Construction and Design of 3D printer

using Fused Deposition Modeling (FDM) Technique

By
Scholar Name: Muhammad Ibrahim
Program of Study: MS/MPhil

Supervisor: Dr. Abdul Basit

Department of Computer Science

University of Balochistan

Session: 2022 – 2024

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Table of Contents

Section Title Page No.

Title Page No Page#

Table of Contents II, III

Abstract IV

List of Tables V

List of Figures VI

List of Abbreviations VII, VIII

1 Introduction 1

1.1 Background of the Study 2

1.2 Problem Statement 4

1.3 Justification of the Study 4

1.4 Objectives of the Study 5

1.5 Limitations of the Study 6

2 Literature Review 7

2.1 Theoretical and Conceptual Framework 7

3 Research Methodology 39

3.1 Selection of Process 39

3.2 Selection of Mechanism 40

3.3 Software used (CAD and CAM) 40

3.3.1 CAD 40

3.3.2 CAM 41

3.4 How FDM printer works 41

4. Description of various components of FDM Printer 43

4.1 Smooth rod m8 500 mm 43

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4.2 T8 Trapezoidal Lead Screw 8mm 44

4.3 Flexible Coupling Coupler 45

4.4 LM8UU 8 mm Linear Ball Bearing 46

4.5 GT2 6MM Open Timing Belt 46

4.6 Teeth Pulley 47

4.7 Aluminium channel frame 48

4.8 V6 J-Head Hotend Bowden Extruder 49

4.9 MK8 Extruder Aluminium Block DIY Kit 50

4.10 PLA 1.75 mm filament 51

4.11 NEMA 17 Stepper Motor 51

4.12 Arduino Mega 2560 52

4.13 Ramps1.4 Shield 53

4.14 A4988 Stepper motor Drivers 54

4.15 End stop switch 55

4.16 12 Volt 20-amp DC power supply 56

4.17 Heat bed 57

5. List of References 59
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Abstract
In the area of additive manufacturing, fused deposition modeling (FDM), often

referred to as fused filament fabrication (FFF), is now expanding quickly. When

creating components using FDM, part strength and dimensional correctness are two

important considerations. FDM is a common technique for producing prototypes with

complex geometry and other component products in a short time. In several industrial

areas, 3D printing technology has become increasingly important in recent years for

producing customized goods quickly and affordably. Many different materials have

been created and researched, and their mechanical, thermal, and electrical

characteristics have been documented. There have also been several documented

efforts to enhance the capabilities of FDM products for use in a variety of industries.

The usage of 3D printing is very common these days. In the fields of agricultural,

healthcare, the automobile, locomotive, and aviation sectors, 3D printing technology

is being employed for mass modification and fabrication of any forms of open-source

designs. Layer by layer, material like plastic or metal may be deposited to create an

item using 3D printing technology and a computer-aided design (CAD) model. Fused

deposition modeling (FDM) deposit materials one layer at a time on top of one

another to produce solid shapes. In contrast to this approach, conventional ink-based

printers create two-dimensional objects (ink on paper). Utilizing procedures like

binder jetting, extrusion, material jetting, direct energy, vat photo-polymerization, and

powder bed fusion, a solid item may be produced utilizing the material (in a solid,

liquid, or powder form) employed by the 3D printing equipment. The goal of this

study is to examine research on the factors that fused deposition modeling (FDM)

method outcomes in 3D printing. The study's foundational elements are the creation
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of FDM printer, filament material kinds, usage and their qualities and finally how

FDM printer works.

List of Tables

Table 2.1 FDM 3D Printer Components and Quantity.................................................37

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List of Figures

Figure 2.1.Diagram of FDM 3D printer.......................................................................15

Figure 2.2 Arduino Mega 2560....................................................................................23
Figure 2.3. Heat Bed....................................................................................................23
Figure 2.4. Extruder.....................................................................................................24
Figure 2.5. End Stop Switch........................................................................................24
Figure 2.6.Ramps 1.4 Sheild........................................................................................25
Figure 2.7. Weft Knitted Fabric....................................................................................28
Figure 2.8. Three-stacked layer....................................................................................28
Figure 2.9. Multi-material Structure............................................................................29
Figure 2.10. pronterface software................................................................................31
Figure 2.11. Cura Software..........................................................................................32
Figure 2.12. Arduino Software IDE.............................................................................33
Figure 2.13 Circuit Diagram of 3D printer..................................................................35
Figure 3.1 Functional Diagram for the 3D printing………….……………………....39
Figure 3.2 FDM Working principles…………………………………………………42
Figure 4.1 Smooth rod m8 500 mm............................................................................ 43
Figure 4.2 T8 Trapezoidal Lead Screw 8mm...............................................................44
Figure 4.3 Flexible Coupling Coupler………………………………………………..45
Figure 4.4 LM8UU 8 mm Linear Ball Bearing………………………………………46
Figure 4.5 4.5 GT2 6MM Open Timing Belt………………………………………………47
Figure 4.6 Teeth Pulley……………………………………………………………….48
Figure 4.7 Aluminium channel frame………………………………………………...48
Figure 4.8 V6 J-Head Hotend Bowden Extruder…………………………………….49
Figure 4.9 MK8 Extruder Aluminium Block DIY Kit……………………………….50
Figure 4.10 PLA 1.75 mm filament…………………………………………………..51
Figure 4.11 NEMA 17 Stepper Motor………………………………………………..52
Figure 4.12 Arduino Mega 2560……………………………………………………..53
Figure 4.13 Ramps 1.4 Shield………………………………………………………..54
Figure 4.14 A4988 Stepper Motor Drivers…………………………………………...55
Figure 4.15 End Stop Switch…………………………………………………………56
Figure 4.16 12 Volt 20-amp DC power supply……………………………………….57
Figure 4.17 Heat Bed………………………………………………………………...58
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List of Abbreviations

Abbreviation Definition
3D Three Dimension
2D Two dimension
AM Additive Manufacturing
CAD Computer-Aided Design
FDM Fused Deposition modeling
FFF Fused Filament Fabrication
ABS Acrylonitrile Butadiene Styrene
PLA Polylactic Acid
PEEK Polyetheretherketone
PP Polypropylene
PPSF Polyphenylsulphone
TPU Thermoplastic polyurethanes
PVA Polyvinyl alcohol
HIPS High-Impact Polystyrene
ISO International Standards Organization
ASTM American Society for Testing and Materials
ULTEM The branded name for polyetherimide (PEI),
SLA Stereolithography
SLS Selective Laser Sintering
IP Inkjet printing
LOM Laminated Object Manufacturing
SLS Selective Laser Sintering
SLM Selective Laser Melting
EBM Electron Beam Melting
LMD Laser Metal Deposition
DLP Digital Light Processing
PET-G Polyethylene Terephthalate-Glycol
PBF Powder Bed Fusion
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BJ Binder Jetting
MJ Material Jetting
DED Directed Energy Deposition
ME Material Extrusion
SL Sheet Lamination
VPP Vat Photopolymerization
DMLM Direct Metal Laser Melting
DMLS Direct Metal Laser Sintering
EBM Electron Beam Melting
SHS Selective Heat Sintering
UV Ultra Violet
DMD Direct Metal Deposition
DIY Do it yourself
RAMPS RepRap Arduino Mega Palolo Shield
CNC Computer Numerical Control
PDMS Polydimethylsiloxane
IDE Integrated Development Environment
OS Operating System
MM Milli Meter
SGC Solid Ground Curing
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1. Introduction
Fused deposition modeling (FDM) is a popular 3D printing technique that focuses on

creating customized products with less waste and other benefits compared to

traditional production methods. FDM is similar to injection molding and involves

melting and forming raw materials to create new forms. The material is a filament that

is rolled up, dragged by a driving wheel, heated to a semiliquid state, and introduced

into a temperature-controlled nozzle head. The nozzle accurately extrudes and directs

materials in ultrathin layers, the software's (usually CAD) defined layer outlines,

integrated into the FDM work system. There are three categories of manufacturing

processes: formative manufacturing, which includes injection molding, casting,

stamping, forging; manufacturing with layer removal, which includes CNC, drilling,

and turning; and additive manufacturing, which includes 3D printing. 3D printing can

produce complex designs quickly, cheaply, and accurately from a useful material. The

desired form is produced piece by piece, with plastics often used as applied materials.

FDM technology requires software that handles the STL file format, used in

stereolithography. The majority of inexpensive 3D printers for personal use or small

firms starting out in the industry utilize FDM. A geometric model built using CAD

software is exported as STL (Surface Tesselation Language). The 3D model must be

"watertight," manifold, and point outwards throughout development. For FDM

models, it is crucial to consider the printer's orientation, support material

requirements, and the presence of "escape holes" for polyamide powder removal after

printing. Wall thicknesses must be large enough for powder flow when the design is

removed from the 3D printer. Product production involves subtractive, formative, and

additive manufacturing (AM) methods, including polymerization, material jetting,

binder jetting, material extrusion, sheet lamination, powder bed fusion, and directed
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energy deposition. Fused deposition modeling, a subset of material extrusion, has

gained significant attention and innovation in recent years. This technology allows a

nozzle holding molten filament to be moved in a 2D plan, producing one layer of a

cross-section of the complete part. Although Crump initially applied for an FDM

patent in 1988 and established Stratasys in 1989, the patent has expired, allowing

consumers to buy low-cost FDM printers.

1.1 Background of the Study

Dr. Hideo Kodama was the first to develop a quick prototyping method and to pioneer

the layer-by-layer method for assembly. By using UV light to polymerize a

photosensitive gum, he also created a precursor for SLA. Other breakthroughs in 3D

printing were made in the 1990s, such as stereolithography (SLA), ballistic particle

manufacturing (BPM), which William Masters had patented, and solid ground curing

(SGC), which Itzchak Pomerantz and others had developed. Medical researchers used

3D printers for the first time in the 1990s, which helped to establish the fields of

pharmaceuticals and 3D printing and provided chances for a wide range of customers.

Leading 3D printing system maker Stratasys has created a number of 3D printers for

business and home use. This year, 3D Systems produced the SLA (stereolithographic)

equipment employing a UV laser-solidifying photopolymer and a liquid that had the

consistency and color of honey. The major players in the 3D printing industry began

to emerge between 1993 and 1999 using a variety of processes, including Sanders

Prototype (later Solidscape), Z Corporation, and Arcam, which was founded in 1997.

These systems served industrial applications in addition to high-end manufacturing

for valuable and intricate items. In 2000, advances in 3D printing enabled the

production of more affordable models with a variety of characteristics. Thomas

Boland of Clemson University patented the method of deposition of cells into ordered
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3D matrices put on a substrate using inkjet printers in 2003. The first 3D-printed

kidney that functioned in the new millennium was made via bioprinting, which is the

printing of biological components. Extrusion bioprinting is one of the additional

printing methods that was investigated and launched as a manufacturing method. The

RepRap project, which was launched in 2004, contributed to the proliferation of FDM

3D desktop 3D printers and the rise in popularity of 3D printers. In 2005, Z-Corp

launched the Spectrum Z510, the first color and high-definition 3D printer, and the

first SLS machine commercially accessible since 2000. Object, a 3D printing startup,

built a machine that could print more than one material, allowing a single part to be

manufactured and fabricated with different material properties. In 2009, the FDM

patents fell into the public domain, giving an expansive wave to the development of

FDM printers. Sculpteo, a French company, offered 3D printing cloud and online

printing services using stereolithography or laser sintering, further advancing 3D

printing technology.

FDM, the first patent for additive manufacturing (AM) technique, was granted to S.

Scott Crump in 1989. He discovered that layer-by-layer melting and extrusion of

thermoplastic filaments could create solid 3D items, leading to the development of the

3D Modeler, the first commercial FDM printer. This technology has since been widely

used in various sectors, including automotive, aerospace, and medical. FDM

technology has evolved continuously, with new materials and advancements in the

printing process enabling more detailed and complicated patterns to be printed with

greater accuracy and precision. For example, FDM Nylon 12CF, a new material from

Stratasys, includes carbon fiber for increased strength and durability. Multi-material

printers, which can print items using two or more materials simultaneously, have
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become significant advancements in FDM technology. This has made it more

accessible to the general public, promoting the maker movement and DIY culture.

However, the issue of surface finish remains a significant challenge for FDM

technology. Layer lines and rough surfaces can occur due to the layer-by-layer

printing process, but post-processing methods like sanding and polishing have helped

reduce this issue. Since its inception in the 1980s, FDM has become a popular

additive manufacturing technique used in various sectors for prototypes and finished

products. Future improvements in FDM technology are likely in the horizon as

technology continues to evolve.

1.2 Problem Statement

The present 3D printing technology is very time consuming with a high

manufacturing cost. This project aims not only to reduce the cost of the 3D Printer but

also working upon its accuracy and time constraints.

 1.3 Justification of the Study

This study's key contribution is the development of an FDM 3D printer that will print

practically any 3D form or item for around 30% of the market price. By focusing on

the restrictions of the FDM printer, I will attempt to further enhance it. There are a

number of shortcomings with FDM 3D printers that can be fixed. This study is

required because I am going to propose a printer model that anyone can simply

manufacture at home, use, and sell to make a lot of money. For the average person,

purchasing a 3D printer from the market is challenging. Making printers more

affordably will help everyone in this way. There are several difficulties with FDM 3D

printers, including overhang and bridging, stringing, warping, hygroscopicity, and

structural inhomogeneity. Rough surface finishing, nozzle clogging, longer print

times, layer adhesion issues (layer shift), weak construction, frequent bed calibration

requirements, and structural integrity issues are all things that will be worked to fix.
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1.4 Objectives of the Study

The objectives of our present work are as follows:

 A 3D printer is a device that can make things out of many different materials,

including nylon and plastic. The current generation of 3D printers are expensive

and not very portable. Through problem analysis, our goal is to create a portable

3D printer, size of 2x2 feet or 60x60cm or 600x600mm.

 The cost of this printer will be considerably less when compared to other 3D

printers available in the market. I started building a printer that costs

approximately $118 which is just 30% of the market. The FDM 3D printer with

a minimum price around $400 (PKR 118,000) in the open market.

 To print and build complicated components.

 Select the most suitable materials for printing objects.

 Accurately building big printing volumes, for example this printer will print

moveable and unmovable objects that do not have exact dimensions.

 I will work to analyze by changing some parameters like travel speed, nozzle

diameter and layer height.

 This printer has capability to print objects with length and width of 250mm by

250 mm.

 We try to address bed leveling issues, which is a major problem in the 3D

printer.

 After building a home FDM 3D printer, our goal is also, attempt to enhance it.
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1.5 Limitations of the Study

The most common limitations, challenges or drawbacks associated with printing parts

with the FDM technology include:

 Nozzle Clogging

 Structural inhomogeneity

 Rough Surface Finishing

 Longer Printing Time

 The price to purchase and set up a 3D printer is very high.

 Overhang and bridging

 Starting the print without extrusion. Plastic is not extruded by the printer at the

start of the print

 Substandard extrusion

 Not Sticking to the Bed

 Extrusion to excess

 Gaps in the top layers

 Excessive heat

 Warping

 Hygroscopicity

 Oozing or stringing

 Layer Adhesion Problem (Layer Shifting/ switching)

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2. Literature review

2.1 Theoretical and Conceptual Framework

3D printing, or additive manufacturing, technology creates objects from different

materials. This technology is used in many fields, like agriculture, healthcare, the

automotive industry, the locomotive industry, and aviation. This technology uses a

computer-aided design (CAD) model to print the 3D objects layer by layer from

bottom to top. A 3D printer was first created by Charles Hull in 1980. 3D printing

technology will reduce costs if it increases production speeds. This study gives an

overview of types of 3D printing technology, applications of 3D technology, and

materials used in this technology for creating objects in industries. Types of 3D

printing technology include binder jetting, directed energy dispensing, material

extrusion, material jetting, powder bed fusion, sheet lamination, and Vat

photopolymerization. Materials that are used in 3D printing technology are metals,

polymers, ceramics, composites, smart materials, and special materials like food,

lunar dust, and textiles. Applications of 3D printing in manufacturing technology are

in the aerospace industry, automotive industry, food industry, healthcare and medical

industry, architecture, building, and construction industry, fabric and fashion industry,

and electric and electronic industries. [1]

The researcher discussed 3D printing, which is a procedure for creating three-

dimensional objects using materials such as plastic or metal. The molten filaments are

deposited one after another in layers. 3D printing technology is different from 2D

printing technology. 3D printing is used in medicine, including ophthalmology, the

manufacturing of eyeglasses, custom prosthetic devices, and dental implants. Printers

like dot matrix, laser, inkjet, and digital printers print two-dimensional images;

however, in 1980, Charles Hull invented the 3D printer. 3D printing technology is

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vastly used in the medical field, including ophthalmology, the culture of cells, blood

vessels, and vascular networks, bandages, bones, ears, exoskeletons, windpipes,

dental prosthetics, including a jaw bone, and future corneas for diseases such as

diabetes, creating prosthetics, stem cells, testing new drugs using printed tissues, and

customized drugs. 3D printing is also being checked as a source to replace organs like

kidneys, hearts, or skin and has the potential to print new organs that perform the

same functions, such as the pancreas in diabetes. So, 3D printing is very helpful in the

medical field.

[2]
3D printing technology has been discussed, and it has been shown that by using 3D

printing technology, we can fabricate customized products at low and minimum costs.

FDM is a 3D printing technique used in different sectors, but due to a lack of

materials, this technology is limited. Techniques in FDM technology and various

polymers and their composites are discussed, and search gaps are pointed out in this

study. Fused modeling is a well-known additive manufacturing technology due to its

production capability and ability to produce complex objects. The object is created on

a plan surface three-dimensionally per CAD design using filaments. Once the initial

layer is printed, the second layer is printed over the previous layer, and so on.

Acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) materials are used in

FDM. Other materials are nylon, ULTEM, polyetheretherketone (PEEK),

polypropylene (PP), polyphenylsulphone (PPSF), thermoplastic polyurethanes (TPU),

polyvinyl alcohol (PVA), high-impact polystyrene (HIPS), and composite filaments

used in FDM techniques. The ISO and ASTM categorized various techniques of 3D

printing technology like sheet lamination, material extrusion, powder bed fusion,

direct energy deposition, binder jetting, material jetting, and vat photopolymerization.

Techniques like stereolithography (SLA), selective laser sintering (SLS), inkjet

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printing (IP), laminated object manufacturing (LOM), and fused deposition modeling

(FDM) are used in 3D printing technology. Thermoplastic polymers and other low-

melting-temperature materials are used in FDM. The researchers are attempting to

improve the quality and properties of polymers. The important parameters used in the

FDM printing technology are infill pattern, infill density, raster angle, raster width,

layer thickness, build orientation, printing speed, air gap, and operating temperature.

Infill patterns are the shapes and structures of the polymers and other materials inside

the part. Many infill pattern densities such as triangular, grid, cubic, honeycomb,

concentric, rectilinear, rectangular, octet, and wiggle are used in Fused Deposition

Modelling. Applications of the FDM are in aerospace, electronics, biomedical,

construction, automotive, and other sectors. There are various challenges and

limitations to FDM technology. Significant studies like design freedom,

customization, and the ability to print complex structures are required. In the limited

materials, quality, accuracy, anisotropic mechanical properties, limited application in

large production, mass production, printing time, clogging, and void formation, also

needed research. [3]

In three-dimensional technology, fused deposition modeling is an extrusion-based

technique that prints objects layer by layer from bottom to top. In this article, the

researcher reviewed FDM-based 3D printing applications like drug delivery systems

and the fabrication of personalized tablets. Computer-aided design techniques are

used in 3D printing technology. In 2015, the US Food and Drug Administration

approved the first 3D-printed drug, spritam. Computer-aided design (CAD) software

is used in 2D and 3D printing. 3D models reduce errors. 3D printing techniques are

applied in drug delivery systems, divided into different categories; however, the

procedure of fabrication is different, but all techniques use layer-by-layer deposition

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to form an object. The categories are 3D printing inkjet-based systems, 3D printing

extrusion-based deposition systems, 3D laser-based printing systems, and 3D printing

powder-based distribution systems. FDM is a 3D printing technology that create

physical objects using X, Y and Z axes. This technique is also helpful for drug

delivery systems to manufacture patient tablets and capsules with great accuracy and

fabricate geometric devices. Fused deposition is a thermo-based technique in which

heat is transferred to melt the polymers to create an object. Commonly used polymers

for FDM drug delivery systems are polyvinyl alcohol, polylactic acid, and ethylene

vinyl acetate. FDM-based 3D printing is a low-cost, effective manufacturing

technology that offers high precision and versatility. The major benefit of FDM 3D

printing is that it is simple to develop and produce custom tablets or devices with

individualized doses. Due to the ability to print objects with different geometries and

drug and polymer proportions, the release profiles of the loaded drug may be

regulated and altered. Due to these benefits, FDM printing is a potential new

technique that may be used to create customized tablets and other medication delivery

systems. Compared to established manufacturing processes for drug delivery devices,

FDM-based 3D printing has competitive advantages. However, as with many

emerging technologies, the limitations of FDM 3D printing must also be recognized

and addressed. First, pre-FDM drug-loading methods are still problematic due to the

use of heat, and even though HME could offer more advanced and tunable drug-

loading, drug candidates are limited to heat-stable compounds. Thermosensitive

agents are not suitable for FDM-based printing, limiting biomedical and

pharmaceutical applications. Furthermore, when additives are incorporated into the

polymer matrix, they can alter the thermoplastic properties of the polymer filaments,

altering their viscosity and flexibility. Second, the printing process requires high
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temperatures to melt the filament at the point of extrusion to build the object, which

can lead to physical instability and degradation issues. Third, the support structure

that needs to be built as a base for the printed object is a source of material waste,

especially if the object has a complex shape or a large footprint. Additionally, it is

difficult to remove the internal supports required to support hollow objects in large-

scale processes. [4]

Fused deposition modeling is a 3D printing method under the additive manufacturing

class. Additive manufacturing technique is used to create various complex objects and

structures. In the FDM manufacturing process, the basic material is only melted and

molded to produce new shapes. The material is a rolled-up filament that is pulled by a

driving wheel, heated to a semi-liquid condition, and then injected into a temperature-

controlled nozzle head. The nozzle precisely extrudes and guides materials in ultrathin

layers to build structural elements layer by layer. This conforms to the layer contours

as defined by the software, often CAD, that has been integrated into the FDM work

system. After creating object, it then solidifies at room temperature after printing. The

polymers, used in FDM are PLA, ABS and PP. Researchers and companies have

created polymer composites as a 3D printing filament material to create systems with

structural features and functional advantages that cannot be produced by single

elements. Extruding polymer pellets or raw materials is used to create FDM filament.

Creating filament from polymer composites or strengthening is done by combining

the materials and preparing each composition in advance. Various techniques can be

used to combine the materials, such as dry mixing or combining the solution and

letting it dry before extracting. The filament's diameter, regularity, and filler direction

are influenced by variables such as die temperature, roller puller speed, spindle speed,

and intake temperature. Polymer filament has two types, pure polymer filament and
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composite filament. The quality and mechanical properties of the FDM engineering

process were influenced by all aspects and input parameters, according to the

literature review. The composition of the filament, the extrusion working parameters,

such as extrusion speed and temperature, the FDM machine specifications, the

extrusion machine specifications, the type of filament polymer, and the FDM work

parameters used when printing the filament have all been identified as having an

effect on the results. The field of additive manufacturing has been defined by this

study's usage of a polymer filament 3D printing technology to analyses and improve

FDM procedures and materials. It has been emphasized that what makes FDM special

are a number of process factors that impact mechanical characteristics and the quality

of outputs. FDM involves a variety of process factors that affect mechanical qualities

and caliber. [5]

FDM is a widely used additive manufacturing technique. This approach is used in

many fields. It was found that high mechanical properties can be achieved by adding

composite reinforcements in different ratios. Therefore, it was expected that the

composite materials created in this study could use a wider range of applications.

Instead of using conventional manufacturing processes and standardized

manufacturing techniques, additive manufacturing (AM) is the process of applying

materials one layer at a time to construct things from 3D model data. The idea behind

conventional manufacturing processes is to separate chip materials from raw materials

during the part manufacturing process. 3rd dimension printer was first developed by

Charles Hull in the year 1984. Advantages of 3D printing technology are minimal

waste, low cost, the ability to produce parts with complex geometries without the use

of molds, the ability to produce parts with the desired composition, use in an office

work environment, measurement accuracy, chip removal, deburring and lack of other
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operations. The use of 3D printing technologies in the automotive, aerospace, defense

and aerospace industries, as well as in product and machine design, prototyping parts

manufacturing, educational equipment, textiles, toys and medical devices is becoming

more common. Selective Laser Sintering (SLS), Selective Laser Melting (SLM),

Electron Beam Melting (EBM), Laser Metal Deposition (LMD), Fused Deposition

Modeling (FDM), Stereolithography (SLA), and Digital Light Processing (DLP)

technologies are the most applied technologies for additive manufacturing. In the

FDM technology, the first step is to model the object using computer-aided design

environment and model is then converted to the STL format. After slicing of the 3D

model, the model in the STL format transmitted to the 3D printer. The superposition

of thermoplastic molten material, known as filament, which is deposited from the

nozzle of the 3D printer, yields the 3D geometry of the object specified in the

computer environment. The FDM method involves layering the molten material onto

a heated flat table surface using a hot nozzle. The FDM manufacturing method is

based on the principle of using a polymer as the printing material and melting and

bonding the thermoplastic material. Due to the advantages of the thermoplastic

materials used, cheap, long service life, high toughness, easy to find, recyclable, some

species dissolve quickly in nature, low forming temperature, heating then it will be

molded. Now even home users can use this method to make a variety of parts. Due to

the simple functional principle and low capital investment, the cost of devices

manufactured using the FDM method is lower than those manufactured using other

AM methods. Because of these properties, the FDM method has been used to create

devices called 3D printers that are suitable for desktop use. FDM techniques are also

used by private users due to the low cost and other advantages of the device and

thermoplastic materials. The thermoplastics used in FDM manufacturing are polymer

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class materials. By heating the solid at a low temperature, it becomes soft and can be

shaped. Once the thermoplastic molding process is complete, it cools and solidifies to

create the desired shape of the product. Acrylonitrile Butadiene Styrene (ABS),

Polylactic Acid (PLA), and Polyethylene Terephthalate-Glycol (PET-G) are the

filament types that are frequently used in production, but in recent years,

metal/polymer composite materials have also been used. These materials are created

by adding metal or thermoplastic materials in varying proportions. The mechanical

characteristics of the materials must be understood in order for them to be utilized

successfully, and if required, these properties should be modified in accordance with

the usage area. Tensile strength, impact strength, elastic modulus, yield strength,

fatigue strength, hardness, etc., are attributes that spring to mind when the mechanical

properties of the material are stated. The impact of 3D printing settings on the

mechanical qualities of 3D printed items has been the subject of several research in

the literature. Here, the filling ratio, printing speed, layer thickness, filament, and

nozzle diameter constant are six distinct filling test samples that are given. [6]

Fused deposition Modelling or fused filament fabrication is the additive

manufacturing process. The fundamental concept of the additive manufacturing
technology is to design a model in software and slice the model and then translate this
model to the 3D printing to create the physical object layer by layer. Additive
manufacturing has many types including polymerization, material jetting, binder
jetting, materials extrusion, sheet lamination, powder bed fusion, and directed energy
deposition. FDM technique is simple and low in cost, used in many applications.
Filaments in FDM are heated, extruded with the help of a nozzle, and printed layer by
layer on a platform. All the layers are fused and solidify when the temperature falls.
The interaction of the molecules will result in bonding between the layers when one
layer is connected to the solid layer while it is still in a liquid state. However, gaps
may form between the layers if molten fibers freeze quickly or if the extruded
material and the solidified material don't overlap. Assessing the mechanical properties
of the fused deposition model is a challenging task.
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The mechanical properties of the printed object are influenced by the thickness,

breadth, and infill density of the layer. The FDM technique has disadvantages like

poor surface quality, lower mechanical qualities, and visibility of layer thickness. In

this research, the researcher described the overview of the FDM process, the influence

of process parameters on the strength of FDM parts, the effect of infill density, the

effect of infill patterns, and the effect of extrusion temperature. Major gaps are

identified in this research, such as tensile qualities of the manufactured part, linear

and circular features, an inquiry on the strength properties of different materials such

as plastic and metal, infill pattern and infill density, Coating is another pre- and post-

enhancement procedure that requires careful consideration. Impact of the sterilization

method on the strength qualities. [7]

 16

There are three categories of manufacturing techniques: formative manufacturing,

manufacturing with layer removal, and additive manufacturing. The first two types

are traditional manufacturing. 3D printing is useful for rapid prototyping and

designing complex 3D models. The last category (additive manufacturing) has been

divided into seven main categories, such as vat photo-polymerization, direct light

processing, multi-jet fusion, direct metal laser sintering, selective laser sintering,

selective laser melting, and selective laser melting. These all-use plastic and metal

elements to build 3D Models. The term fused deposition modelling is used by

Stratasys.

The FDM process has many phases while creating the 3D physical objects: design

phase (the 3D model of the object is built in the CAD software), Manufacturing phase

(slice the 3D design and transmit it to the 3D printer for creating physical objects),

and Testing phase (The FDM-obtained prototype is put through physical and

mechanical testing to learn more about how well it performs). Many useful

applications have been made by 3D printing, like parts of the human body, implants

and devices for medical use, biotech (human tissue replacement), building implants

after a certain shape (for example, dental or bone implants), skeletons, and corpse

replicas. The mechanical, thermal, and structural characteristics of the PLA material

were examined in the experimental findings. The Effect of Process Parameters on

PLA Mechanical Properties (Experimental Methodology, Construction Orientation,

Thickness of Layer) and the Effect of Continuous Fiber Reinforcement on the

Mechanical Properties of PLA Samples The lack of results in scientific studies of

potential variables, such as build material, extruder temperature, shell, etc., highlights

the need for research in this area in order to better understand the behavior of 3D

prototyped parts from a mechanical standpoint and to determine their optimal settings.
 17

The mechanical qualities of the 3D-printed items are greatly improved by utilizing

fibers to strengthen the PLA material using FDM technology. In terms of PLA

material reinforcement, the conventional reinforcing technique has been enhanced,

bringing additive manufacturing by material extrusion closer to many industrial

industries. One of these enhancements entails combining continuous carbon fibers in

the printing head of the apparatus, enhancing the PLA matrix and fiber adhesion. Due

to its benefits in terms of pricing, product quality, functionality, and production time,

FDM technology is being used more and more by research organizations, businesses,

and consumers. [9]

Examples of 3D fabrication technology are Architecture/Engineering, Art, Biology,

Chemistry, Computer Science, Geography, History, Math, Performing Arts, Writing.

The Seven types of additive manufacturing methods and 3D printers include are

Powder Bed Fusion (PBF), Binder Jetting, Material Jetting, Directed Energy

Deposition (DED), Material Extrusion, Sheet Lamination, Vat Photopolymerization.

PBF employs melting to fuse together fragments of a powder substance (metal or

plastic). An electron beam, laser, or heated print head can all conduct full or partial

melting. By applying a small layer of material to the print chamber region, the build

layers are accomplished. The layer that defines the print object has melted. The

procedure is repeated until only the layer-containing object particles are melted,

creating the desired item. The newly formed item is then shown once the un-melted

material is blown away. Because of its great strength and variety of post-print

finishing options, this process is frequently employed for the production of finished

goods. Several 3D printers employ the PBF technique. Direct Metal Laser Melting

(DMLM), Direct Metal Laser Sintering (DMLS), Electron Beam Melting (EBM),

Selective Heat Sintering (SHS), Selective Laser Melting (SLM), Selective Laser
 18

Sintering (SLS). Binder jetting employs nozzles to drop material onto the print area in

a manner akin to an inkjet printer. In this technique, a binder substance is placed onto

a layer of powdered metal, glass, or ceramic material. A fresh layer is prepared to be

added on top of the preceding layer once the powdered material has been bonded.

This technique occasionally results in brittle prints and requires finishing after the

print is finished. It is suitable for more aesthetic applications as a result. Inkjet printers

use nozzles to drop waxy photopolymer onto a print bed, cured or hardened using UV

radiation. Supports are deployed, and the process is repeated for accurate, smooth, and

precise printing in various colors. DED, or Direct Metal Deposition, uses thermal

energy to melt and fuse materials like metal powder and wire filament in heated or

vacuumed print regions. This technique is used for repairing original or damaged

objects. The process of material extrusion involves heated thermoplastic filament that

is sprayed in layers through a nozzle onto the print surface. During cooling, these

layers combine with the preceding layer. The materials utilized in this approach

include plastics and polymers that have been infused with other materials, however

they may not be as strong as those used in other additive manufacturing processes.

Rapid prototyping is made possible by the method's overall speed and cost efficiency.

Fused deposition modeling (FDM)/Fused Filament Fabrication (FFF) – this type of

3D printer is one of the more commonly known by the public. It is widely used by

both industry and DIY enthusiasts. Very thin layers of material are adhered to one

another during sheet lamination. Layers of glue and material are alternated to

accomplish this. You may use a number of materials, including metal and paper. After

the layers have dried, they are sliced into a print using a laser or blade. Vat

photopolymerization employs liquid photopolymer resins in a number of deployment

techniques that fuse/cure the resins in layers to create the object using light rather than
 19

heat. One deployment technique, for instance, places the construction area inside a vat

of liquid resin. An object's outline is traced by a laser. Layer by layer, the resin is

solidified by the laser light as it outlines the item. Printing things with fine features

and smooth surfaces is done using this technique. The components of FDM printer are

Mechanical components, Bed, Motor, and Frame Components and Electrical

Components. Extruder is the main component of any 3D FDM printer. It pulls, melts

and extrudes filaments through a nozzle. The extruder has two parts such as the cold

end which draws the filament in from the spool and pushes it through to the hot end

and the hot end that melts the filament with a heating element and extrudes it out

through a nozzle. Subcomponents of cold end are Hobbed Gear, Idler Gear, Direct

Drive and Bowden Drives. The Hot end consists of PEEK/PTFE or All-Metal Insert,

Heater Cartridge, Heater Block, Thermistor/Thermocouple, Heat Break, Heat

Sink/Hot End Fan, Layer Cooling Fan(s), Nozzle. Bed, Motor, and Frame

Components are Print Bed, Bed Surfaces, Bed Leveling and Tramming Mechanisms,

End Stops (one for each axis), Threaded Rods or Leadscrews, Stepper Motors, Belts,

Frame, Enclosure and Filament and Holder. Electrical Components are Power Supply,

Motherboard/Controller Board, SD Card Slot, USB Connector, Stepper Drivers,

Screens and User Interfaces, Screens and User Interfaces, Enclosure Fan and Filter.

[10]

Additive manufacturing technology involve the following eight steps. 1) Computer

Aided Design: In this step, we used any professional CAD modeling software to

design any 3D model. 2) Conversion to STL: Every CAD software can output an STL

format. We convert the CAD design to STL format. 3) Transfer to AM Machine and

STL File Manipulation: The STL is then transferred to the AM machine for 3D

printing. 4) Machine Setup: Before starting the build process, the AM machine has to
 20

be correctly configured. These options would be in relation to the construction

parameters, such as the material restrictions, energy supply, layer thickness, timings,

etc. 5) Build: The process of making the part is largely automated, and the machine

may operate mostly unattended. To verify that no mistakes have occurred, such as

running out of material, electricity, or software, etc., only cursory monitoring of the

machine is required at this stage. 6) Removal: The components need to be removed

when the AM machine has finished building them. In order to accomplish this, you

might need to communicate with the machine, which might include safety interlocks

to make sure, for instance, that the operating temperatures are low enough or that

there are no actively moving parts. 7) Post-processing: Parts may need some further

cleaning after being taken out of the machine before being put to use. At this point,

parts might be fragile or contain extraneous components that need to be removed. As

a result, doing so frequently calls for patience and precise, skilled physical

manipulation. 8) Application: Possibly now is the time to use the parts. Before they

are suitable for usage, they can also need extra treatment. For instance, they can need

painting and priming to get a surface quality and texture that is suitable. Treatments

could be difficult and drawn out if the finishing standards are exceedingly strict.

Additionally, they might need to be put together with other mechanical or electrical

parts to create a finished model or item. [11]

The Municipal Industrial Research Institute printed the physical object from a digital

design, but the 3D printer was first designed by Charles Hull in 1984 while he was

working for 3D Printer Corp. Charles A. Hull is credited with developing the

stereolithography solid imaging technique and the STL (stereolithographic) file

format, which is still the most used 3D printing file type today. Fused deposition

modeling (FDM) is the name given by Stratasys to the plastic extrusion method that is
 21

most commonly linked with the phrase "3D printing" and was developed in 1990.

Additive manufacturing is also called desktop manufacturing, rapid manufacturing,

and agile tooling on demand manufacturing. 3D models are created with the help of

computer-aided design. In 3D printing, data is analyzed and collected on the shape

and object, and then a 3D object can be produced. A 3D model is basically a .stl file,

and this file is sliced to convert the .stl file to a series of layers and produce G-code.

Cura, KISSlicer, Slic3r, etc. are slicing software used today. After converting to G-

code, the 3D printer follows the G-code instructions to build the physical model.

Selective Laser Sintering, Fused Deposition Melting, Stereolithography, and

laminated object manufacturing are AM processes. S. Scott Crump created the merged

deposition modeling (FDM) technique in the late 1980s, and Stratasys designed it in

1990.

The following materials are used in 3D printing: Acrylonitrile Butadiene Styrene

[ABS] is one of the materials that has been utilized the most since 3D printing first

became popular. This substance is ideal for 3D printing since it is lightweight,

somewhat flexible, and extremely robust. Compared to PLA, another common 3D

filament, it extrudes with less force. For tiny pieces, extrusion is facilitated by this

characteristic. The fact that ABS demands a higher temperature is a drawback. Its

glass transition temperature is around 105°C, and temperatures between 210 and

250°C are often employed for ABS printing. Another negative of this material is the

printing process, which produces strong fumes that can be harmful to animals or

humans with respiratory problems. So, a well-ventilated location is required for the

placement of 3D printers. Avoiding inhaling fumes when printing is also a good idea

because 3D materials are expensive. Because ABS is the least expensive, it has

historically been a favorite in the printing industry.

 22

Poly Lactic Acid [PLA]: Another popular material among those who enjoy 3D

printing is poly lactic acid (PLA), which can be made from maize and is

biodegradable. It is a thermoplastic that degrades naturally and is made from

renewable materials. As a result, compared to other plastic materials, PLA products

are more ecologically friendly. The biocompatibility of PLA with the human body is

one of its other outstanding qualities. PLA melts at a lower temperature than ABS,

between 180 and 220 degrees Celsius, and has a tougher structural makeup than ABS.

Because the glass transition temperature for PLA is between 60 and 65 °C, using PLA

and ABS together might be a smart choice for any of your projects.

High Impact Polystyrene [HIPS]: Another example of a support 3D material is HIPS

filament, which is constructed of High Impact Polystyrene. In the food business, this

material is often used for packaging. Naturally, this filament has a dazzling white hue

and is also biodegradable, so there are no negative effects when it is placed in close

contact with a human or animal body. It is also used to pack CD discs and

manufacture trays in the medical industry. By utilizing a heated bed when printing,

curling and adhesion issues with HIPS filaments can be lessened. HIPS material that

may be dissolved in a clear liquid hydrocarbon solution after serving as a printing

support structure There are many advantages like Time-to-Market, Mitigate Risk,

provide feedback, Get the Feel, Personalize It, Build Your Imagination, Square Holes,

Fail Fast, Fail Cheap. Disadvantages include Intellectual property issues, Limitations

of size, Limitations of raw materials, Cost of printers, Fewer Manufacturing Jobs, and

unchecked production of dangerous items. [13]

 23

In this article, a 3D printer is constructed using the Arduino Mega 2560. The hardware

design consists of the following components: Arduino Mega 2560, Stepper Motor,

Heat Bed, Extruder, End stop switch, and Rams 1.4 shield. The Arduino Mega 2560's

microcontroller board is seen in Figure 2.2. There are 54 digital I/O pins. It can accept

16 analog inputs. Four Universal Asynchronous Receiver Transmitters make up the

device. The quartz crystal oscillator has a 16-MHz frequency.

Figure 2.2 Arduino Mega 2560

The suggested concept makes use of NEMA 17 stepper motors. It is a hybrid stepping

motor with a 1.8° step angle, which translates to 200 steps per revolution. Using a

holding torque of 3.7 kg/cm, each phase will drain 1.2 A at 4 V. The motor has six

lead wires and a rated potential of roughly 12 volts. The construction of the heat bed

is seen in Figure 3. Another component of a 3D printer will be a heated bed. It offers

the cooling system needed to provide optimal printing results. To prevent thermal

runaway, heat beds. Additionally, prevent issues like poor adherence to the print bed

and low adhesion between layers.

 24

Figure 2.4 illustrates the Figure 2.3. Heat Bed 3D extruder, a crucial

component of a 3D printer that immerses material in liquid or semi-liquid to store it in

successive layers inside the 3D

printing volume.

Figure 2.4. Extruder

The extruder often only aids in depositing the bonding agent and solidifying more

material. The End Stop Switch Module is seen in Figure 2.5. When the bound was

reached, those end-stops' primary function was to align the logical state of a pin on

the ATmega (or other controller board) to point. Hardware end-stops will signal when
 25

the end stop condition has occurred and are electrically connected to the end-stop

ports on the printer control board.

The Ramps 1.4 shield's module is seen in Figure 2.6. The RAMPS offers plenty of

room for expansion and connects an Arduino Mega to the sturdy Arduino MEGA

stage. On an Arduino MEGA shield, it includes of stepper drivers and extruder control

hardware for clear help, component replacement, redesign capability, and expansion.

The softwares that are used in this 3D printing are Arduino Integrated Development

Environment (IDE), Pronterface, is a set-up of host interfaces for 3D printers and

CNC is printrun, and SLIC3R.

Figure 2.6.Ramps 1.4 Sheild

The following steps are involved in the construction of 3D printing model.

1: Using CAD software, create a 3D model.

2: A high-quality Standard Tessellation Language (STL) file is created from the CAD

model.

3: The STL file is sent to the computer that manages the 3D printer. The user

configures printing settings and determines the printer's size and orientation.
 26

4: Every machine has different setup needs, such as replenishing the polymers,

binders, and other consumables the printer will need.

5: Start the machine and wait for the construction to be finished.

6: Printing of the item is complete. The item will be removed.

7: Post-processing is the final stage in 3D printing. Many 3D printers need to be

postprocessed in some way, such ignoring and chopping out extra material. [14]

3D printing technology has been used for over 30 years. A rapid increase was seen in

the use of 3D printing in analytical and microfluidics research. 3D printing was also

used for the fabrication of channels, sample cartridges, hydrophobic patterning,

labware, and customized setups. Such types of works can be achieved with several 3D

printing approaches like SL, FDM, inkjet 3D printing, DLP, and SLS. In this study,

the researcher describes FDM 3D printing and describes the possibilities and

limitations concerning biological analytical devices. A polymer filament is melted and

extruded as the foundation of FDM. A heated metal cylinder with a nozzle is where

the filament is fed and melted. The molten polymer is forced out of the nozzle and

forms a thread that is roughly the diameter of the nozzle, as long as fresh filament is

continually fed into this component. The nozzle is positioned above a metal plate

(print bed) at a distance that depends on the required resolution to form this thread

into a plastic object. The filament is discharged from the nozzle and placed on this

print bed, which may be heated to facilitate adhesion. We can create a two-

dimensional figure on the print bed that is one polymer thread thick when the print

bed and nozzle are both moveable in perpendicular directions. The relationship

between (i) the distance between the nozzle and the print bed and (ii) the flow rate of

the filament through the nozzle and the printing speed determines this thickness,

which is typically between 0.1 and 0.3 mm. When the first layer is complete, the print
 27

bed is lowered by a predetermined amount (i.e., the thickness of a single layer),

allowing for the printing of a second layer on top of the first. These actions are

repeated to produce an item in an additive fashion. A 3D-drawn model must first be

converted into a file that instructs the printer how to operate before it can be printed.

Gross and colleagues go into great depth about this procedure. In essence, the 3D

artwork (typically a vector file) is saved in the triangular surface mesh *.STL format.

The solid object is then transformed into a digital representation of filament threads

by using this file to carve a route for the extruder to follow (creating G-code). A

number of 12 FDM filament materials were discussed in this study that are available

for FDM and have different polymers and varying degrees of elasticity. In the context

of this study, biocompatibility is the feature of a substance that prevents cells and

tissues from losing viability when exposed to it in in vitro culture settings.

Characterizations of a Benchtop FDM 3D Printer are Resolution, Surface roughness,

overhang, prevention of leakage, transparency, combining materials, and warping.

Polymers for FDM 3D Printing are Polymer Printability, Autofluorescence, Solvent

Compatibility, and biocompatibility. Applications of FDM 3D Printing are 3D-Printed

Masters for PDMS Casting, 3D-Printed Channels, Patterning in Paper Microfluidics,

Customizing Laboratory Equipment, and 3D-Printed Tools. FDM is perhaps the most

accessible printing method in comparison to other printing techniques. The printer

itself is affordable, as are the supplies. The simplicity with which various materials

may be changed during a print and the ability to include and embed external

components into a single product are further benefits of the FDM technology. Other

advantages include the large variety of printing materials available and the

biocompatibility of most FDM materials with tissue and cells. The resolution and

surface smoothness issues are the primary drawbacks (although these issues are
 28

partially improved with alternative 3D printing techniques, including DLP). However,

given the speed at which technology is developing, we anticipate that higher-

resolution (FDM) printers will soon be accessible.

[15]

The 3D model has to be manifold and impermeable. One industry where 3D printing

is applied is the textile industry. We produce several apps and physical things using

3D printing. 3D printing may be used to create clothing as well. German RepRap

created the first FDM printer, the X400. Weft knitted constructions may be 3D printed

using a CAD model as a starting point. Single-face weft knitted fabric CAD model

created using Blender (upper left panel), 3D printed using SLS (upper right panel),

FDM using

Bend Lay with

support structures

(lower left

panel), and FDM

using soft PLA

without support

structures (bottom

right panel).

Measurements are shown via the ruler.

 29

Figure 2.7. Weft Knitted Fabric

With the use of FDM technology, several layered structures have been created. In

order to determine if single strings may be placed on top of reasonably open structures

without any support structures, a test construction is shown in Figure 7. A three-

stacked layer test pattern for a layered construction . Designers have made lace with a

base layer that unites mostly floral and circular motifs by taking their cues from the

well-known Figure 2.8. Three-stacked layer

Plauen lace. Since there are no free-floating zones, printing with the FDM process is

simple if all connecting lines have enough width. A multi-layer, multi-material

structure is shown in BlenderTM as having three distinct layers and a separate ring

made of a different material that is colored red (left panel), and the printed object is

shown in the right panel

 30

with a hard Bend Lay ring made of soft PLA layers. The pattern is 8 cm by 8 cm in

size. being partially fixed by the bottom and top layers after the design is complete.

Such a multi-material model can be produced in this manner. Similarly, reinforced

pieces made of hard PLA or Bend Lay may be included in lace forms that have three

or more layers of soft PLA. [16]

The FDM printer is Figure 2.9. Multi-material Structure flexible and can

handle the lower layers easily. It has some restrictions, like the fact that it cannot

produce undercuts without supporting material. Materials like ABS and PLA are used

to create physical objects. The outer frame of the printer must be strong to protect it

from any kind of damage while carrying it from one place to another. Their

mechanical parts as well as electronic parts must be well assembled and fitted. We

used reverse engineering to retrieve the original documentation and dimensions in

order to implement this. The next phase describes the method's essential elements.

Reverse engineering is a labor-intensive engineering procedure where we use 3D

digitalization to determine the CAD geometry of an actual, physical product. Reverse

engineering starts with the finished product. It is intended for rebuilding. There are

several steps in Reverse engineering, such as Scanning, Preliminary processing of the

point cloud after scanning, Final processing of the point cloud, The use of RapidForm

XOR for creating a model or virtual prototype is not recommended because, after

printing, the undercut surfaces collapse. We intended to incorporate two extrusion

head units into the planned printing unit because of this. Design of the extrusion head

unit (The retortion unit and Structure of the extrusion head unit) implementation of

the X-Y movement with the new extrusion head unit and Belt tension. The author

described how to create a machine using FDM technology and how to reverse
 31

engineer it. After learning from the printer, they began to create an experimental

printer unit to address the shortcomings of the earlier model. A head-holder console

and a small, user-friendly jog unit make up the intended printing unit. The aim was to

build a structure that could print support material and have the X-Y movement

performed simultaneously by the extrusion head unit. They included two extrusion

heads in the printing machine because of this. As a result, they have created a unit that

makes a fantastic assembly of an existing or completely new machine. [17]

Three steps make up the FDM process: (1) extrusion of molten material, (2) layer

deposition of material, and (3) layer solidification (usually cooling of the printed

layers). In a nutshell, heating elements melt the thermoplastic polymeric filaments

(printing materials) slightly above the softening point when they are fed through the

nozzle tip of the printer head. On the build plate, these semi-molten ingredients are

extruded via the printer head's nozzle tip to create a thin layer of material. Typically,

the outside layer is printed first, followed by layer-by-layer printing of the inside

structures, with an extruded polymer known as the "infill" filling in any internal

spaces. FDM has been widely used with a variety of polymeric materials, including

thermoplastic polyurethane (TPU), high-impact polystyrene (HIPS), acrylonitrile

butadiene styrene (ABS), polylactic acid (PLA), polyvinyl alcohol (PVA), aliphatic

polyamides (nylon), and polyvinyl alcohol (PVA). [18]

3D printing is a rapid prototyping technique using small, light machines and CAD

tools like Cura and Pronterface. This technology reduces acquisition costs and allows

for the creation of intricately formed items. However, most 3D printers operate in

open-loop systems, resulting in incomplete results. A closed-loop system uses a

stepper motor controller to count steps and resume printing when they are missed. The

principle behind 3D printing is additive manufacturing, which involves layer-by-layer

 32

printing. Fused filament manufacturing is the most popular, using materials like

plastic, metal, or powdered metal. 3D printing is an open-loop system that doesn't

check for errors and requires extra time. It doesn't detect skipped steps or excessive

filament extrusion, leading to ringing on the printing surface. The process is

complicated due to excessive formatting, parameters, and mechanical tinkering. The

main issue is that 3D printing may not produce a flawless result due to factors like

overheating, skipped procedures, and failure to try again. Most 3D printing equipment

is not user-friendly, and users need basic knowledge of Arduino programming and g-

code to fix errors. Building a 3D printer is costly, with each component costing

around $3. Plastic and metal-based 3D printers also contribute to pollution and energy

consumption. 3D printing primarily uses plastic, including polystyrene,

polycarbonate, and acrylonitrile butadiene styrene, for toys and home goods. Metals

like stainless steel, bronze, gold, nickel, aluminum, and titanium are widely used, with

direct metal laser sintering being the aerospace sector's method.

Other materials include paper, graphite, graphene, nitinol, and carbon fiber. Fused

deposition modeling (FDM) and material extrusion are other 3D printing methods that
 33

use resins in the vat processing process, resulting in detailed and flawless products for

various applications. Fused filament printing involves using polylactic acid (PLA)

filament and a 3D printer setup. The setup includes an Arduino Mega 2560 R3,

RAMPS 1.4 shield, stepper motors, stepper motor driver, extruder, hotend, heatbed,

and end stops. Cura is used to divide the item into horizontal layers, and a g-code file

is created using Pronterface. The printer monitors the process and recreates missing

steps, resulting in a finished product. Proteus software can be used to simulate the

process. [19]

The open-source software known as the Arduino IDE is used to create and upload

code to Arduino boards. For different operating systems, including Windows, Mac OS

X, and Linux, the IDE program is appropriate. The programming languages C and C+

+ are supported. Integrated Development Environment is referred to in this sentence.

Sketches are computer programs created using the Arduino Software (IDE). These

drawings are created in a text editor and saved as files with the.ino extension. The

editor offers functions for text replacement and text searching. When saving and

exporting, the message section provides feedback and shows errors. The console

shows text generated by the Arduino Software (IDE), including error messages in

their entirety and other data. The configured board and serial port are visible in the
 34

window's bottom right corner. You may create, save, and save drawings, validate and

upload programs, view the serial monitor, and more using the toolbar buttons.

Marlin is an open-source firmware created for FDM 3D printers used in the RepRap

project that runs on the Arduino platform. It is controlled by a mainboard that has

built-in hardware and general-purpose I/O pins and accepts G-code commands via

USB ports or other sources of input or media. Real-time operations, including stepper

motors, heaters, sensors, lighting, displays, and user interfaces, are managed by the

main loop. Marlin supports a number of 3D printing robot platforms, including less

traditional models like Hang printer and Belt printer as well as Cartesian, Core XY,

Delta, and SCARA printers. Any equipment that has to be controlled and interacted

with may use it, including SLA and SLS 3D printers, specialized CNC mills, laser

engravers, laser cutters, vinyl cutters, pick-and-place devices, foam cutters, and robots

that paint eggs.

[23]

Printing history began with stamp replication, followed by flatbed printing in the 18th

century, and then chromolithography in the 19th century. The 2D printer

revolutionized color printing, leading to the development of 3D printers. Current

research focuses on designing and developing low-cost 3D printers. The main idea

behind a 3D printer is to create items layer by layer, giving the product its "three-

dimensional" name. However, 3D printers are more expensive due to the printing

technique and materials used. This project aims to reduce the price of 3D printers by

recycling leftover materials and creating a frame. The main goal is to make 3D

printing accessible to the general public by making the machinery simple to use and

automating operations. The goal is to reduce interaction time and make the gadget

reasonable and accessible to everyone. This project targets those with cost constraints,
 35

making 3D printers useful in school laboratories, fake jewelry production,

automobiles, and other sectors. The goal was to research, develop, and build a 3D

Figure 2.13 Circuit Diagram of 3D printer

printer. The team purchased a complete toolkit and used Solid Works to create a CAD

model. They created the necessary components and assembled them on the Solid

Works CATIA V5R21 workbench. The voltage converter and microcontroller were

used to control the components. Characteristics such as bed temperature, extruder

temperature, feed rate, and flow rate were considered before producing a product.

Fans were necessary for cooling the bed and metallic elements. After programming

the Arduino Mega 2560, the system was tested for the first time, and the display was

functional. The 20 mm x 20 mm x 20 mm cube was manufactured in 90 minutes. A

bed heating issue was fixed by switching the wire to a heavy-duty wire (2.5 mm). The

updated setup was used to create the new cube, which was calibrated for precision,

ensuring accurate dimensions within 0.5%. [20]

 36

The most popular desktop printer uses FDM, stereolithography, and DLP, using light-

sensitive resin media cured by ultraviolet light. Repeated printing of tiny layers

produces 3D items. These printers are relatively new to DIY and small business

markets, but are increasingly used for miniatures and dental accessories. Despite their

high costs and challenges, these printers are becoming more popular for small-scale

production. An FDM 3D printer is a hot glue gun with a small nozzle and mechanical

carriage, drawing an object's contour and increasing height with each layer. Portable

versions, called 3D pen, are used for impromptu drawing. 1) The extruder, which is

connected to a 3-axis system for accurate movement in the X, Y, and Z axes, is loaded

by the printer with a spool of thermoplastic filament. 2) The printed item is outlined

by tiny strands of filament that are extruded one layer at a time. 3) The filament

hardens as it cools, and cooling may be sped up by using a cooling fan. 4) To support

top layers and maintain the item sturdy, infill is frequently required. 5) Up until the

item is finished, the procedure is repeated as the extruder advances to create way for

the following layer. There are a few main types and configurations of FDM printers.

1) Freehand pen, 2) Cartesian , 3) Delta, 4) Polar, 5) Robotic arm.

Components of FDM printer include: Mechanical components and electrical

components. Mechanical components are extruder, Bed, Motor, and Frame

Components. An extruder contains two parts 1) The cold end and 2) The hot end. The

cool end consists the filament drive. Cold end’s subcomponents are Hobbed Gear,

Idler Gear, Direct Drive and Bowden Drives. Hot End consists of all parts used to heat

and extrude the material. Hot end’s subcomponents are Heater Cartridge, Heater

Block, Thermistor/Thermocouple, Heat Break, Heat Sink/Hot End Fan, Layer

Cooling Fan(s), Nozzle. Bed, Motor, and Frame components comprising Print Bed,

Bed Surfaces, Bed Leveling and Tramming Mechanisms, End Stops (one for each
 37

axis), Threaded Rods or Leadscrews, Stepper Motors, Belts, Frame, Enclosure,

Filament and Holder. Electrical Components of the FDM printer are Power Supply,

Motherboard/Controller Board, SD Card Slot, USB Connector, Stepper Drivers,

Screens and User Interfaces, Lights (LEDs), Camera, Enclosure Fan and Filter. [21]

Table 2.1 FDM 3D Printer Components and Quantity

S# Description of the Components Quantity Budget in PKR

1 NEMA 17 Stepper Motor 5 2000
2 Arduino Mega 2560 1 4500
3 Ramps1.4 Shield 1 1000
4 A4988 Stepper motor Drivers 5 2000
5 V6 J-Head Hot end Bowden Extruder 1 1500
6 Mk8 Extruder Aluminium Block DIY Kit 1 4500
7 Smooth rod m8 500 mm 6 2100
8 T8 Trapezoidal Lead Screw 8MM 6 500
9 Flexible Coupling Coupler 6 2100
10 LM8UU 8 mm Linear Ball Bearing 6 2100
11 End stop switch 3 600
12 GT2 6MM Open Timing Belt +Pulley 2m 500
13 20 Teeth Pulley 5mm Bore 2 500
14 S-240 12 Volt 20-amp DC power supply 1 4000
15 PLA 1.75 mm filament 100m 1500
16 2 x 1.5-inch Aluminium Channel -- 2000
30cm Pin to Hole Arduino Jumper Wire
17 -- 200
Dupont
18 M5 Threaded Rod 8 3000
19 4mm glass for printed Bed 1 500
20 Total Budget in PKR 35000

Stratasys' FDM machines are effective because to their inexpensive price and

advantageous material characteristics. They do, however, suffer from limitations in

terms of material density, construction precision, and speed. Longer construction

durations result from the layer thickness choice of 0.078 mm available on the most

expensive machines. The nozzle, acceleration and deceleration traits, and viscoelastic

behavior of the material all affect the form that is created. An FDM system's speed is

determined by the feed rate and plotting speed. On early Quantum machines, Stratasys
 38

employed Magna drive technology to move the plotting head, which decreased

friction and made it simpler to move the heads at greater speeds. A specific

construction method seeks to strike a compromise between the speed of utilizing thick

layers and the accuracy of using small layers. In the most modern FORTUS 900MC

machine, conventional ball screw drives have taken the place of this strategy. When

designing using FDM, it's crucial to take different stacking techniques and a part's

anisotropic nature into mind. It is preferable to construct sections with significant

stress axes aligned with the x-y plane rather than in the z-direction for portions that

experience stress in a certain direction. [22]

 39

3. Research Methodology
The following flow chart shows the methodology used by me in the construction of a

3D printer. The first step is to download the 3D model or design from the website,

upload the model to Cura (3D modeling software), and generate an STL file. After

generating the STL file, slice the model, add support, generate G-code, and upload the

G-code file to the Arduino board through for further processing and printing the

Figure 3.1 Functional Diagram for the 3D printing

physical object. We upload the G-code to Pronterface software for printing the object,

and the machine does level processing and layer processing, and the object is printed

layer by layer. After printing the object, remove the support and clean the surface.

Finally, the model is ready after printing.

3.1 Selection of Process

The 3D printing industry is constantly evolving, with advancements in hardware, raw

materials, and production techniques. FDM technology, which is environmentally

friendly, clean, and user-friendly, is a popular choice for printing complex pieces and

forms. It is a more economical and environmentally friendly option compared to other

3D printing methods. FDM begins with creating an STL file and cutting and

positioning the model for construction. It can distribute various materials to achieve

various goals. The filament is extruded into the proper form layers, hardening after
 40

leaving the nozzle. A metal or plastic wire is released, supplying material to an

extrusion nozzle that controls flow. The filament is pushed into the nozzle at a

regulated pace using a worm drive, and an ejection head protects the thermoplastics.

The nozzle can be moved by numerically controlled components on both even and

vertical bearings, and the part is created from the last layer at a time. FDM is flexible

but excels at handling fine details by reducing the number of layers.

3.2 Selection of Mechanism

We have chosen cartesian arrangement of developments. The most prevalent type of

FDM 3D printer available now is cartesian models. This technology employs three

orthogonal axes—X, Y, and Z—to calculate the proper placements and directions of

the print head in accordance with the mathematical Cartesian coordinate system.

Depending on the printer's model and maker, the Z axis will be controlled by the print

platen, allowing the X and Y axes to be used to position the extruder such that it may

travel in four directions. The main advantage of these solutions is that they are

generally inexpensive and are sold as kits to be assembled by the user. [26]

3.3 Softwares used (CAD and CAM)

3.3.1 CAD

Computer Aided Design (CAD) is a software used to create 2D and 3D models and

designs. It is a manufacturing method that uses computer software and automatable

machinery to create products with high accuracy and precision. CAD software is used

across various industries and occupations, including architectural designs, building

plans, floor plans, electrical schematics, mechanical drawings, technical drawings,

blueprints, and special effects. It is used to create 3D parts for printing and is used to

improve efficiency, configuration, documentation, and manufacturing databases.

 41

CAD files are essentially parametric records, representing parts as a tree of Boolean

operations on primitive shapes like cubes, spheres, cylinders, and pyramids.

3.3.2 CAM

Computer-aided manufacturing, or CAM, technologies manage the intermediate step

of turning CAD data into a machine-friendly form used by our 3D printer electronics.

We'll be using software that combines object slicing, G-code and M-code creation,

object positioning, and other printer settings in this situation. When CAM software

transforms a 3D object into a machine format, it frequently needs an STL file. The

machine-friendly printing format is known as G-code. A product model developed in

CAD software is used by a CAM tool. The former handles production and translates

the computer models into a language that the machining tool can understand.

3.4 How FDM printer works

The most popular kind of Cartesian printers are FDM ones. Cartesian describes the

coordinate system that the printer uses to move the build plate and print head. Three

rails are present in these printers, one for each of the three axes (X, Y, and Z). The

Build platform moves in the Z-direction, whilst the Printhead (the complete Extruder

and nozzle assembly) moves in the X and Y directions. The extruder is first supplied

with filament, the raw material. The two diameters of FDM printer filaments are 1.75

mm, which is the most popular size, and 3 mm. One specific printer only utilizes one

kind of filament. The filament is pulled up by the gear mechanism in the extruder and

pushed down to the heater, where it melts. According on the filament type, the

melting temperature typically ranges from 190°C for PLA to 300°C for

polycarbonate. The nozzle is then reached by this molten filament. The nozzle is

typically offered in two diameters (0.2 & 0.4 mm), while it is also available in

additional sizes. The layer thickness and print quality can be impacted by the nozzle
 42

diameter. The material is applied by the nozzle to the build platform in the precise

geometry required by the model that will be printed. The initial layer of the print is

laid down by the nozzle, which travels in an X and Y direction. The key processes of

the 3D printing using fused deposition modeling are as follows:

Step 1: After entering the CAD data, the already-loaded solid construction material

filament is heated in the liquefier head to liquify it.

Step 2: Using an extrusion nozzle that travels in all directions according to the CAD

data, this liquid plastic that is molten is fed onto the foam construction platform as a

layer. The liquid/semi-solid layers are repeatedly added one on top of the other in this

manner. Support structures are employed if the design has overhangs or other

Figure 3.2 FDM Working principles

elements that might possibly strain or bend. Depending on the option, the support

material may be the same as the building material.

Step 3 – In case support structures were used, they are later removed once the build is

complete.
 43

4. Description of various Components of FDM Printer

4.1 Smooth rod m8 500 mm

These are the straight rods that come with 3D printer kits. They are composed of high-

carbon steel that has been chrome-plated, and when used with linear bearings, they

offer smooth, reliable motion. These smooth rods, which are made for use in CNC and

linear motion applications as well as hydraulic and 3D printing, can withstand heavy

use without breaking down. It has the following features.

 High stability, hardness, and accuracy.

 Control every precise procedure rigorously to guarantee quality.

 Simple construction, robust material, high-temperature preheating, and precise

outside hole sizing.

 It has been used in numerous sectors due of its mild hardness.

 Made of stainless steel, which has good wear resistance, high strength, and

resistance to corrosion.

Figure 4.1 Smooth rod M8 500 mm

 44

4.2 T8 Trapezoidal Lead Screw 8mm

For use with a CNC machine, this 8mm T8 brass screw nut is available. With ACME

shaft lead, this 2mm lead screw is utilized in common machine equipment like 3D

printing. Brass T8 lead screws are extremely dependable when used in applications

involving linear motion. This lead screw for a 3D printer has anti-corrosion, wear

resistance, and is non-slip. Simple to use; no processing required. It has the following

features.

 resistant to wear, corrosion, and slipping. Simple to use; no processing required.

 8mm lead screw is appropriate for 3D printers.

 8mm lead screw size.

 Hole spacing for screws is 4 * 3.5mm.

 Compact craftsmanship, high-quality brass material.

 applicable to step motor, machine tool guide rail, and other equipment supported

by screw rod.

 This will make it simple to install and practical to use.

Figure 4.2 T8 Trapezoidal Lead Screw 8mm

 45

4.3 Flexible Coupling Coupler

Your driving shaft and the driven shaft can be connected by a 5x8mm flexible

coupling shaft. 5x8mm Flexible Coupling Shaft is particularly effective in eradicating

misalignment to the greatest degree feasible. Another fantastic benefit of this

aluminum flexible coupling is very minimal backlash. This flexible connection is

made of machined aluminum and has an outside diameter of 19mm and a length of

25mm. The first bore has a diameter of 5 mm, while the second bore has an 8 mm

diameter as well.

Since it has a spiral cut through the center of its length, it is flexible and can fit to two

shafts even if they are not precisely co-linear, which will lessen the impacts of

binding. These couplings are also referred to as Flexible coupling, Beam coupling,

and Helical coupling. It has the following features.

 shaft end-play, parallel misalignments, and angular misalignments are all

absorbed by spring action.

 High durability and resistance to corrosion.

 connect the shaft for a small torque.

 a single-piece design that offers durable performance.

 Consistent velocity is provided by a low moment of inertia.

 46

 Torsion ally flexible coupling

is frequently utilized

in drive systems for

encoders, instruments, lead

screws, tiny pumps, feed

rollers, and anyplace light to

medium Figure 4.3 Flexible Coupling Coupler duty coupling is

needed.

4.4 LM8UU 8 mm Linear Ball Bearing

You may get a very accurate, secure, and dependable linear motion system with the

LM8UU 8 MM Linear Motion Bearing. These CNC (Computer Numerical Control)

machines and 3D printers are the main applications for such linear motion bearings.

An LM8UU 8 MM Linear Motion Bearing may offer low friction motion along a

single axis, making it useful for a variety of robotics and do-it-yourself projects.

This LM8UU 8 MM Linear Motion Bearing closed type ball bushing, which has a

15mm outer diameter and an 8mm bore, can be used to transport components in a

mounted sliding unit. There is no need to worry about replacing any worn components

because these Bearings have a variety of standardized parts that are interchangeable.
 47

Figure 4.4 LM8UU 8 mm Linear Ball Bearing

4.5 GT2 6MM Open Timing Belt:

Highest level of accuracy Black Open Timing Belt For 3D Printer, GT2 Width 6mm.

Manufactured from NEOPRENE, a synthetic rubber that has been strengthened with

Figure 4.5 GT2 6MM Open Timing Belt

fiberglass strands. On April 17, 1930, DuPont scientists created neoprene, a synthetic

rubber that resists oil. The mechanical drive belt of the timing belt, also known as the

synchronous belt, is well recognized for not sliding. It is made out of a flexible belt

with a row of teeth implanted on the inner surface. The timing belt and timing pulley

function when their toothed components mesh.

4.6 Teeth Pulley

The linear motion is the only use for the GT2 20T pulley. 20 teeth and an 8mm inner

bore can be found on this GT2 timing pulley. It may be securely fastened to any 8mm

diameter shaft using two set screws. These are extremely lightweight and robust since

they are made entirely of aluminum. When you reverse the pulley direction, there is

no room for the belt to move in the groove because they employ a rounded tooth

profile, which ensures that the belt tooth fits smoothly and properly in the pulley
 48

groove. For building 3D printers, the GT2 8mm pulley wheel with 20 teeth or grooves

is a good option. The 20 teeth, 8mm diameter GT2 series of belts and pulleys are

made exclusively for linear motion.

When you reverse the pulley

orientation, there is no room for the belt

to move in the groove because

they employ a rounded tooth

profile that ensures that the belt tooth

fits smoothly and properly in the

pulley groove.

Figure 4.6 Teeth Pulley

4.7 Aluminium Channel Frame

 49

These channels are most frequently used for framework, tracks, slides, safety edges,

railings, rails, rims, and ornamentation.

Figure 4.7 Aluminium channel frame

4.8 V6 J-Head Hotend Bowden Extruder

 50

This is a cooling fan-equipped 3D Printer Short Distance V6 J-head All Metal Hotend

Extruder. This hotend extruder for a 3D printer uses a 1.75/3mm 12V 0.4mm Nozzle.

Before depositing the filament in the building area, the hotend is a group of

components designed to melt and extrude the filament. Whether mounted directly or

indirectly, the hotend always functions in tandem with the extruder (bowden).

Figure 4.8 V6 J-Head Hotend Bowden Extruder

To put it simply, the filament is pushed into a tiny chamber by the extruder, where it

melts. Under pressure, the molten material escapes through a tiny hole and deposits

itself on the foundation of the building or the piece, where it solidifies. Because the

filament is being pushed, maintaining maximum stiffness prior to entering the melting

zone is crucial. To do this, the hotend must have two clearly distinct sections: a cold

zone and a hot zone, with as little time as possible passing between them. These

characteristics are present.

 51

 High temperature and heat ventilation: 12V/40W NTC heater, which doesn't

burn or break often; 304 stainless steel nozzle throat and high-quality resistance;

12V high-speed fan, which swiftly loses heat.

 Design features that prevent material spilling and blockage include a smooth

connection between the nozzle and tube.

 NTC connection with terminal makes installation simple; just do it.

 Compatible with all 1.75mm V6 3D printers.

4.9 MK8 Extruder Aluminium Block DIY Kit

This aluminum alloy block is a premium MK8 extruder replacement. Replace your

broken or clogged extruder with it. This block is provided in kit form, and the user

must assemble it. You may find several assembly instructions and tutorials on the

internet to assist you in building your extruder because it is a widely used model.

There are three different varieties of the MK8 Extruder: right side, left side, and right

short. The direction in which the filament is extruded with regard to the extruder

block differs between these extruders. Any extruder may be utilized with single

extruders. One right side and one left side extruder can be used when employing twin

extruders.
 52

4.10 PLA 1.75 mm filament

3D printers use PLA Filament as a material. There is 1.75mm wire diameter filament

available in Pakistan. Army Green, Black, Blue, Bronze, Brown, Coffee, Dark Blue,

Dark Orange, Dark Purple, Gold, Green, Grey, Lake Blue, Light Green, Orange, Pink,

Purple, Red, Silver, Skin, Sky Blue, White, Wood, and Yellow are the hues that are

Figure 4.9 MK8 Extruder Aluminium Block DIY Kit

readily accessible. For finer details where dependability and extruder efficiency are

crucial, 1.75mm filament is preferable. There is no other option than 3.00mm

Figure 4.10 PLA 1.75 mm filament

filaments if you want to print with a 2.00mm nozzle.

4.11 NEMA 17 Stepper Motor

The stepper motors are the motors of choice for machines requiring precise position

control because they move in perfectly repeatable increments. At 1.2A current per

phase, the NEMA17 4.2 kg-cm Stepper Motor is capable of producing 4.2 kg-cm of
 53

torque. Stepper Motor Drivers enable the motor's position to be ordered to move or to

remain in a single position. The NEMA17 4.2 kg-cm Stepper Motor responds to

starting, halting,

and reversing

pulses from the

Stepper Motor

Driver with

remarkable accuracy. They are quite helpful in a variety of applications, particularly

those that need for low speed and great precision. Numerous devices, including 3D

printers, CNC mills and routers, camera platforms, XYZ plotters, etc.

Figure 4.11 NEMA 17 Stepper Motor

 54

4.12 Arduino Mega 2560

A microcontroller board called the Arduino Mega 2560 is based on the ATmega2560

(datasheet). It contains 16 analog inputs, 4 hardware serial ports (UARTs), a 16 MHz

crystal oscillator, 54 digital input/output pins (14 of which may be utilized as PWM

outputs), a USB connector, a power jack, an ICSP header, and a reset button. It comes

with everything needed to support the microcontroller; to get started, just plug in a

USB cable, an AC-to-DC converter, or a battery. The majority of shields made for the

Arduino Uno, Duemilanove, or Diecimila are compatible with the Mega. Features of

Arduino Mega are: -

 Microcontroller: ATmega2560

 Operating Voltage: 5V

 Input Voltage (recommended): 7-12V

 Input Voltage (limits): 6-20V

 Digital I/O Pins: 54 (of which 15 provide PWM output)

 Analog Input Pins: 16

 DC Current per I/O Pin: 40 mA

 DC Current for 3.3V Pin: 50 mA

 Flash Memory: 256 KB of which 8 KB used by bootloader

 SRAM: 8 KB

 EEPROM: 4 KB

 Clock Speed: 16 MHz

 55

 USB Host Chip: MAX3421E

Figure 4.12 Arduino Mega 2560

4.13 Ramps 1.4 Shield

 56

The main function of the 3D printer controller board RAMPS 1.4 Arduino Mega

Shield RepRap Prusa Model is to use pololu stepper driven boards (comparable to

4988 driven boards). Only when attached to its mother board Mega 2560 and

4988/DRV8825 can RAMPS function. due to its excellent interoperability with the

majority of 3D printers (all Reprap models, including the Pursa i2 and i3) and

operational stability. The Ramps1.4 + MEGA2560 + A4988/DRV8825 combo is

Figure 4.13 Ramps 1.4 Shield

quickly gaining popularity as a DIY 3D printer control board. As long as the primary

RAMPS board is retained at the top of the stack, the system may also accommodate a

number of Arduino extension boards. Ramps boards are the brains of the majority of

commercially available DIY 3D printers and a great, tidy, small approach to

incorporate all the systems into a mountable, compact enclosure structure.

4.14 A4988 Stepper Motor Drivers

Pakistan offers the A4988 driver Stepper Motor Driver, a comprehensive micro-

stepping motor driver with a built-in converter that is simple to use. It can give up to 1

A per phase without a heat sink or forced air flow while operating between 8 V and 35

V. It is rated for 2 A per coil with enough supplementary cooling. A fixed off-time

current regulator is included in the A4988 driver Stepper Motor Driver; the regulator
 57

may operate in either slow or mixed decay mode. The converter is essential for the

A4988's simple implementation. Phase sequence tables, programming for the high-

frequency control interface, etc. are not present. When a complicated microprocessor

is not accessible or is overloaded, the application of the A4988 interface is particularly

Figure 4.14 A4988 Stepper Motor Drivers

suited. The A4988's chopping control automatically chooses the current decay mode

(slow or mixed) throughout the stepping process. The mix decay current control

system can enhance step precision, decrease power consumption, and minimize

audible motor noise.

4.15 End Stop Switch

Lever switches are used in CNC 3D Printer Mech Endstop Switch to determine when

they are triggered. The CNC end stop switch is configured to draw the signal to LOW

when engaged. On the board, there is also an LED that will turn on when the switch is

turned. This top limit switch accepts a regular, vintage CD-ROM audio connection

cable and uses a conventional 4 pin, 100′′ pitch header. We want to be able to

determine when an X/Y/Z stage has achieved its lowest or maximum. Rather than

fiddling with flags or intricate light beam interruption, we employ a mechanical

switch as the mechanical end stop. If the switch is placed in the stage's route, the stage
 58

will simply close the switch module when it passes over it. We don't need to change

the stage in any way other than where the switch should be. You may get a good

Figure 4.15 End Stop Switch

night's sleep even if you are concerned about dependability. The limit switch modules

we employ have a 1 million operation failure rate rating. You may print one million

times before needing to replace the switches because we only utilize them once every

print.

4.16 12 Volt 20-amp DC power supply

A dependable switching power supply that is made of high-quality materials, long-

lasting, and secure to use is the LED Switching Power Supply. a novel design for a

power supply that can maintain voltage stability at 12 volts dc. For residential

appliances, a great switching mode power supply. A universal AC input with a wide

range and an automated on-off cooling fan provides cooling. Tested at full load. One

of the most widely used power sources in use today is the 12V power supply (also

known as the 12VDC power supply). Transformers, diodes, and transistors are often

used in conjunction to convert a 110VAC or 220VAC input into a 12VDC output.

 59

Figure 4.16 12 Volt 20-amp DC power supply

4.17 Heat Bed

RepRap MK2B heatbed for 3D printer A heated bed called the Dual Power Supply is

made for 3D printers like the Reprap Prusa and the Mendel. It is also compatible with

various 3D printers. The newest heat bed model, the MK2B, has LED lighting and

dual power supply choices for 12 and 24 volts. This heatbed has a high heat output

and offers uniform, even heating since it is directly engraved on 35 m of copper clad.

Features of 3d Printer Heated bed:

 Color: Red

 Etching: 35um copper

 Dimensions 214 x 214mm

 Laminate FR4 1.6+-0.15mm

 2 layer, 35μm copper

 Red Solder Mask – both sides

 White Silkscreen – both sides

 60

 Power Input: 12V or 24v

 Copper plated holes

 Resistance between 1.0 and 1.2 ohm

Figure 4.17 Heat Bed

 61

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printing technology: Technological, materials, and applications. Procedia

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 62

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Learning And Information Dulles, Virginia Boston, Massachusetts.

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Digital Manufacturing Second Edition by Ian Gibson, David Rosen, Brent

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Digital Manufacturing Second Edition by a Gibson David Rosen Brent

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Lucknow, Uttar Pradesh, Harshit Srivastava Department of ME SRMCEM,

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26.https://www.3dnatives.com/en/four-types-fdm-3d-printers140620174/

#:~:text=Cartesian%203D%20printers%20are%20the,direction%20of%20the

%20print%20head.

27. https://3dprintingindustry.com/3d-printing-basics-free-beginners-guide

28. https://manufactur3dmag.com/working-fdm-3d-printing-technology/

29. https://digilog.pk/products