CAD-II Semester Project Report

5-Axis 3D Printer
Swivel Bed Design

Group Members

Sr Name Registration No.

1 Aleem Ullah Khan 04-3-1-005
2 Muhammad Tayyab 04-3-1-035

Submitted to: Sir Waqqas Ahmed

Date: 21st June 2023

Department of Mechanical Engineering

Pakistan Institute of Engineering and Applied Sciences

Nilore, Islamabad
Table of Contents

A. Proposal Statement .............................................................................................................................. 1

B. Group Members................................................................................................................................... 1
C. Design Elements.................................................................................................................................. 1

1.1 Introduction ........................................................................................................................................ 2

1.2 Literature Review............................................................................................................................... 3
Evolution of 3D Printers: .................................................................................................................. 3
Advantages and Limitations of Traditional 3D Printers: .................................................................. 3
Introduction of 5-Axis Swivel Bed Design:...................................................................................... 3
1.3 Applications of the 5-Axis Swivel Bed Design & Industrial Scope .................................................. 4
Aerospace and Aviation: ................................................................................................................... 5
Automotive and Transportation: ....................................................................................................... 5
Medical and Healthcare: ................................................................................................................... 5
Architecture and Construction: ......................................................................................................... 5
Design and Prototyping: ................................................................................................................... 5
Art and Sculpture: ............................................................................................................................. 5
Education and Research: ................................................................................................................... 6
1.4 Conclusion of Literature ..................................................................................................................... 6

2.1 Optimization Objectives .................................................................................................................... 7

2.2 CAD Model Images ........................................................................................................................... 7
Components of Modeling ............................................................................................................... 11

3. Modeling of the Printer .................................................................................................................... 12

3.1 Modeling of the Extruder Assembly ................................................................................................ 12
Parts & Drawings of Extruder Unit ................................................................................................ 13
3.2 Modeling of Basic Gantry Unit ........................................................................................................ 14
Parts & Drawings of Gantry Unit ................................................................................................... 16
3.3 Modeling of Basic Structure ............................................................................................................ 17
 Drawing of Basic Structure............................................................................................................. 18
3.4 Modeling of Support Elements, Lead Screws and Rods .................................................................. 19
Parts & Drawings of Secondary Support Elements ........................................................................ 21
3.5 Final Assembly ................................................................................................................................ 22

4.1 Optimization .................................................................................................................................... 23

Objective # 1 ................................................................................................................................... 23
Objective # 2 ................................................................................................................................... 23
4.2 Parametrization ............................................................................................................................... 23
4.3 Equations.......................................................................................................................................... 24
4.4 How Parametrization was done........................................................................................................ 28
1. Assuming Global Variables ....................................................................................................... 28
2. Creating Main Variables ......................................................................................................... 28
3. Approach.................................................................................................................................... 29
4.5 Final Use of Main Variables ............................................................................................................ 29
4.6 Final Presentation and Manipulation of Parametrized ..................................................................... 30
4.7 Motion Study ................................................................................................................................... 30
1. Motor 1 (rotate platform along B-axis)....................................................................................... 30
2. Motor 2 (rotate platform along C-axis)...................................................................................... 31
3. Motor 3 (motion in Z direction) ................................................................................................. 33
4. Motor 4 (motion in y direction) .................................................................................................. 34
5. Motor 5 (linear motion to nozzle in x direction)......................................................................... 36

5.1 Conclusion ....................................................................................................................................... 38

0
A. Proposal Statement

To design a 3D CAD Model of a Swing Bed Desk Model 5 Axis 3D Printer

for Industrial and small-scale usage.

B. Group Members

Sr Name Registration Mail CGPA

No.
1 Muhammad Tayyab 04-3-1-035 bsme2031@pieas.edu.pk 3.77
2 Aleem Ullah Khan 04-3-1-005 bsme2032@pieas.edu.pk 3.37

C. Design Elements

The 3D Model of the project includes designing:

• Support Structure
• Build Platform
• Extruder Assembly
• Motors and Lead Screws
• Swing Bed & Rotating Gantry
• Secondary support units e.g., belts, small support frames, rails, bearings,
pulleys
• Filament and Filament Holder
• Assemblage, Mating, and flexibility of the model
• Design Study and Motion Analysis

1
1.1 Introduction

In recent years, the field of 3D printing has experienced remarkable advancements,

revolutionizing the way we manufacture and create objects. From rapid prototyping to intricate
designs, 3D printing has proven to be a game-changer across various industries. Among the
many innovations in this domain, the emergence of the 5-axis swivel bed design 3D printer has
captured the imagination of professionals and enthusiasts alike.
This report aims to provide an insight into the functioning of a 5-axis swivel bed design 3D
printer, exploring its capabilities, applications, and the endless possibilities it offers to the realm
of 3D model making.
Traditionally, 3D printers have been limited to building objects layer by layer in a predefined
direction. However, the advent of the 5-axis swivel bed design has transformed the
manufacturing landscape by introducing enhanced freedom of movement and enabling more
intricate and complex geometries to be fabricated. This innovation opens new horizons for
designers, engineers, and artists, enabling them to bring their most ambitious ideas to life with
unparalleled precision and efficiency.
Applications by examining the various industries and fields that can benefit from the capabilities
of the 5-axis swivel bed design 3D printer are also discussed briefly. From architecture and
aerospace to medical and automotive sectors, this technology has the potential to revolutionize
the way we approach design, prototyping, and manufacturing, paving the way for faster, more
intricate, and highly customized solutions.
In conclusion, the 5-axis swivel bed design 3D printer represents a significant leap forward in the
realm of 3D model making. Its ability to transcend the limitations of traditional printers and its
potential to bring even the most intricate designs to life make it a powerful tool for professional
use.
The report discusses majorly the design and CAD Model Development of the 5 Axis 3d Printer.
The report is broken down into multiple aspects of development including CAD Model
Development, Drawings, Optimization, Parametrization, and the Motion Analysis following the
Model development steps.

2
1.2 Literature Review

The advent of 3D printing has revolutionized manufacturing and design processes across
a wide range of industries. This technology allows for the creation of three-dimensional objects
directly from digital models, enabling greater customization, faster prototyping, and increased
complexity in product design. In recent years, significant advancements have been made in 3D
printer technology, with the emergence of the 5-axis printing representing a significant milestone
in pushing the boundaries of what can be achieved in additive manufacturing.

Evolution of 3D Printers:
The development of 3D printers can be traced back to the 1980s when the first techniques
for layer-by-layer additive manufacturing were introduced. Over the years, various
printer designs and technologies have emerged, including fused deposition modeling
(FDM), stereolithography (SLA), selective laser sintering (SLS), and digital light
processing (DLP). These printers have found applications in industries such as aerospace,
automotive, healthcare, and consumer goods, among others.

Advantages and Limitations of Traditional 3D Printers:

Traditional 3D printers, such as those employing FDM or SLA technologies, offer
significant advantages in terms of cost, speed, and accessibility. They have played a
crucial role in democratizing 3D printing and making it more accessible to a wider
audience. However, these printers typically have limitations in terms of the complexity of
objects they can produce and the need for support structures in certain geometries.

Introduction of 5-Axis Swivel Bed Design:

To overcome the limitations of traditional 3D printers, the concept of a 5-axis swivel bed
design has emerged as a groundbreaking solution. Unlike conventional printers that rely
on static print beds and limited movement axes, the 5-axis swivel bed design allows for
greater freedom of movement and rotation. This enhanced range of motion enables the
printer to fabricate complex geometries and overhangs without the need for support
structures, resulting in more intricate and accurate prints.

Mechanics and Kinematics of 5-Axis Swivel Bed Design:

The mechanics of the 5-axis swivel bed design involve a combination of rotational and
translational movements. The printer typically comprises a rotating bed that can tilt along

3
 multiple axes, complemented by a movable print head. The interplay between these axes
enables the printer to achieve intricate layer deposition, reducing the need for manual
post-processing and improving overall print quality.

Figure 1: 5 Axis Swing Bed Desk Model 3D Printer

Figure 2: 5 Axis 3D Printer Degree of Freedom and Rotation

1.3 Applications of the 5-Axis Swivel Bed Design & Industrial

Scope

The 5-axis swivel bed design has vast potential across multiple industries. It has the potential to
revolutionize various industries, offering unprecedented levels of precision, efficiency, and
creativity in the field of additive manufacturing.

4
Here are some key areas where the industrial scope of a 5-axis 3D printer is particularly
significant:

Aerospace and Aviation: The aerospace industry often requires complex, lightweight
components with intricate geometries. A 5-axis 3D printer can fabricate parts with
optimized designs, reducing weight while maintaining structural integrity. It enables the
production of turbine blades, engine components, brackets, and other aerospace parts
with high precision, leading to improved performance and fuel efficiency.

Automotive and Transportation: In the automotive industry, 5-axis 3D printers can

be used to manufacture customized and lightweight parts, including engine components,
prototypes, exhaust systems, and interior elements. The ability to create intricate
geometries without the need for assembly or complex machining processes makes it ideal
for rapid prototyping and small-scale production.

Medical and Healthcare: The medical field can greatly benefit from the capabilities
of a 5-axis 3D printer. It allows to produce patient-specific implants, prosthetics, and
surgical guides with precise anatomical fits. The printer's ability to create intricate and
complex geometry also facilitates the development of medical models for training,
planning surgeries, and improving patient outcomes.

Architecture and Construction: Architects and construction professionals can utilize

5-axis 3D printers to create intricate building components, decorative elements, and
prototypes. The printer's ability to fabricate complex geometries and overhangs without
support structures enables the production of unique designs and customized architectural
features, pushing the boundaries of what can be achieved in construction.

Design and Prototyping: The design industry benefits from the capabilities of a 5-axis
3D printer in terms of rapid prototyping and creating highly detailed models. It allows
designers to transform their digital designs into physical objects quickly, enabling better
visualization, evaluation, and iteration of concepts. The printer's ability to produce
complex shapes and textures enhances the design process and reduces time to market.

Art and Sculpture: Artists and sculptors can explore new creative possibilities with a
5-axis 3D printer. It enables the production of intricate and complex sculptures,
decorative elements, and artistic installations with a high level of detail. The printer's

5
 versatility and precision empower artists to bring their visions to life in ways that were
previously challenging or impossible using traditional techniques.

Education and Research: 5-axis 3D printers have a significant role in educational

institutions and research facilities. They provide students, researchers, and scientists with
hands-on experience in advanced additive manufacturing, encouraging innovation and
exploration of new design concepts. The printer's ability to create complex geometries
aids in studying material properties, structural behavior, and functional prototypes.

The industrial scope of a 5-axis 3D printer is vast and diverse. Its unique capabilities
make it suitable for industries such as aerospace, automotive, medical, architecture, design, art,
and education. By enabling the fabrication of complex and customized objects with precision, a
5-axis 3D printer offers numerous opportunities for innovation, efficiency, and creative
expression across various industrial sectors.

1.4 Conclusion of Literature

The evolution of 3D printers has transformed the manufacturing landscape, enabling faster
prototyping, customization, and complex geometries. The introduction of the 5-axis swivel bed
design represents a significant advancement in 3D printer technology, overcoming the limitations
of traditional printers and unlocking new frontiers of design possibilities. As this literature
review has demonstrated, the 5-axis swivel bed design has the potential to revolutionize various
industries, offering unprecedented levels of precision, efficiency, and creativity in the field of
additive manufacturing.

6
2.1 Optimization Objectives

The following design objectives were catered for in the following design mechanism:
• Optimization of Printing Space and Printer Size based on parameters of Product.
• Torque and Force computation for further Analysis and Fabrication

2.2 CAD Model Images

Figure 3: 5 Axis 3D Printer (Model in SolidWorks)

7
Figure 4: 5 Axis 3D Printer ( Close Up Preview )

8
 Figure 5: Extruder Assembly

Figure 6: Rotatable Gantry Unit

9
Figure 7: 5 Axis 3D Printer ( Top View Close Up )

10
 Figure 8: 5 Axis 3D Printer ( Side View Close Up )

Components of Modeling

• Modeling of the Extruder Assembly

• Modeling of Basic Gantry Unit
• Modeling of Basic Structure
• Modeling of Support Elements, Lead Screws and Rods

11
 3 Modeling of the Printer

3.1 Modeling of the Extruder Assembly

Figure 9: Extruder Unit

Purpose
The extruder assembly is a crucial component in a 3D printer, responsible for melting and
depositing the filament material to create the printed object. It consists of several key
components that work together to ensure accurate and reliable extrusion.

Components & Sub-Assemblies

The main parts of an extruder assembly include the extruder motor, hot end, nozzle,
filament drive mechanism, and cooling system. The extruder motor provides the
necessary torque to drive the filament through the system. The hot end is where the
filament is melted using a heating element, typically a heating cartridge or a heater block,
and a thermistor measure and controls the temperature. The nozzle, a small opening at the
end of the hot end, determines the size of the extruded filament. The filament drive
mechanism, often composed of a gear and a stepper motor, pushes the filament into the
hot end. Finally, a cooling system, such as a fan, helps to quickly solidify the molten
filament after extrusion to ensure precise layering and prevent deformities. Together,
these components form the extruder assembly, enabling the 3D printer to create intricate
and accurate prints.

12
Parts & Drawings of Extruder Unit

13
3.2 Modeling of Basic Gantry Unit

Figure 10: Gantry

Purpose
The rotatable gantry is a key feature in a 5-axis 3D printer, allowing for enhanced
freedom of movement and versatility in printing. This gantry system consists of various
components that work together to achieve precise and complex printing capabilities.

Components & Sub-Assemblies

The primary components of a rotatable gantry include the base, the gantry structure,
rotary axes, and the print head assembly. The base serves as the foundation, providing
stability and support for the entire printer. The gantry structure is typically composed of
sturdy beams or rails that allow for movement along the X, Y, and Z axes. Additionally,

14
the gantry structure houses rotary axes, which enable rotation and tilting movements.
These rotary axes can be controlled by servos or stepper motors, allowing for precise
positioning of the print head assembly. The print head assembly is responsible for
extruding and depositing the filament material. It comprises components like the
extruder, hot end, nozzle, and cooling system, like those found in traditional 3D printers.
Together, these components of the rotatable gantry enable the 5-axis 3D printer to create
intricate and complex objects by providing the ability to rotate and tilt the print head
during the printing process. This allows for greater freedom in design and the creation of
geometries that were previously challenging or impossible to achieve with traditional 3D
printers.

15
Parts & Drawings of Gantry Unit

16
3.3 Modeling of Basic Structure

Figure 11: Basic Support Frame

Purpose
The basic support frame serves as the structural backbone of a 5-axis 3D printer,
providing stability and rigidity to the entire system. It is composed of various components
that work together to ensure precise and accurate movements during the printing process.

Components & Sub-Assemblies

The key components of the support frame include the base, columns, crossbeams, and
platform. The base serves as the foundation, providing a stable platform for the printer.
The columns, typically vertical structures, connect the base to the crossbeams and
provide vertical stability. The crossbeams span horizontally between the columns,
creating a rigid framework that supports the gantry system. The platform is where the
object being printed is placed and secured. It can be adjustable in height or position to
accommodate different printing requirements. Additionally, the support frame may also
include components like guide rails, bearings, and linear actuators, which facilitate
smooth and precise movements.

17
Drawing of Basic Structure

18
3.4 Modeling of Support Elements, Lead Screws and Rods

Figure 12: Secondary Support Elements

Purpose
In a 5-axis 3D printer, motors, belts, rod holders, and secondary support frames play vital
roles in enabling precise and coordinated movements during the printing process.

Components & Sub-Assemblies

The motors used in this type of printer are typically stepper motors or servo motors,
which provide controlled rotational movements to drive the gantry system and the rotary
axes. These motors are connected to the gantry and rotary axes through belts or pulleys,
transmitting motion from the motor to the respective components. Belts, commonly made
of reinforced rubber or timing belts, ensure synchronized movement and accurate
positioning of the gantry along the X, Y, and Z axes. Rod holders are used to secure the
guide rods or linear rails, providing stability and smooth motion for the gantry and other
moving components. They help maintain the alignment and prevent any unwanted
vibrations or wobbling during operation. Additionally, secondary support frames may be

19
employed to enhance the rigidity and stability of the printer's structure, reducing flexing
or distortion during movements. These frames often reinforce the primary support frame,
ensuring consistent and precise printing. Together, these components form a cohesive
system that allows for controlled movements and high precision in a 5-axis 3D printer,
enabling the creation of intricate and complex designs with exceptional accuracy.

20
Parts & Drawings of Secondary Support
Elements

21
3.5 Final Assembly

The final assembly of a 5-axis 3D printer involves combining various components to

create a functional and workable machine. The process begins with assembling the extruder unit,
which includes the extruder motor, hot end, nozzle, filament drive mechanism, and cooling
system. This component is mounted onto the rotatable gantry unit, which consists of the gantry
structure, rotary axes, and print head assembly. The gantry unit is then integrated with the basic
support frame, which comprises the base, columns, crossbeams, and platform. The support frame
provides stability and rigidity to the printer. Motors, such as stepper or servo motors, are
connected to the gantry system and rotary axes, and belts or pulleys transmit motion from the
motors to the moving parts. Rod holders secure the guide rods or linear rails, ensuring smooth
and precise movements. Finally, secondary support elements, such as additional frames or
braces, are added to reinforce the structure and reduce flexing. By combining all these
components and ensuring proper alignment and calibration, the 5-axis 3D printer is ready for use.
It can now accurately translate digital designs into physical objects, offering the capability to
create complex and intricate prints with exceptional precision.

22
4.1 Optimization

Objective # 1
The printer parameter optimization was achieved by developing parametrized
equations based on the definition of various global variables. The approach with which
the variables were defined and utilized is discussed later in the report. With the provision
of Length, Width and Height of the printable work piece i.e., its extensions, the printer
was designed to alter its own dimensions to accommodate the part to freely move without
clash within its bounds. This was achieved with the calculation of the gap between the
printer inner bounds where the printable part must occupy the space on the base plate in
all three dimensions. To visualize how the dimensions of the part would lie within the
bounds of the printer, a cuboid was constructed having suitable mates with the base plate
such that it was placed in contact with it at its center. Now the cuboid having
corresponding maximum dimensions in x, y, z of the actual part to produce, the plate
carrying it can be rotated, moved linearly, swiveled, and rotated/ moved in all directions
and checked to be not clashing with any of the printer parts.

Objective # 2
The Second objective was achieved utilizing the Motion study feature in Solid
works to get the force and torque data for the motion of the printer and its movable /
rotatable parts. The necessary forces were calculated which would serve the purpose of
validifying stresses result computed form any other simulation software. So, such data
would easily accommodate any stress simulations and would be helpful in designing and
selecting the right stepper or serve motor with providing an estimate as to what are the
forces, torque requirement, etc. Here 5 motors applied in the motion study were utilized
to obtain the associated force and torque graphs.

4.2 Parametrization

The Parameterization of the printer assembly was done in the light of the following steps:
1. Definition of Global Variables
2. Development of Main Variables
3. Calculation of the space required for the work piece on the base plate.
4. Definition of Equations based on main variables.
5. Iteration of the equations developed.
6. Ensuring non-clash condition for different

23
4.3 Equations

Global Variables
Evaluates
Name Value / Equation (Value in cm )
to (cm)
X 16 16
Y 15 15
Z 20 20
Dimension 18 18
Tolerance to add 5 5
ON OFF SWITCH 0 0
int ( ( ( ( "X" ^ 2 ) + ( "Y" ^ 2 ) ) ^
DIA 26
0.5 ) + "Tolerance to add" )

Top Level Equations

Evaluates
Name Value / Equation
to (cm)
IF ( "Z" < ( 30 *
"D1@Sketch1@top plate<1>.Part"
/ 18 ) , ( "D1@Sketch1@top
D1@Distance2 plate<1>.Part" * 1 / 18 * 12.5cm ) , 12.5
( 18.75 * 71.75 /
"D1@Sketch1@BODY 2<1>.Part"
))
"D1@Sketch1@BODY 2<1>.Part"
D1@Distance3 27
* 1 / 60 * 27.00cm
"D1@Sketch1@top plate<1>.Part"
D1@Distance5 2
* 1 / 18 * 2.00cm
"D1@Sketch1@top plate<1>.Part"
D1@Fillet1
* 1 / 18

24
 Equations of Components
Evaluates
Name Value / Equation
to (cm)
"D1@Sketch1@top plate<1>.Part"
D1@Sketch2@Inner case<1>.Part 54
* 1 / 18 * 54.00cm
"D1@Sketch1@top plate<1>.Part"
D4@Sketch1@Belt ring<2>.Part 3.5
* 1 / 18 * 3.50cm
"D1@Sketch1@top plate<1>.Part"
D4@Sketch1@Belt ring 2<1>.Part 3
* 1 / 18 * 3.00cm
"D1@Sketch1@top plate<1>.Part"
D1@Sketch2@bottom on rotation disk<1>.Part 18
* 1 / 18 * 18.00cm
"D1@Sketch1@top plate<1>.Part"
D1@Sketch2@Motor<1>.Part 5
* 1 / 18 * 5.00cm
"D1@Sketch1@top plate<1>.Part"
D1@Sketch2@Motor holder<1>.Part 5
* 1 / 18 * 5.00cm
"D1@Sketch1@top plate<1>.Part"
D1@Boss-Extrude3@Outer case<1>.Part 29
* 1 / 18 * 29.00cm
"D1@Sketch1@top plate<1>.Part"
D1@Boss-Extrude1@pin<1>.Part 12
* 1 / 18 * 12.00cm
"D1@Sketch1@top plate<1>.Part"
D1@Sketch2@plat<1>.Part 18
* 1 / 18 * 18.00cm
"D1@Sketch1@top plate<1>.Part"
D1@Sketch1@Railing Holder<1>.Part 8
* 1 / 18 * 8.00cm
"D1@Sketch1@top plate<1>.Part"
D2@Sketch1@s<1>.Part 6
* 1 / 18 * 6.00cm
"D1@Sketch1@top plate<1>.Part"
D1@Sketch1@Top on rotation disk<1>.Part 18
* 1 / 18 * 18.00cm
"D1@Sketch1@top plate<1>.Part"
D1@Boss-Extrude1@pin 7<1>.Part 3
* 1 / 18 * 3.00cm
"D1@Sketch1@top plate<1>.Part"
D1@Boss-Extrude1@pin 8<1>.Part 6.8
* 1 / 18 * 6.80cm
"D1@Sketch1@top plate<1>.Part"
D1@Boss-Extrude1@pin 9<1>.Part 2.5
* 1 / 18 * 2.50cm
"D1@Sketch1@top plate<1>.Part"
D1@Boss-Extrude1@pin 10<1>.Part 5.5
* 1 / 18 * 5.50cm
"D1@Sketch1@top plate<1>.Part"
D1@Boss-Extrude1@pin 11<1>.Part 4
* 1 / 18 * 4.00cm
"D1@Sketch1@top plate<1>.Part"
D1@Boss-Extrude1@pin 6 - Copy<1>.Part 6
* 1 / 18 * 6.00cm
"D1@Sketch1@top plate<1>.Part"
D1@Sketch6@left Nozzle and Rod holder<1>.Part 14
* 1 / 18 * 14.00cm

25
 "D1@Sketch1@top plate<1>.Part"
D2@Sketch1@Motor Top<1>.Part 7
* 1 / 18 * 7.00cm
"D1@Sketch1@top plate<1>.Part"
D2@Sketch1@right Nozzle and Rod holder - C<1>.Part 8
* 1 / 18 * 8.00cm
IF ( ( "Z" + 21 + ( 30.22 *
"D1@Sketch1@top plate<1>.Part"
D1@Boss-Extrude1@Rod<1>.Part * 1 / 18 ) ) < 75 , 72.5 , ( "Z" + 21 + 72.5
( 27.72 * "D1@Sketch1@top
plate<1>.Part" * 1 / 18 ) ) )
"D1@Sketch1@top plate<1>.Part"
D1@Boss-Extrude1@Rod 2<1>.Part 71
* 1 / 18 * 71.00cm
"D1@Sketch1@top plate<1>.Part"
D1@Sketch2@Rod holder<1>.Part 5
* 1 / 18 * 5.00cm
IF ( ( "Z" + 21 + ( 30.22 *
"D1@Sketch1@top plate<1>.Part"
D1@Boss-Extrude1@Screw<1>.Part * 1 / 18 ) ) < 75 , 70.9 , ( "Z" + 21 + 70.9
( 26.12 * "D1@Sketch1@top
plate<1>.Part" * 1 / 18 ) ) )

D1@Boss-Extrude1@Screw part of Nozzle and Rod "D1@Sketch1@top plate<1>.Part"

2
holder<1>.Part * 1 / 18 * 2.00cm

"D1@Sketch1@top plate<1>.Part"
D1@Sketch1@Upper holder<1>.Part 5
* 1 / 18 * 5.00cm
IF ( "Z" < ( 30 *
"D1@Sketch1@top plate<1>.Part"
D1@Boss-Extrude1@rod 3<2>.Part / 18 ) , ( "D1@Sketch1@top 60
plate<1>.Part" * 1 / 18 * 60.00cm )
, ( 2.25 * "Z" ) )
IF ( "Z" < ( 30 *
"D1@Sketch1@top plate<1>.Part"
D1@Sketch1@BODY 2<1>.Part / 18 ) , ( "D1@Sketch1@top 60
plate<1>.Part" * 1 / 18 * 60.00cm )
, ( 2.25 * "Z" ) )
"D1@Sketch1@top plate<1>.Part"
D2@Sketch3@Motor holder 3<2>.Part 10
* 1 / 18 * 10.00cm
"D1@Sketch1@top plate<1>.Part"
D4@Sketch1@Hollow<1>.Part@Assem1<1>.Assembly 3
* 3 / 18

D1@Boss- "D1@Sketch1@top plate<1>.Part"

2
Extrude2@Hollow<1>.Part@Assem1<1>.Assembly * 2.00 / 18cm

"D1@Sketch1@top plate<1>.Part"
D2@Sketch3@Hollow<1>.Part@Assem1<1>.Assembly 6.5
* 6.5 / 18
"D1@Sketch1@top plate<1>.Part"
D1@Sketch3@Hollow<1>.Part@Assem1<1>.Assembly 1
* 1 / 18
"D1@Sketch1@top plate<1>.Part"
D1@Sketch1@PIN123<1>.Part 1
* 1.00 / 18cm

26

D1@Sketch1@top plate<1>.Part
D1@Sketch1@WORK AREA<1>.Part
( "Dimension" * ( 1 - "ON OFF
SWITCH" ) ) + ( ( ( ( "X" ^ 2 ) + (
18
"Y" ^ 2 ) ) ^ 0.5 ) + "Tolerance to
add" ) * "ON OFF SWITCH"
"X" 16

D2@Sketch1@WORK AREA<1>.Part "Y" 15

D1@Boss-Extrude1@WORK AREA<1>.Part "Z" 20

D1@Boss-Extrude5@BODY 2<1>.Part
D1@Boss-Extrude1@Motor Top<1>.Part
D2@Sketch1@BODY 2<1>.Part
D2@Sketch8@BODY 2<1>.Part
D1@Sketch1@Rod<1>.Part
D5@Sketch2@BODY 2<1>.Part
D1@Sketch2@rod 3<2>.Part
D1@Sketch2@Screw<1>.Part
D1@Sketch1@Rod 2<1>.Part
D1@Sketch1@Motor ring<6>.Part
IF ( ( "Z" + 21 + ( 30.22 *
"D1@Sketch1@top plate<1>.Part"
* 1 / 18 ) ) < 75 , 75 , ( "Z" + 21 + ( 75
30.22 * "D1@Sketch1@top
plate<1>.Part" * 1 / 18 ) ) )
IF ( ( "Z" + 21 + ( 30.22 *
"D1@Sketch1@top plate<1>.Part"
* 1 / 18 ) ) < 75 , 1 , ( "Z" + 21 + ( 1
30.22 * "D1@Sketch1@top
plate<1>.Part" * 1 / 18 ) - 74 ) )
"D1@Sketch1@top plate<1>.Part"
5
* 5.00cm / 18
"D1@Sketch1@top plate<1>.Part"
1.5
* 1.50cm / 18
1 * "D1@Sketch1@top
1
plate<1>.Part" * 1 / 18
"D1@Sketch1@top plate<1>.Part"
8
* 8.00cm / 18
"D1@Sketch1@top plate<1>.Part"
1
* 1.00cm / 18
"D1@Sketch1@top plate<1>.Part"
1
* 1.00cm / 18
"D1@Sketch1@top plate<1>.Part"
1
* 1 / 18
"D1@Sketch1@top plate<1>.Part"
1
/ 18

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4.4 How Parametrization was done

1. Assuming Global Variables

The following Global Variables were assumed to make the project file fully customizable
having the provision to alter the model geometry with as few as sufficient part
parameters.
• X dimension ( “ X ” )
• Y dimension ( “ Y ” )
• Z dimension ( “ Z ” )

2. Creating Main Variables

Two Main variables are utilized having their definition based on the global variables:
• Dimension (“ DIMENSION” )
• Z Dimension (“ Z” )
For simplicity and ease of use, a main global variable as disk Diameter is provided by the
name of “Dimension” to serve as the foundation of Parametrization throughout the model
majorly. Another variable which was the part of global parameter i.e., its height or z-
dimension becomes important in design optimization of the model.
Since the gantry can turn about its axis, the height characteristic can be translated into
width of the part when the gantry turns 90 degrees either clockwise or anti-clockwise
from its mean or home position. Similarly the height of the printer can be adjusted to
adjusted based on the equation result obtained directly by incorporating the height of the
part, the available printer space in z -direction and the height of the corresponding parts
in between.
The use of these global variables can be explained by the use of the following chart flow
diagram.

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 3. Approach

Figure 13: Approach to Parametrization

4.5 Final Use of Main Variables

The Main variables were used to control the output of the various dependent variables’
parameters of the printer model. The dependent parameters can be divided into two
categories:
1. Parameters changing with Cross-Section of Plate
2. Parameters changing with Height of the Plate

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4.6 Final Presentation and Manipulation of Parametrized

With the help of these main variables and their associated parameter dependencies, the
design of the printer was exploited for matching the printable requirement of the work
piece. The work piece now can be moved along any axis, rotated, and found to be within
the bounds of the printer structure. The safety of not colliding with the body is ensured
primarily by calculation of the gaps and the product space and making an equation which
is mathematically guided to allow the movement with safety. Further tolerance and safety
margins are included in terms of both added distance and a percentage tolerance margin.

4.7 Motion Study

1. Motor 1 (rotate platform along B-axis)

The motor responsible for rotating the base along the B-axis in a 5-axis 3D printer
is a critical component that enables the printer to achieve rotational movements
and create complex geometries.
In a 5-axis 3D printer, the B-axis rotation allows for the base or platform to rotate
around a horizontal axis. This rotational movement adds another degree of
freedom, enabling the printer to create objects. with intricate details, angled
surfaces, and complex geometries

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 Data of Angular velocity

Data Motor Torque

2. Motor 2 (rotate platform along C-axis)

The motor responsible for rotating the base along the C-axis in a 5-axis 3D printer
is a critical component that enables the printer's ability to achieve rotational
movements and create intricate designs.
In a 5-axis 3D printer, the C-axis rotation allows for the base or platform to rotate
around a vertical axis. This rotational movement adds another dimension of

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freedom, enabling the printer to create curved surfaces, complex geometries, and
objects with intricate details.

Angular Velocity

Torque

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3. Motor 3 (motion in Z direction)

In a 5-axis 3D printer, the Z-axis rotation allows for vertical movement of the
extruder. This additional degree of freedom enables the printer to create objects
with varying heights, intricate details, and overhangs, expanding the range of
possible geometries and designs.

Angular Velocity

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 Torque

4. Motor 4 (motion in y direction)

The motor responsible for moving the platform along the Y-axis in a 5-axis 3D
printer is a crucial component that enables precise positioning and controlled
movement of the print bed.
In a 5-axis 3D printer, the Y-axis movement of the platform allows for horizontal
displacement of the print bed. This capability enables the printer to create objects
with complex geometries, overhangs, and intricate details by accurately
positioning the print bed in different locations.

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Angular Velocity

Torque

35
5. Motor 5 (linear motion to nozzle in x direction)

In a 5-axis 3D printer, the X-axis movement of the extruder allows for horizontal
displacement along the print bed. This capability enables the printer to create
objects with complex geometries, overhangs, and intricate details by accurately
placing the extrusion head in different positions on the print bed.

Angular Velocity

36
Torque

37
5. Conclusion

In conclusion, the CAD model of the 5-axis 3D printer presented in this project encompasses a
well-designed extruder assembly, a rotating gantry, a sturdy base frame, and essential support
elements. The geometric parametrization was executed meticulously, taking into consideration
the specific dimensions of each part required for optimal production. By achieving the objectives
of geometric parametrization, the printer model exhibits enhanced flexibility, adaptability, and
efficiency.
The optimization objectives for the geometric parametrization were successfully accomplished.
Through careful analysis and refinement, the model now showcases optimized torque and forces
for the motors employed in the system. These optimized parameters ensure smooth and precise
movements throughout the printing process, resulting in improved printing accuracy and overall
print quality.
The obtained plots for torque and forces for the utilized motors illustrate the effectiveness of
geometric parametrization. The optimized settings allow for optimal motor performance,
reducing strain and ensuring a reliable and stable operation. These plots serve as valuable
references, providing valuable insights into the system's behavior and facilitating future
enhancements or modifications.
In summary, the 5-axis 3D printer CAD model, incorporating the extruder assembly, rotating
gantry, base frame, and support elements, showcases a meticulous geometric parametrization
process. The successful achievement of the optimization objectives is evident in the obtained
plots for torque and forces, which demonstrate the effectiveness and efficiency of the utilized
motors. The presented model serves as a solid foundation for further advancements in the field of
3D printing and stands as a testament to the benefits of geometric parametrization in enhancing
the performance and capabilities of additive manufacturing systems.

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