7 Chapter 4

“DESIGN AND MANUFACTURING OF 3D PRINTER”
CHAPTER 4
TESTING AND EXPERIMENTAL WORK
DEPARTMENT OF PRODUCTION ENGINEERING [DYPCET] Page 89

CHAPTER 4
TESTING AND EXPERIMENTAL WORK
This chapter includes the summary of various problems faced after assembly of 3D
printer and further steps carried out to overcome these problems. The results obtained
from multiple tests carried out on our very own 3D printer. It proceeds further with
comparison study of products obtained from Pratham MK 3D printer and our printer.
4.1. PROBLEMS & SOLUTIONS:

Problem Statement: After manufacturing of frame we found that position of column
& beam of frame is at center, which reduces the print area. But in actual practice we
required position of column & beam at some distance back from center.
Solution: Alternate solution of reversing the frame and changing the mounting position
of motor is applied which allowed us to get the maximum print area.
Fig.4.1. Error in Frame Fig.4.2. Reversed frame

and Position change of motor

Problem Statement: Due to miss-position of holes of Y-axis on frame, acrylic bed was
facing sudden stoppage due to friction caused between frame and specific bed.
Solution: Solution was found out to increase height of the acrylic bed from the frame
by allowing wooden spacers between the frame and Y-axis bearing mounting.
Fig.4.3. Wooden spacer between Y-axis bearing mounting and frame

Problem Statement: Nozzle was rubbing against aluminum heat bed due to leveling of
heat bed.
Solution: To overcome this rubbing action, automatic bed leveling system is necessary.
Thus we used 9 position bed leveling method by installing inductive proximity sensor
for automatic leveling of specific bed.
Fig.4.4. Inductive Proximity Sensor

4.2. EXPERIMENTAL WORK:

Manufacturing 3D printed parts were done by varying parameters of printing as
mentioned below and the best of them are found out for preceding trials.
Fig.4.5. Manufacturing Components (Square Block)
Table 4.1.Result Sheet (20 mm × 20 mm × 20 mm Square Block)
Bed Material Material

Layer In filled
Temperatur Speed Required Required Time(Min)
Thickness Percentage
e (Wt.) gm. (Length) mm.
0.15 WT 60 40 3.71 1232.7 35
0.15 40 80 60 3.13 1042 27
0.15 70 100 80 4.28 1422.5 23
0.25 WT 80 80 4.41 1468.4 17
0.25 40 100 40 3.39 1128.7 16
0.25 70 60 60 3.91 1299 21
0.3 WT 100 60 3.95 1314.7 14
0.3 40 60 80 4.42 1470.6 18
0.3 70 80 40 3.48 1158 14

Fig.4.6. Manufacturing Component (Gripper Shaft)
Table 4.2.Result Sheet (Gripper Shaft)
Material
Material
Layer Bed In Filled Required Actual
SPEED Required
Thickness Temperature Percentage (Length) Time(Min)
(Wt.) gm.
mm.
0.15 WO 60 40 2.03 674.1 56
0.15 40 80 60 2.15 716.4 47
0.15 70 100 80 2.28 757.2 36
0.25 WO 80 80 2.28 759.1 29
0.25 40 100 40 2.08 691 22
0.25 70 60 60 2.18 725.4 35
0.3 WO 100 60 2.17 722.3 24
0.3 40 60 80 2.27 754.3 28
0.3 70 80 40 2.07 289.3 25

4.3 OPTIMIZATION USING RESPONSE OPTIMIZER IN RESPONSE

SURFACE METHODOLOGY:
The printed Square Block samples are shown in Fig.4.5, where total 9 components are printed
and results are shown in Table4.1. This printed square block optimization discuss below.
Analysis of experimental data obtained through Taguchi experimental design is carried out
using MINITAB 16. Analysis of Means and further multiple responses Prediction is
performed to determine the influence of process parameters such as Layer Thickness (LT),
Printing Speed, Infill Percentage (IP), Heat Bed Temperature (BT) on the response variables
such as Material required in Weight (gms.), Material required in Length (mm) and Time
(min).
Optimal LT SPEED IP BT
High 0.30 100.0 80.0 WT
D: 0.9872
Cur [0.30] [85.0505] [45.2525] 40
Predict Low 0.150 60.0 40.0 40
Composite
Desirability
D: 0.9872
TIME(min
Minimum
y = 14.0027
d = 0.99995
MATERIAL
Minimum
y = 1072.0581
d = 0.97842
MATERIAL
Minimum
y = 3.2169
d = 0.97929
Fig.4.7. Optimal Result of Square Block

Multiple Response Prediction:
Table 4.3.Optimal Result of Square Block
Variable Setting
LT 0.3
SPEED 85.0505
IP 45.2525
BT 40
Main Effects Plot for MATERIAL REQUIRED (wt) gm. Main Effects Plot for TIME(min)
LT BT SPEED IP Data Means
4.4
LT BT SPEED IP
30.0
4.3
4.2 27.5
4.1
25.0
Mean
4.0
Mean
22.5
3.9
3.8
20.0
3.7
17.5
3.6
3.5 15.0
0.15 0.25 0.30 40 70 WT 60 80 100 40 60 80 0.15 0.25 0.30 40 70 WT 60 80 100 40 60 80
Main Effects Plot for MATERIAL REQUIRED (length) gm.

Data Means
LT BT SPEED IP
1450
1400
1350
Mean
1300
1250
1200
0.15 0.25 0.30 40 70 WT 60 80 100 40 60 80
Fig.4.8. Influence of Process Parameters on Response variables
Process parameters such as Layer Thickness (LT), Speed, Infill Percentage (IP), Bed
Temperature (BT) do not affect the response variables as alone; they are interdependent on
each other.

One of the process parameter Layer Thickness has a significant rise with respect to material
required upto a certain limit (3.7-3.9 gms.) and thereafter it has to follow a negligible rise
(3.9-3.95 gms.). While in case of time required for printing has a drastic change (27.75 min.
to 17.5 min.) because as the layer thickness increases, the time required decreases.
Another process parameter Bed Temperature follows linear characteristics graph in case of
material required. While for time required the bed takes some time to attain required
temperature after that it follows a linear path no matter if no temperature is given to bed. Bed
temperature alone can’t directly affect on material required but can influence surface finish
and adhesion of layers.
Process parameter printing speed influences the response variable time required such that
significant reduction of time can be seen (from 25 min. to 17.5 min) for speed of 60-100
mm/sec.
Infill percentage has a direct influence to material required as well as time required. Material
required follows a significant rise upto 60% and thereafter it has a sudden rise which goes on
increasing even after 80%. Whereas time required follows a linear reduction in path as soon
as infill percentage increases.

7 Chapter 4

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

7 Chapter 4

Uploaded by

Copyright:

Available Formats

“DESIGN AND MANUFACTURING OF 3D PRINTER”

TESTING AND EXPERIMENTAL WORK

DEPARTMENT OF PRODUCTION ENGINEERING [DYPCET] Page 89

TESTING AND EXPERIMENTAL WORK

4.1. PROBLEMS & SOLUTIONS:

of motor is applied which allowed us to get the maximum print area.

Fig.4.1. Error in Frame Fig.4.2. Reversed frame

DEPARTMENT OF PRODUCTION ENGINEERING [DYPCET] Page 90

Fig.4.3. Wooden spacer between Y-axis bearing mounting and frame

DEPARTMENT OF PRODUCTION ENGINEERING [DYPCET] Page 91

for automatic leveling of specific bed.

Fig.4.4. Inductive Proximity Sensor

DEPARTMENT OF PRODUCTION ENGINEERING [DYPCET] Page 92

4.2. EXPERIMENTAL WORK:

Fig.4.5. Manufacturing Components (Square Block)

Table 4.1.Result Sheet (20 mm × 20 mm × 20 mm Square Block)

Bed Material Material

DEPARTMENT OF PRODUCTION ENGINEERING [DYPCET] Page 93

Fig.4.6. Manufacturing Component (Gripper Shaft)

Table 4.2.Result Sheet (Gripper Shaft)

DEPARTMENT OF PRODUCTION ENGINEERING [DYPCET] Page 94

4.3 OPTIMIZATION USING RESPONSE OPTIMIZER IN RESPONSE

Fig.4.7. Optimal Result of Square Block

DEPARTMENT OF PRODUCTION ENGINEERING [DYPCET] Page 95

Multiple Response Prediction:

Table 4.3.Optimal Result of Square Block

Main Effects Plot for MATERIAL REQUIRED (length) gm.

0.15 0.25 0.30 40 70 WT 60 80 100 40 60 80

Fig.4.8. Influence of Process Parameters on Response variables

DEPARTMENT OF PRODUCTION ENGINEERING [DYPCET] Page 96

and adhesion of layers.

as infill percentage increases.

DEPARTMENT OF PRODUCTION ENGINEERING [DYPCET] Page 97

You might also like