Professional Documents
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3D Printer
3D Printer
BY
KRISHNENDU MONDAL 27600714042
BISHAN HOWLADAR 27600715081
KRISHNA RAJAK 27600714041
SAYANDIP BHOWMIK 27600715085
VIKRANT TIWARI 27600714099
RITURAJ GHOSH 27600714071
SOMNATH PANDA 27600714085
SURYA SEKHAR GHORUI 27600714095
ANUPAM MONDAL 27600714016
SAYAN BACHHAR 27600715084
May2018
TITLE: FABRICATION OF 3D PRINTER
Of
Bachelor of Technology
In
MECHANICAL ENGINEERING
BY
KRISHNENDU MONDAL 27600714042
BISHAN HOWLADAR 27600715081
KRISHNA RAJAK 27600714041
SAYANDIP BHOWMIK 27600715085
VIKRANT TIWARI 27600714099
RITURAJ GHOSH 27600714071
SOMNATH PANDA 27600714085
SURYA SEKHAR GHORUI 27600714095
ANUPAM MONDAL 27600714016
SAYAN BACHHAR 27600715084
I hereby certify that the work which is being presented in the B.Tech. Major (or Minor)
Project Report entitled “ Fabrication of 3D Printer ”, in partial fulfillment of the
requirements for the award of the Bachelor of Technology in Mechanical Engineering
and submitted to the Department of Mechanical Engineering of Budge Budge Institute of
Technology Kolkata is an authentic record of my own work carried out during a period
from January 2018 to June 2018 under the supervision of Prof. Samriddhya Ray
Chowdhury, Assistant Professor, and Prof. Rituparna Biswas, Assistant Professor,
Department of Mechanical Engineering.
The matter presented in this thesis has not been submitted by me for the award of any other
degree elsewhere.
Signature of Candidate
Roll.No.
This is to certify that the above statement made by the candidate is correct to the best of my
knowledge.
Date:
Signature of Supervisor(s)
PAGE NO.
ACKNOWLEDGEMENT I
LIST OF FIGURE II
LIST OF TABLE III
CHAPTER 1: INTRODUCTION 8-11
1.1. Objective 8
1.2. Abstract 9
1.3. Application 10
CHAPTER 2: BACKGROUND RESEARCH 12-19
2.1. Introduction 12
2.2. Literature Review 13
2.3. History 16
CHAPTER 3:REQUIRMENTS FOR MAKING 3D PRINTER 20-28
3.1. Parts Requirements 20
3.2. Softwares Requirements 28
ACKNOWLEDGEMENT
My endeavor stands incomplete without dedicating our gratitude to everyone who has
contributed a lot towards the successful completion of our project work. First of all, we
offer our sincere thanks to my parents for their valuable blessings. I am indebted to God
Almighty for blessing me with his grace and thanking my endeavor to successful
culmination.
I would like to thank my guides Prof. Rituparna Biswas and Prof. Samriddhya Ray
Chowdhury, associate professors of Mechanical Engineering, Budge Budge Institute of
Technology for guiding and evaluating throughout the period.
LIST OF FIGURES
SL no. Figure Description Page no
1 1 Application in biology 10
2 2 Application in Chemistry 10
3 3 Application in engineering 10
4 4 Application in geography 10
7 7 Application in history 11
8 8 Application in architecture 11
14 14 Arduino 21
15 15 UNO R3 Board 22
16 16 Stepper motor 23
19 19 Power Supply 25
20 20 Extruder 26
24 24 3D Printer 30
25 25 Output 33
III
LIST OF TABLE
CHAPTER
1
INTRODUCTION
1.1 OBJECTIVE:
1) Fabrication of a 3D printer
2) Make the printer printable using G-Codes.
3) Study the errors and try to overcome them
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1.2 Abstract
Additive manufacturing technologies have gained prominence in the recent past, and are
increasingly becoming important not only as a prototype manufacturing technology, but
also as large scale manufacturing industry. Expansive research on these technologies is
being done to realize the full potential of the field. In this paper, we briefly describe the
historical evolution of additive manufacturing technologies, understand the basic working
principle of a three dimensional printer, present an exploratory study on the material
properties of a 3D printed object highlighting the strength of the material used. We also
highlight current three dimensional printing applications in both the consumer and business
markets.
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1.3 Application:
3D printers have actually been around for about 25 years. Barriers like costs are breaking down,
so they are now very affordable and easy to use.
3D printing has caught the attention of educators who are looking into ways to
incorporate it into the classroom.
CHAPTER
2
BACK GROUND RESEARCH
2.1 Introduction:
3D printing is the process of creating an object using a machine that puts down material
layer by layer in three dimensions until the desired object is formed. A 3D printer extrudes
melted plastic filament or other material, building objects based on specifications that come
from modelling software or from a scan of an existing object. The process is widely used in
industry to create prototypes more quickly than traditional methods, and in some situations
it has begun to replace conventional manufacturing processes, such as injection moulding.
The technology has caught the attention of educators as prices for 3D scanners and extrusion
printers have dropped, making it feasible to use them for design, production, or preservation
in a wide range of educational venues.
In a “Brief History of Additive Manufacturing and the 2009 Roadmap” by Beaman et al, they
cite that in 1972 Ciraud released the first technology that truly represented today’s definition of
additive manufacturing. Ciraud’s process is described as taking meltable materials and using a
beam of energy to melt the material, thereby building a product by melting layer on top of layer.
Unfortunately, while there are drawings and sketches regarding Ciraud’s invention, there is no
proof that the technology was actually produced and executed.
In a final report published by the Japanese and World Technology Evaluation Centres in 1997,
Beaman again is a contributor on the historical perspective of additive manufacturing. Here, he
references Hideo Kodama as the first scientist known to have produced a functioning additive
manufacturing system in 1981. Alan Herbert of 3M in 1982 then closely followed him. This
time, there was proof that the technologies were developed and tested. Both Kodama and
Herbert developed technologies where a prototype part was actually built, layer by layer.
After a few years, Chuck Hull invented the stereolithography machine (SLA) in 1986. This
machine is considered to be the first 3D printer. The stereolithography machine slowly poured
liquid plastic to build plastic outputs. Thus, this technology was only economically viable to
large research universities, large companies and government research labs.
“tinkering” known as tinkerers. These collective groups of experimenters are also known as
“Makers”. Tinkerers and Makers who purchase 3D printers, such as MakerBot, learn the
technology and then make their own products, designs, and/or outputs at home. These products
FABRICATION OF 3D PRINTER P a g e | 14
are sometimes for home use and sometimes just to experiment. In many cases, tinkerers and
makers can also be sophisticated ‘consumers’ who are trying to fashion solutions to their own
particular problems, in the absence of marketplace choices.
In an article titled “Custom Nation: Why Customization is the Future of Business and How to
Profit From It”, the authors imagine an economy where consumers have 3D printers in their
homes. When a consumer identifies or creates a product that can better fit their requirement,
the consumer designs a prototype with CAD software, prints it on their 3D printers at home or
sends it to a 3D printing service for production. This idea, where consumers are creating their
own products, rather than waiting for companies to customize product offerings, is known as
“Personal Manufacturing”.
As labour costs continue to rise in markets like China, the cost advantage of outsourcing jobs
oversees begins to dissipate. Hence, a recent article by MKinsey has coined the term, “Next
Shoring”. Next Shoring is the idea that manufacturing jobs will return to the United States
because there is a competitive advantage to setting up facilities near the markets served.
Arguably, this is partially credited to 3D printing, “Think local, act global approach”. When
specifications or drawings of products are sent directly to a local manufacturing facility, the
logistical cost associated with transporting an item from the facility to the end user are reduced,
as well as the cost associated with inventory management. Theoretically, setting up smaller
local facilities for each respective market could make the product cheaper and faster. This is
also suggested by another article published by CSC- “3D Printing and the Future of
Manufacturing.
According to a report, “Advanced technology and market trend of printed electronic”
(Korean Scientist and Engineers Network [KOSEN], 2011), “Printing engineering can be
classified into printing technology and printing material.” Printing technology is the way to
manufacture the electronic devices, and it is classified into 2dimensional (2D) and 3dimensional
FABRICATION OF 3D PRINTER P a g e | 15
(3D) printing technology according to structure of printed product. This paper reviews the types
of 2D and 3D printing and the difference between the two technologies.
In present times, there are three major additive manufacturing/ 3D printing methods namely
Fused Deposition Modelling (FDM), Selective Laser Sintering (SLS) and Stereolithography
(SLA) as mentioned on July 8th, 2013, by Dr. NamSoo Peter Kim, Associate Professor in
Department of Metallurgical and Material Engineering in UTEP, Texas, USA during an
interview.
FABRICATION OF 3D PRINTER P a g e | 16
2.3 History:
The earliest 3D printing technologies first became visible in the late 1980’s, at which time
they were called Rapid Prototyping (RP) technologies. This is because the processes were
originally conceived as a fast and more cost-effective method for creating prototypes for
product development within industry. The very first patent application for RP technology
was filed by a Dr Kodama, in Japan, in May 1980. Unfortunately for Dr Kodama, the full
patent specification was subsequently not filed before the one year deadline after the
application, which is particularly disastrous considering that he was a patent lawyer! In real
terms, however, the origins of 3D printing can be traced back to 1986, when the first patent
was issued for stereo lithography apparatus (SLA). This patent belonged to one Charles
(Chuck) Hull, who first invented his SLA machine in 1983. Hull went on to cofind 3D
Systems Corporation — one of the largest and most prolific organizations operating in the
3D printing sector today.
The reality of affordable on-demand prototyping was first conceived by visionaries at MIT
who in 1993 developed the fastest and most affordable method of prototyping — 3D
printing. Upon Z Corporation’s founding in 1994 by some of these same visionaries, it
promised to put on-demand prototyping within the reach of every designer or engineer. This
promise would entail developing 3D printers that would follow the footsteps of document
printers and quickly evolve to deliver speed, affordability, accuracy, colour and usability.
3D printing is increasingly growing into a revolutionary technology in today’s world. Its
stunning ability to create complex and creatively designed objects and prototypes has made
3D printing crucial to the production activities of a great number of companies across the
world.
FABRICATION OF 3D PRINTER P a g e | 17
I) First generation 3D printer arrives in 1996, the Z402, the market’s first 3D printer was
introduced, redefining speed and affordability in rapid prototyping. Later versions like
the Z402c and Z406 introduced multicolor 3D printing for more vivid and informative
models when needed.
.
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II) Second Generation 3D printer has improved performance, affordability and colour.
The release of the ZPrinter 310 in 2003 introduced breakthrough speed, a simplified
user experience and unprecedented affordability. In 2005, the spectrum Z510 redefined
3D printing with a new generation of high-resolution printing and vivid colour.
III) Third Generation 3D printer focused on ease of use. In 2007, the ZPrinter 450
replaced the third generation of 3D printers with a focus on ease of use and office
compatibility. The automated, self-contained, all-in-one (print, depowder) solution
improved convenience and office-friendliness. It was followed by the ZPrinter 650 in
2008, with size and performance, and the ZPrinter 350 in 2009, which introduced a
new level of 3D printing affordability. These printers increased the accessibility for
new classes of users.
CHAPTER
3
REQUIREMENT FOR
MAKING 3D PRINTER
The 3D printer we are making is based on NC machines. The 3D printer gets the
information from computer through NC programming (G-Codes) and according to the
instructions the 3D printer works.
The 3D printer consists of three axes which are controlled by an electronics controller
unit. Every axes has a stepper motor. The electronics controller unit mainly control that
stepper motor.
The movement of the extruder is pretty much same as that of a head of an NC machine.
Fig.14. Arduino
FABRICATION OF 3D PRINTER P a g e | 22
A stepper motor or step motor or stepping motor is a brushless DC electric motor that
divides a full rotation into a number of equal steps. The motor's position can then be
commanded to move and hold at one of these steps without any position sensor for
feedback (an open-loop controller), as long as the motor is carefully sized to the
application in respect to torque and speed.
We are using stepper motor from the DVD writer with its trolley setup for our
project purpose.
Stepper motor controller is nothing but a electrical circuit which helps to drive a
stepper motor. Stepper motor controller can`t work without an arduino unit. Basically
from computer arduino gets the information and according to information it sends codes
to the stepper motor driver and the stepper motor driver instructs the stepper motor how
much rotation the stepper motor will rotate. Stepper motor driver is mounted on the
Arduino. For every singlestepper motor we need a stepper motor controller for various
work.
V) Power Supply(SMPS):
When we are running any electrical equipment, power supply is the main concern
there. For running the Arduino and the stepper motors best preferable Power supply is
DC12 volt. SMPS is the only thing which can give the rated power output. So our
preferable power supply is SMPS
Fig.20. Extruder
Here in this project we are using glue instead of the thermoplastic material. While
we are using silicon based glue it`s preferable to use the silicon glue gun. That`s
why we are using the heater or extruder of the silicon glue gun.
Table 1:
CHAPTER
4
MAKING PROCEDURE
1) Our first work is to disassemble the DVD writers to get the stepper motors with the tray.
2) Solder the wires to Arduino and the stepper motor.
3) Put the motor drivers into the ports give in the arduino CNC Shield
4) Connect the Arduino CNC shield to the UNO board.
5) Connect the USB cable between computer and the UNO board.
6) Give 12 volt power supply to Arduino.
7) Test the stepper motors are working or not.
8) If working then align the stepper motors tray to make the 3 axes.
9) Disassemble the glue gun to take the extruder part.
10) Fixed the extruder to the z-axis.
Fig.24. 3D PINTER
FABRICATION OF 3D PRINTER S P a g e | 31
CHAPTER
5.1. Objective
Try to print an easy object by using the newly made 3D printer. Check the dimensions
of the printed object, and check is it as per the requirement or not. Try to find out faults, and
try to find the scopes of improvement to make the printer more advanced.
5.2. PROCEDURE
5.3. G-Code:
5.4. Output:
5.5. Conclusion
After printing the object we found that the 1st layer of the glue is as the required dimension
but the upper layers are little incorrect as per required dimension because of the hot glue
and the reason behind this is the glue does not get enough time to be cooled. The printer
needs some upgrade to make it usable in industries.
Table 2:
Pros Cons
In future, a further study can be done to improve the printer, by updating the extruder in
better technology. Future study can also improve the printing time and better printing
quality with best perfection. If it’s possible by future study then it will be an awesome gift
for additive manufacturing technology which will decrease the cost of making prototypes
very easily.