DESIGN OF 3D PRINTER

MAJOR PROJECT 1

Presented by
Under the guidance of Pulkit Saini 20UME024
Rahul Kumawat 20UME082
Dr. Manish Bhargava
Associate Professor Sarita Jakhar 20UME101
Prateek Sharma 20UME129
Mechanical Engineering Department
NATIONAL INSTITUTE OF TECHNOLOGY AGARTALA
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Content:
Introduction
Literature Review
Objective
Motivation
Designed Machine
Machine Part
Mechanism
Advantages
Future Scope
Safety Concerns
Conclusion

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 Introduction
A 3d printer is an additive manufacturing technique where 3D objects and parts are made by the addition of
multiple layers of material. It can also be called rapid prototyping. It is a mechanized method where 3D
objects are quickly made as per the required size machine connected to a computer containing blueprints of
any object . The additive method may differ with the subtractive process, where the material is removed
from a block by sculpting or drilling. The main reason to use a 3d printer is for 90% of material utilization,
increasing product life, and making it lighter and stronger. 3D printing is efficiently utilized in various fields
such as aerospace, automobile, medical, construction and in manufacturing of many household products.

Various techniques developed for additive manufacturing:

1. Photopolymerization
I . Material jetting
II. Two photon Polymerization
2. Powder
I . Selective Laser Sintering
II. Binder Jetting
3. Material Extrusion: Extruding a filament at appropriate temperature (Ex: FDM, DWA)
I . Fused Deposition Modelling (FDM)
II. Direct Writing Assembly
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Fused Deposition Modelling (FDM):
This is a process by which a
machine deposits a filament
(Thermoplastics or wax). On top or
next to the same material, in order
to create a joint by heat or
adhesion.

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Types of 3D printers:
Based On Motion Configuration in 3D Printers:

1. Cartesian configuration:
Cartesian 3D printers are pretty much named after the
coordinate system, the X Y and Z axis which is used to
determine where and how to move in three dimensions. It has
a heated bed which moves only in the Z axis. The extruder sits
on the X-axis and Y-axis, where it can move in four directions
on a gantry.
2. Delta configuration:
Delta 3d printers feature a circular print bed. The extruder will
be suspended above that by three arms in a triangular
configuration thus the name “Delta”. These nifty robots were
designed for speed and they also have the advantage of a print
bed that does not move which could be advantageous for
certain prints.
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3. SCARA Configuration:
Selective Compliance Assembly Robotic
Arm abbreviated as SCARA type robotic
system has three degrees of freedom and it
is actuated by three servo motors, to do
one vertical and two horizontal motions.
Feeding system for 3d printing is placed to
the back of the robot and it is extended at
the end of the robotic arm.

4. Polar configuration:
This category uses a polar coordinate
system. It is very much similar to that of
Cartesian configuration except that the
coordinate sets describe points on a
circular grid rather than a square.

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 Objective

1. To study different methods of 3d printing and their applications.

2. To study the working procedure of each component of a 3d printer and the evolution of a 3d printer.
3. To design and fabricate a 3d printer.
4. The measurement, precision and accuracy through comparing hand measurements and 3D scanned
measurements.

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Designed Machine

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Machine Part:
Stepper Motor:
There are three stepper motor are used in this
machine. Two motors are used to provide the
motion to the tool in X and Y direction
respectively. While the third one is used to
provide the Z axis motion to the printing bed.
Here we are using the NEMA 17 stepper
motor. A NEMA 17 stepper motor is a typical
motor with 1.7x1.7 inch faceplate. The NEMA
14 is bigger and for the most part exceptionally
heavier than the alternate motors, for example,
NEMA 14, yet this additionally implies it has
more space to put a higher torque. Its size isn't
an indication of the power.

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 End Stops: While printing an object, all three axes need to be altered from the initial position
to their starting one. This is known as the zero position of any Cartesian robot. The axes can’t
move any further than zero. To acquire this, three end stops are to be installed, one for each axis.
An end stop needs to be mounted at such a position where the axis shouldn’t go beyond.

Print Bed: A heated build platform HBP improves the printing quality
of the 3d model by helping prevent warping. As extruded plastic cools it
shrinks slightly. When this shrinking process does not occur throughout
the printed part evenly, the result is the warped part. This warping is very
commonly seen as corners being lifted off the build platform. Printing on
a warmed bed permits the printed part to remain warm amid the printing
procedure and permit all more not with standing contracting of the plastic
as it cools underneath the softening point. The warmth bed prompts
higher complete quality that works with materials, for example, ABS and
PLA. A HBP can likewise enable clients to print without rafts.

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 Carriage rod: There are eight carriage rods used in this 3D Printer. Two carriage rods are used
to carry the tool in X direction and two are used for the movement of tool in Y direction. while
the rest of two are used for the movement of bed in the Z direction. The X – axis rods are fixed
to the carriages with the help of holes in side face of the carriages. The carriages will slide along
the Y – axis over the two cylindrical rods using linear bearings.

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Lead screw : There are three lead screws used in this 3D Printer which convert the
rotational motion of the stepper motor to the translational motion. It is used to move the
carriage through the carriage rod in all 3 dimensions.

Design of Lead Screw for Z - axis movement:

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Considering:
Single start thread n = 1
Pitch = 2mm

Coefficient of friction µ = 0.17

Torque = 3Nm
Considering Torque equation: -
]

Conclusion for lead screw

The diameter of lead screws is found to be 9.77mm and standardized to12mm.

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Bearings:
➢ Linear Bearing:

This linear bearing is sort of the opposite of the radial ball

bearings. Its Intended to slide along a 16mm linear shaft, rather
than to rotate around it.

➢ Ball bearing:
A ball bearing is a sort of moving
component bearing that can utilise
balls to keep up the detachment
between the bearing races.

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 Extruder: Extrusion is a procedure used to make objects of a settled cross-sectional profile. A
material is pushed or pulled through a die of the desired cross-sectional profile. The two main
advantages of this process over manufacturing processes are its ability to create very complex
cross-sections and to work with materials that are brittle. Because the material only encounters
compression and shear stresses. It also forms parts with an excellent surface finish. Commonly
extruded materials include metals Polymers, ceramics, concrete, play dough, and foodstuff.

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Filament PLA:

First and foremost, PLA is easy to print with. It has a lower

printing temperature than ABS and it doesn’t warp as easily,
meaning a heated print bed isn’t required (although it
definitely helps). Another benefit of using PLA is that it
doesn’t emit an off-putting odour during printing (unlike
ABS). It’s generally considered an odourless filament, but
many have reported smelling sweet candy-like fumes
depending on the type of PLA.

Nozzle:
It is used for deposition of melted material to make the model
through additive manufacturing. The melting point of nozzle
material is very high.

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Frame:
It is the major part of the machine to which all the parts are connected and attached to perform the operation. It is made up of Aluminium Material.

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 Mechanism

Presently mechanisms such as, for example, SCARA, Cartesian,

Polar, Delta and so on are used as a part of development of FDM
3D Printers. We have chosen cartesian arrangement of
developments, where the bed moves in the vertical heading i.e.,
in Z pivot bearing and the extruder spout moves horizontal way
i.e., both in X and Y hub course. Z hub development on such a
3D printer is extremely exact and requires low increasing speeds,
however the bed should be lightweight with a specific end goal
to look after precision, which makes it harder to include a
completely programmed bed levelling framework. Controlling a
straight Cartesian framework like this is mechanically
straightforward and furthermore generally simple from a product
point of view, which is the reason most 3D printers available
today use this kind of plan. The Cartesian arrange frameworks
has for quite some time been used for instruments like plotters,
CNC processing machines, and 2D printers.

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 Advantages:

1. More Affordable
2. Faster Production
3. Better Quality of Objects
4. Risk Reduction
5. Sustainability

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Safety concern:
 Be Aware Of Toxic Fumes From Materials.
 Avoid Electric Shocks.
 Watch Out For Scraper Blades.
 Avoid Pinch-Point Injuries From Moving Parts.
 Watch Out For Burn Risks From Heated Parts.
 Adhere To Standard Safety Guidelines.
 Minimize Risk Of Fire.

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 Future work plan

The outcome of this project was to build a portable 3D Printer which will be taken up in the next semester.
The design of the frame will be made robust and compact using Aluminium sections. The material selection of
the various elements is economical. Using a single motor for vertical movement along with a proximity sensor
makes bed levelling easy and the bed movement is monitored with resolution in microns. The drawback in few
3D Printers which use bed movement in the Y axis is distortion of the printed layer at high rates of printing. To
overcome this drawback, a new mechanism has been developed which uses bed movement in Z. The control
of the mechanism becomes easy because of less number of motors and good synchronization can be achieved
using this new 3D printer technique.

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 Future of 3D printing technology
1. Additive manufacturing is leading the way in the digital transformation of Industry. Rather than
stocking a warehouse full of parts that consume mass quantities of space, Additive manufacturing
condenses and converts the physical space into a digital file that can be stored.

2. The market for medical 3D printing, including materials, services, software and hardware, is currently
estimated to be worth $1.25 billion.

3. The orthopaedics 3D printing market was valued at $691 million in 2018 and is predicted by SmartTech
Analysis to grow into a $3.7 billion market by 2027.

4. 3D printing will become a mainstream technology for serial production.

5. Design software for additive will become more integrated and easier to use.

6. Focusing on education will enable more 3D printing applications and adoption.

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THANK YOU

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