𝑀𝑡)𝑐 = 𝜇𝑐𝑊 4 . (𝐷0 + 𝐷𝑖) Where, 𝜇𝑐= coefficient of friction at the collar 𝐷0= outer diameter of the collar (mm) 𝐷𝑖= inner diameter of the collar (mm) (𝑀𝑡)𝑐= collar friction torque (N-mm)
  • 38. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 38 Total Torque Transmitted, (𝑀𝑡)𝑡 = 𝑀𝑡 + (𝑀𝑡)𝑐 The torque generated by the motor is used to raise and lower the platform. The parameters of the platform are:- Material used: Aluminum Density: 2700 kg/𝑚3 Total weight: 1 kg The parameters of the Motor are: Holding Torque = 300 × 103 Nm. Cogging Torque = 12 × 103 Nm. Pitch (P) = 1.25 mm Mean diameter (𝐷𝑚) = 8 mm Collar Diameter (𝐷𝑐) = 6.75 mm Coefficient of friction (µ) = 0.15 Coefficient of collar friction (µ𝑐) = 0.17 Force (F) = 1 kg × 9.81 𝑚 𝑠2 ⁄ = 9.81 N Lead (L) = 8 mm Applying Power screw equations, The frictional angle (𝜑) = tan−1(𝜇) Or, (𝜑) = tan−1(0.15) (𝜑) = 8.5307° The pitch angle (𝛼) = tan−1( 𝐿 𝜋×𝐷𝑚 ) Or, (𝛼) = tan−1( 8 𝜋×8 ) (𝛼) = 17.6567 Therefore, Torque required to raise the load will be: 𝑀𝑡 = 9.81 × 0.008 2 .tan(17.6567 + 8.5307) 𝑀𝑡 = 0.0192 𝑁𝑚 (𝑀𝑡)𝑐= 9.81×0.17 2 . 0.008 2 (𝑀𝑡)𝑐 = 0.0033 𝑁𝑚
  • 39. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 39 (𝑀𝑡)𝑡 = 0.0192 + 0.0033 (𝑀𝑡)𝑡 = 0.0225 Nm Therefore, Torque required to lower the load will be: 𝑀𝑡 = 9.81 × 0.008 2 .tan(17.6567 − 8.5307) 𝑀𝑡 = 0.0063 𝑁𝑚 (𝑀𝑡)𝑐= 9.81×0.17 2 . 0.008 2 (𝑀𝑡)𝑐 = 0.0033 𝑁𝑚 Therefore, Number of motors required to move the platform = 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑡𝑜𝑟𝑞𝑢𝑒 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑡𝑜𝑚𝑜𝑣𝑒 𝑡ℎ𝑒 𝑝𝑙𝑎𝑡𝑓𝑜𝑟𝑚 𝑇𝑜𝑟𝑞𝑢𝑒 𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑 𝑏𝑦 𝑜𝑛𝑒 𝑚𝑜𝑡𝑜𝑟 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑀𝑜𝑡𝑜𝑟𝑠 = 0.0225 0.012 = 1.875 ≈ 2 Minimum height oflayer produced ( 𝒕 ) = 𝐿𝑒𝑎𝑑 𝑜𝑓 𝑆𝑐𝑟𝑒𝑤 360° × 𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑎𝑛𝑔𝑢𝑙𝑎𝑟 𝑠𝑡𝑒𝑝 𝑜𝑓 𝑚𝑜𝑡𝑜𝑟 ( 𝑡 ) = 8 360 × 1.8 = 0.04𝑚𝑚
  • 40. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 40 Chapter 6 - CONCLUSION As the 3D printer is a device, it should be analyzed with the advantages and disadvantages, how the device can change the society and engineering etc. in mind. The very nature of 3D printing, creating a part layer by layer, instead of subtractive methods of manufacturing lend themselves to lower costs in raw material. Instead of starting with a big chunk of plastic and carving away (milling or turning) the surface in order to produce your product. Additive manufacturing only "prints" what you want, where you want it. Other manufacturing techniques can be just as wasteful. 3D printing is the ultimate just-in-time method of manufacturing. No longer do you need a warehouse full of inventory waiting for customers. Just have a 3D printer waiting to print your next order. On top of that, you can also offer almost infinite design options and custom products. It doesn't cost more to add a company logo to every product you have or let your customers pick every feature on their next order, the sky's the limit with additive manufacturing. Figure: 3D printing growth & cost projection
  • 41. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 41 Whether you are designing tennis shoes or space shuttles, you can't just design whatever you feel like, a good designer always take into account whether or not his design can be manufactured cost effectively. Additive manufacturing open up your designs to a whole new level. Because undercuts, complex geometry and thin walled parts are difficult to manufacture using traditional methods, but are sometimes a piece of cake with 3D printing. In addition, the mathematics behind 3D printing are simpler than subtractive methods. For instance, the blades on a centrifugal supercharger would require very difficult path planning using a 5-axis CNC machine. With so many potential benefits of 3D printing, there’s no surprise that this method is making its way through a diverse number of industries and quickly becoming a favorite tool of progressive marketers. Comparing the numerous advantages, applications and future scope, we can conclude that the 3D printer and its technology is able to create next industrial revolution.
  • 42. Pimpri Chinchwad College of Engineering and Research, B.E(Mechanical) 42 Chapter 7 - REFERENCES [1] Ojas Dandgaval, Pranita Bichkar: Rapid Prototyping Technology - Study of Fused Deposition Modeling Technique. [2] Fawaz Abdullah: Fused Deposition Modeling (FDM) Mechanism. [3] Fred Fischer: FDM AND POLYJET 3D PRINTING. [4] Justin Lan: Design and Fabrication of a Modular Multi-Material 3D Printer. [5] Bill Earl: All About Stepper Motors. [6] Siddharth Bhandari And B Regina: 3D Printing and Its Applications [7] School of Industrial Engineering, Barcelona (ETSEIB) Bachelor Thesis- 3D Printer Electronics Design [8] 3D Printing: The Next Revolution in Industrial Engineering By Consumer Technology Association [9] 3D Printing: A patent overview, UK intellectual property office patent informatics team. [10] Bethany C. Gross, Jayda L. Erkal, Sarah Y. Lockwood, Chengpeng Chen, and Dana M. Spence: Evaluation of 3D printing and its potential impact on biotechnology and the chemical sciences. [11] White paper on 3D printing. [12] Dina R. Howeidy and Zaina Arafat: the impact of using 3D printing on model making quality and cost in the architectural design projects [13] 3D - printing aspects and various processes used. [14] Liu Yu-Qing, Zhang Chunyan,Zhangqiu-Jie, Xu Yao, Yang Liu-Song and Huang Xiao-Fei: Desktop 3D Printer Of Parallel Mechanism [15] Alexandru Pîrjan, Dana-Mihaela Petroşanu: The Impact Of 3D Printing Technology on The Society and Economy [16] Manoj Gupta: 3D Printing of Metals