SPPU Explores Benefits of 3D Printing

Savitribai Phule Pune University
1. INTRODUCTION
3D printing or additive manufacturing (AM) is any of various processes for making a

three-dimensional object of almost any shape from a 3D model or other electronic data
source primarily through additive processes in which successive layers of material are
laid down under computer control. A 3D printer is a type of industrial robot.
Early AM equipment and materials were developed in the 1980s. In 1984, Chuck Hull of
3D Systems Corp invented a process known as stereo lithography employing UV lasers
to cure photopolymers. Hull also developed the STL file format widely accepted by 3D
printing software, as well as the digital slicing and infill strategies common to many
processes today. Also during the 1980s, the metal sintering forms of AM were being
developed (such as selective laser sintering and direct metal laser sintering), although
they were not yet called 3D printing or AM at the time. In 1990, the plastic extrusion
technology most widely associated with the term ―3D printing‖ was commercialized by
Stratasys under the name fused deposition modelling (FDM). In 1995, Z Corporation
commercialized an MIT-developed additive process under the trademark 3D printing
(3DP), referring at that time to a proprietary process inkjet deposition of liquid binder on
powder.
AM technologies found applications starting in the 1980s in product development, data

visualization, rapid prototyping, and specialized manufacturing. Their expansion into
production (job production, mass production, and distributed manufacturing) has been
under development in the decades since. Industrial production roles within the
metalworking industries achieved significant scale for the first time in the early 2010s.
Since the start of the 21st century there has been a large growth in the sales of AM
machines, and their price has dropped substantially. According to Wohlers Associates, a
consultancy, the market for 3D printers and services was worth $2.2 billion worldwide in
2012, up 29% from 2011. Applications are many, including architecture, construction
(AEC), industrial design, automotive, aerospace, military, engineering, dental and
TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

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medical industries, biotech (human tissue replacement), fashion, footwear, jewellery,

eyewear, education, geographic information systems, food, and many other fields.[1]
1.1 Problem Statement

The question is whether FDM is practical and if so, are there any potential benefits over
other processes. The hypothesis is that layered fused deposition is practical as the basic
input to any RP system is in the form of CAD files; it is essentially, processing the CAD
files or the internal surface models using appropriate mathematical models. Considering
the volume of the work involved, the current research is confined to studying a working
software system and establishing the effectiveness of the technology is again left for the
future. The scope of the research is to focus on current software solutions and their
effectiveness. The methodology involves use of existing software solutions for gathering
the basic data on the outer surfaces and then developing mathematical algorithms for
proper nozzle movement co-ordination. Existing solutions would be considered for
quickly building the hardware system and necessary schemes would have to be worked
for integrating the data generated from the CAD models and the slicing methodology.
1.2 Objective
1. Study the 3D printing technology
2. To study different methods of 3d printing and their applications.
3. To study the working procedure of each component of a 3d printer and the evolution of
3d printer.
4. To study and fabricate (Assemble) 3d printer
5. To implement software that converts CAD file into STL file & making 3D Model
according to CAD design

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Fig.no.1.Typical 3D Printer
1.3 SCOPE
Since over a century the visual world of printed scriptures has been dominated by the 2D
printing methods. Be that easy to read or comprehend but when it comes to imaging of
definite and real life models it is sorely outsourced. Any 3-D model cannot be
represented and displayed easily in a 2-D workplace. The only thing worth mentioning
for likable perception is the rendering of the image. This ushered in the era of the much
needed idea of ―3-D‖ printing.
Basically the singular purpose for the division of 3-D printer was to prepare 3-D samples
directly on the bed of the printer. It has been an effective way of manufacturing since
many companies are now opting for this type of method for their production operations,
and that production operation needs a software for its successful implementation and due
to this there is a wide scope for developing, upgrading and adding features and
techniques for more efficient and easy use of this software.

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1.4 METHODOLOGY
The step by step methodology of project development is as per following:

1. Deciding need for the project technology.
2. Research for possibilities of use to technology and its future scope.
3. Finalizing project plan accordingly.
4. Preparing detailed project plan.
Fig.no.1.2. Process flow chart

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2. LITERATURE REVIEW
The 1980s: Birth of the 3 main 3D Printing Techniques. The first 3D printing attempts
are granted to Dr Kodama for his development of a rapid prototyping technique in 1980.
He was the first to describe a layer by layer approach for manufacturing, creating an
ancestor for SLA: a photosensitive resin was polymerised by an UV light.. Unfortunately,
he did not file the patent requirement before the deadline. Four years later, a French team
of engineers was interested by the stereolithography but abandoned due to a lack of
business perspective. In the same time, Charles Hull was also interested in the technology
and deposited a first patent for stereolithography (SLA) in 1986. He founded the 3D
Systems Corporation and a year later, released the SLA-1. In 1988, at the University of
Texas, Carl Deckard brought a patent for the SLS technology, another 3D printing
technique in which powder grains are fused together locally by a laser. In the meantime,
Scott Crump, a co-founder of Stratasys Inc. filed a patent for Fused Deposition Modelling
(FDM): the third of the main 3D printing technologies, in which. Over less than ten years,
the three main technologies of 3D printing were patented and 3D printing was born.
Recap:
1980: first patent by japanese Dr Kodama Rapid prototyping
1984: Stereolithography by french then abandoned
1986: Stereolithography taken up by Charles Hull
1987: First SLA-1 machine
1988: first SLS machine by DTM Inc then buy by 3D system
The 1990s: Emergence of the Main 3D Printers Manufacturers & CAD tools In Europe,
EOS GmbH was founded and created the first EOS ―Stereos‖ system for industrial
prototyping and production applications of 3D printing. Its industrial quality is today
recognized worldwide in SLS technology for plastics and metals. In 1992, the Fused
Deposition Modeling patent was issued to Stratasys, who that developed many 3D
printers for both professional and individuals. From 1993 to 1999, the main actors of the
3D 3 printing sector emerged with various techniques: ZCorp and binder jetting: Based
on MIT‗s inkjet printing technology, they created the Z402, which produced models

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using starch- and plaster‐based powder materials and a water‐based liquid binde Arcam
MCP technology and Selective Laser Melting. At the same time, CAD tools for 3D
printing became more and more available and developed, with for example the creation
of Sanders Prototype (now known as Solidscape), one of the first actors to develop
specific tools for additive manufacturing. The 1990s were also the decade of the first
application of 3D printing by medical researchers, who started to combine medicine and
3D printing, opening the path to many uses.
Charles Hull was awarded the European Inventor Award in the Non-European countries
category, by the European Patent Office Price in 2014.
Recap:
1990: First EOS Stereos system
1992: FDM patent to Stratasys
1993: Solidscape was founded
1995: Z Corporation obtained an exclusive license from the MIT
1999: Engineered organs bring new advances to medicine
The 2000s: 3D Printing Gains Media Visibility In 2000, the millennium saw the first 3D
printed working kidney. We will have to wait 13 more years to see it transplanted into a
patient. 3D printed kidneys are now perfectly working and researchers are experimenting
on accelerated growth to transplant organs very rapidly. 2004 was the year of the
initiating of the RepRap Project which consists in a self-replicating 3D printer. This open
source project led to the spreading of the FDM 3D desktop 3D printers, and of the
popularity of the technology in the makers community. In 2008, 3D printing reached an
even greater media presence thanks to another medical application: the first 3D printed
prosthetic limb. It incorporated all parts of a biological limb, was printed as is‗, without
the need for any later assembly. Nowadays, combined with 3D scanning, medical
prosthesis and orthosis are more and more cheaper and extremely fast to obtain.2009 was
the year in which the FDM patents fell into the public domain, opening the way to a wide
wave of innovation in FDM 3D printers, a drop of the desktop 3D printers price, and
consequently, since the technology was more accessible, an increased visibility. 2009 was

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also the year Sculpteo was created, one of the pioneer of the now flourishing online 3D
printing services, another step toward 3D printing accessibility.
Recap:
2000: a 3D printed working kidney is created
2000: MCP Technologies (an established vacuum casting OEM) introduced the SLM
technology 2005: Z Corp. launched Spectrum Z510. It was the first high-definition color
3D Printer on the market.
2006: An open source project is initiated (Reprap)
2008: The first 3D printed prosthetic leg
2009: FDM patents in the public domain
2009: Sculpteo is created
At the same time, efforts are constantly made to make 3D printing more accessible,
through education (see our ebook on how to Graduate in 3D printing), shared spaces like
fablabs and makerspaces, and of course 3D printing services like ours: we‗re constantly
adding new materials to our catalogue, new repair and optimisation tools to make sure
you 3D print exactly what you had in mind, and new ebooks and tutorials so you master
the technology from design to finish.
Recap:
2010: Urbee is the first 3D printed prototype car presented
2011: Cornell University began to build 3D food printer.
2012: The first prosthetic jaw is printed and implanted
2013: 3D printing‖ in Obama‗s State of the Union speech
2015: Carbon 3D issues their revolutionary ultra-fast CLIP 3D printing machine
2016: Daniel Kelly‗s lab announces being able to 3D print bone

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3. FUSED DEPOSITION MODELEING
3D-Printer is a machine reminiscent of the Star Trek Replicator, something magical that
can create objects out of thin air. It can ―print‖ in plastic, metal, nylon, and over a
hundred other materials. It can be used for making nonsensical little models like the over-
printed Yoda, yet it can also print manufacturing prototypes, end user products, quasi-
legal guns, aircraft engine parts and even human organs using a person‘s own cells.
We live in an age that is witness to what many are calling the Third Industrial
Revolution.
3D printing, more professionally called additive manufacturing, moves us away from the
Henry Ford era mass production line, and will bring us to a new reality of customizable,
one-off production. 3D printers use a variety of very different types of additive
manufacturing technologies, but they all share one core thing in common: they create a
three dimensional object by building it layer by successive layer, until the entire object is
complete.[8]
Fig-3.1-3D printer

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3.1 PROCEDURES FOR PRINTING
Fig.no.3.2 - Printing process
There are some procedures for printing. First you must create a computer model for
printing the object. For creating that, you can use Computer Aided Design Software like
Auto-CAD, 3DS Max etc. After the object file is created, the file need to be modified.
The object file contains numerous amount of curves. Curves cannot be printed by the
printer directly. The curves has to be converted to STL (Stereo lithography) file format.
The STL file format conversion removes all the curves and it is replaced with linear
shapes. Then the file need to be sliced into layer by layer. The layer thickness is so
chosen to meet the resolution of the 3D printer we are using. [9]

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3.2 Designing using CAD
Computer-aided design (CAD) is the use of computer systems to assist in the creation,
modification, analysis, or optimization of a design. CAD software is used to increase the
productivity of the designer, improve the quality of design, improve communications
through documentation, and to create a database for manufacturing. CAD output is often
in the form of electronic files for print, machining, or other manufacturing operations.
CAD software for mechanical design uses either vector-based graphics to depict the
objects of traditional drafting, or may also produce raster graphics showing the overall
appearance of designed objects. However, it involves more than just shapes. As in the
manual drafting of technical and engineering drawings, the output of CAD must convey
information, such as materials, processes, dimensions, and tolerances, according to
application-specific conventions.
CAD may be used to design curves and figures in two-dimensional (2D) space; or
curves, surfaces, and solids in three-dimensional (3D) space. CAD is an important
industrial art extensively used in many applications, including automotive, shipbuilding,
and aerospace industries, industrial and architectural design, prosthetics, and many more.
CAD is also widely used to produce computer animation for special effects in movies,
advertising and technical manuals, often called DCC digital content creation. The modern
ubiquity and power of computers means that even perfume bottles and shampoo
dispensers are designed using techniques unheard of by engineers of the 1960s. Because
of its enormous economic importance, CAD has been a major driving force for research
in computational geometry, computer graphics (both hardware and software), and
discrete differential geometry.
The design of geometric models for object shapes, in particular, is occasionally called
computer-aided geometric design (CAGD). Unexpected capabilities of these associative
relationships have led to a new form of prototyping called digital prototyping. In contrast
to physical prototypes, which entail manufacturing time in the design. That said, CAD

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models can be generated by a computer after the physical prototype has been scanned
using an industrial CT scanning machine. Depending on the nature of the business, digital
or physical prototypes can be initially chosen according to specific needs.
Today, CAD systems exist for all the major platforms (Windows, Linux, UNIX and Mac
OS X); some packages even support multiple platforms which enhances the capabilities
of 3D printing into a new level. [2]
3.3 Conversion to STL file format
An STL file is a triangular representation of a 3D surface geometry. The surface is

tessellated logically into a set of oriented triangles (facets). Each facet is described by the
unit outward normal and three points listed in counterclockwise order representing the
vertices of the triangle. While the aspect ratio and orientation of individual facets is
governed by the surface curvature, the size of the facets is driven by the tolerance
controlling the quality of the surface representation in terms of the distance of the facets
from the surface. The choice of the tolerance is strongly dependent on the target
application of the produced STL file. In industrial processing, where stereo lithography
machines perform a computer controlled layer by layer laser curing of a photo-sensitive
resin, the tolerance may be in order of 0.1 mm to make the produced 3D part precise with
highly worked out details. However much larger values are typically used in pre-
production STL prototypes, for example for visualization purposes.
The native STL format has to fulfill the following specifications:

(i) The normal and each vertex of every facet are specified by three coordinates each, so
there is a total of 12 numbers stored for each facet.
(ii) Each facet is part of the boundary between the interior and the exterior of the object.
The orientation of the facets (which way is ``out'' and which way is ``in'') is specified
redundantly in two ways which must be consistent. First, the direction of the normal is

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outward. Second, the vertices are listed in counterclockwise order when looking at the
object from the outside (right-hand rule).
(iii) Each triangle must share two vertices with each of its adjacent triangles. This is
known as vertex-to-vertex rule.
(iv) The object located must be located in the all-positive octant (all vertex coordinates
must be positive).
However, for non-native STL applications, the STL format can be generalized. The
normal, if not specified (three zeroes might be used instead), can be easily computed
from the coordinates of the vertices using the right-hand rule. Moreover, the vertices can
be located in any octant. And finally, the facet can even be on the interface between two
objects (or two parts of the same object). This makes the generalized STL format suitable
for modeling of 3D non-manifolds objects. [9]
Fig.No.3.3 Pre-process for 3D Printing

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3.4 Rapid prototyping
Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a

physical part or assembly using three-dimensional computer aided design (CAD) data.
Construction of the part or assembly is usually done using 3D printing or "additive layer
manufacturing" technology.
The first methods for rapid prototyping became available in the late 1980s and were used
to produce models and prototype parts. Today, they are used for a wide range of
applications and are used to manufacture production-quality parts in relatively small
numbers if desired without the typical unfavorable short-run economics. This economy
has encouraged online service bureaus. Historical surveys of RP technology start with
discussions of simulacra production techniques used by 19th-century sculptors. Some
modern sculptors use the progeny technology to produce exhibitions. The ability to
reproduce designs from a dataset has given rise to issues of rights, as it is now possible to
interpolate volumetric data from one-dimensional images. As with CNC subtractive
methods, the computer-aided-design - computer-aided manufacturing CAD-CAM
workflow in the traditional Rapid Prototyping process starts with the creation of
geometric data, either as a 3D solid using a CAD workstation, or 2D slices using a
scanning device. For RP this data must represent a valid geometric model; namely, one
whose boundary surfaces enclose a finite volume, contains no holes exposing the interior,
and do not fold back on themselves. In other words, the object must have an ―inside.‖
The model is valid if for each point in 3D space the computer can determine uniquely
whether that point lies inside, on, or outside the boundary surface of the model. CAD
post-processors will approximate the application vendors‘ internal CAD geometric forms
(e.g., B-splines) with a simplified mathematical form, which in turn is expressed in a
specified data format which is a common feature in Additive Manufacturing: STL
(stereolithography) a de facto standard for transferring solid geometric models to SFF
machines. To obtain the necessary motion control trajectories to drive the actual SFF,
rapid prototyping, 3D printing or additive manufacturing mechanism. [2]

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4. ASSEMBLY OF PRINTER.
4.1 Components are used for assembly

• Stepper motor -Nema 17
• Hard chrome bar 8mm diameter
• Lead screw T8
• Motor Coupler
• Hot bed
• Graphic Display
• Mother board -Mega RDNO
• linear bearing
• Motor Pulley
• Power supply
• Extruder Nozzle
4.2 Components & there specifications
4.2.1 Stepper motor –Nema 17
The Mosaic stepper motor (part no.STEPMOT-1) is a four phase, unipolar, permanent
magnet stepper motor. It is a standard size, 200-steps-per-revolution, NEMA 17 (1.7 in.
square footprint, 5 mm shaft diameter), 12 V motor. This motor, like most stepper motors
is a permanent magnet motor. The Mosaic stepper is typical of common high resolution
motors – a full revolution requires 200 steps, while each step turns the shaft only 1.8° for
a full step, or 0.9° in half-stepping mode. This sized motor is commonly used in
household appliances, medical equipment, stage lighting devices, and in various
industrial control applications. In use, the center taps of the windings are typically wired
to the positive supply, and the two ends of each winding are alternately grounded through
a drive circuit to reverse the direction of the field provided by that winding. The Motor

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Wiring Diagram also illustrates the order of the stator poles in the motor: A, B, A‘, B‘.
This is the order in which they must be energized to cause the motor to step in a specified
direction (clockwise or counterclockwise).The motor physical dimensions are shown in
the following figure. The motor is 1.7‖ square, 1.5‖ long, with a 5 mm shaft. Mounting
holes take 3 mm dia., 0.5 mm pitch metric screws. Four screws are installed in the back
side of the motor. Two diagonally mounted screws are 40 mm long and extend 5.5 mm
through the front side and two are 30 mm long and leave a 4.5 mm deep threaded socket
in the front. [3]
Stepper Motor Specifications

Size Nema 17
Drive System Unipolar
Step Angle 1.8° full step 0.9° half-step
Phase/ Winding 4/2
Voltage & Current 12V at 400MA
Holding Torque 200 g-cm
Weight 0.24kg
Max power 5w
Table no. 1 Specifications of Stepper Motor
Fig.no.4.1 Stepper Motor –Nema 17

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4.2.2 Hard chrome bar
External Diameter Accuracy: f8

Surface Roughness: Ra0.2μm ~ Ra0.4μm
Hard Chrome Thickness: 20Micron ± 10%
Surface Hardness: HV 850 (Minimum) up
Straightness: 0.15-0.25/1000mm
The hard chromium bars used in 3D printers on which motor and extruder is mounted.
They are also used for supporting members of printers. [3]
Fig.no.4.2. Hard chrome bar
4.2.3. Lead screw
Lead screws are precision machined components used for pretty much all proper CNC
equipment. They have almost no backlash, they're perfectly straight, and they allow for
higher load transfers without jamming. A lead screw turns rotary motion into linear
motion combining a screw and a nut where the screw thread is in direct contact with the
nut thread. In the case of roller screws, the rollers rather than the nut are in direct contact
with the screw thread offering greater efficiency. Within a 3D printing application,
screws are typically driven by a stepper motor and guided by profile rails on the X and Y

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axes. Precision engineered acme nuts are connected to the carriage mechanism. All axes
are actuated with a stepper motor- driven screw with an anti-backlash nut, and move
along linear ball bearing guides.
An important advantage of the screw-rail configuration for controlling linear motion in

3D printers is that it requires a fraction of the number of components that are necessary
for belt-driven 3D printers and takes much less time to assemble. Compared to belt-
drives, which deliver linear motion with repeatability of ±0.1 mm/m and a layer height of
100 microns in 3D printing applications, screws offer linear motion with repeatability of
±0.02 mm/m and a layer height of 50 microns, making them a lot more precise and
accurate for controlling 3D printer performance.
Precision-grade screws have increasingly become the preferred option for low-cost,
desktop 3D printers because they deliver the accuracy, repeatability, and performance
that users demand - all at at an affordable price. In other words, 3D printer designers no
longer need opt for belt drives for controlling linear motion in 3D printers just to keep the
cost down. With precision-engineered screws, you can produce high-resolution parts
while reducing cost.
Fig.no.4.3 Lead Screw

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4.2.4. Motor coupler
Couplings can be rigid or flexible depending on the alignment accuracies of the system
and torque requirements. Shaft couplings are used for power and torque transmission
between two rotating shafts such as on motors and pumps, compressors, and generators.
In a more general context, a coupling can also be a mechanical device that serves to
connect the ends of adjacent parts or objects. Couplings do not normally allow
disconnection of shafts during operation, however there are torque limiting
couplings which can slip or disconnect when some torque limit is exceeded.
A coupling is a device used to connect two shafts together at their ends for the purpose of
transmitting power. The primary purpose of couplings is to join two pieces of rotating
equipment while permitting some degree of misalignment or end movement or both. In a
more general context, a coupling can also be a mechanical device that serves to connect
the ends of adjacent parts or objects. Couplings do not normally allow disconnection of
shafts during operation, however there are torque limiting couplings which can slip or
disconnect when some torque limit is exceeded. Selection, installation and maintenance
of couplings can lead to reduced maintenance time and maintenance cost. [4]
Fig.no.4.4 Motor Coupling

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4.2.5. Hot bed

Heat beds are used because they dramatically improve print quality by keeping the
extruded plastic warm and thus preventing warping. Warping is a common condition
caused by plastic on the edges of the part cooling down at an uneven rate when compared
to the plastic inside of the part
 WHY HOT BED USED?
Heat beds are used because they dramatically improve print quality by keeping
the extruded plastic warm and thus preventing warping. Warping is a common
condition caused by plastic on the edges of the part cooling down at an uneven
rate when compared to the plastic inside of the part. The result is that corners
warp up and deform your model.
In the past, techniques such as the raft (building parts on top of a ‗raft‘ of material
which is larger than the final part onto the build surface) were used to prevent
warping by increasing the surface area of the part (and increasing it‘s adhesion –
thus fighting warping).
Derived from the raft, mouse ears are a clever and effective technique to make
sure that the corners of your prints are well secured to the platform and won‘t lift.
Although they offer greater adhesion by increasing the surface area for your part
to grip onto the bed, they are not 100% effective without a heat bed. Sometimes
the warping forces are simply too great and can overcome the mouse ears. Heat
beds work to prevent this warping effect by keeping your part warm during the
whole printing process which keeps the material at or above heat-deflection
temperature (the temperature at which it is malleable).
Keeping the parts in the heat-deflection range ensures that the part remains flat on
the print bed. Heat beds, in combination with other tools to increase adhesion, will
be covered in this article to bolster your ability to fight unwanted effects and
improve your printing quality. The following video shows what happens with no
heat bed and no adhesive added to the glass. It depicts what can typically happen
when printing on a non-sticky platform with no heat bed – Disaster!

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There are several types of heat beds & heating elements. We specifically discuss
the PCB heat bed, the polyamide film heater and the aluminium clad heater. You
can find a more exhaustive list of heater types here.
 What is the function of hot bed in 3D printer?
Heat bed is the 3D printer‗s build platform with heating function, but why do we
need a heat bed？ In the following situations, 3d printer heat bed will be
required:
1. Heat bed will be needed if you want to 3D print with ABS material. This is
because contraction rate of ABS is a bit high, which will lead to
the warping issues during 3D printing. If the 3d printer's bed can be heated, ABS
will be able to attach on the heat bed more firmly with a lower chance of
warping.
2. Although it is not always necessary to print the PLA material with a 3d
printer heat bed, if the shape of the 3D model is long, or the bottom surface of the
3D model which touches the bed is large, heat bed will be required. This is
because long shape and big bottom surface can lead to warping issues easily.
 Heat beds have two purposes:
1. Increase surface energy of the print bed to improve bonding strength of the first
layer (particularly important when using surfaces like PEI or Kapton)
2. Keep the bottom few millimeters of the print hot enough to provide a warp-free
foundation for the rest of the print. [3]

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Fig.no.4.5. Hot Bed
4.2.6. Graphic display
Liquid crystal display technology works by blocking light. Specifically, an LCD is made
of two pieces of polarized glass (also called substrate) that contain a liquid
crystal material between them. A backlight creates light that passes through the first
substrate. We can easily interface a liquid crystal display (LCD) with an Arduino to
provide a user interface. Liquid crystal displays (LCDs) are a commonly used
to display data in devices such as calculators, microwave ovens, and many other
electronic devices. The liquid has a unique advantage of having low power consumption
than the LED or cathode ray tube. Liquid crystal display screen works on the principle of
blocking light rather than emitting light. LCD's requires backlight as they do not emits
light by them. [4]
Fig.no.4.6.1. LCD Layered Diagram

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We have used 16x2 LCD has a total no of 16 pins. A 16x2 LCD means it can display 16
characters per line and there are 2 such lines. There are a lot of combinations available
like, 8×1, 8×2, 10×2, 16×1, etc. but the most used one is the 16×2 LCD. So, it will have
(16×2=32) 32 characters in total and each character will be made of 5×8 Pixel Dots.
Now, we know that each character has (5×8=40) 40 Pixels and for 32 Characters we will
have (32×40) 1280 Pixels. Further, the LCD should also be instructed about the Position
of the Pixels. Hence it will be a hectic task to handle everything with the help of MCU,
hence an Interface IC like HD44780is used, which is mounted on the backside of the
LCD Module itself. The function of this IC is to get the Commands and Data from the
MCU and process them to display meaningful information onto our LCD Screen.
 How LCDs Work?

The principle behind the LCD‘s is that when an electrical current is applied to the liquid
crystal molecule, the molecule tends to untwist. This causes the angle of light which is
passing through the molecule of the polarized glass and also cause a change in the angle
of the top polarizing filter. As a result a little light is allowed to pass the polarized glass
through a particular area of the LCD. Thus that particular area will become dark
compared to other. The LCD works on the principle of blocking light. While constructing
the LCD‘s, a reflected mirror is arranged at the back. An electrode plane is made of
indium-tin oxide which is kept on top and a polarized glass with a polarizing film is also
added on the bottom of the device. The complete region of the LCD has to be enclosed by
a common electrode and above it should be the liquid crystal matter.
Next comes to the second piece of glass with an electrode in the form of the rectangle on
the bottom and, on top, another polarizing film. It must be considered that both the pieces
are kept at right angles. When there is no current, the light passes through the front of the
LCD it will be reflected by the mirror and bounced back. As the electrode is connected to
a battery the current from it will cause the liquid crystals between the common-plane
electrode and the electrode shaped like a rectangle to untwist. Thus the light is blocked
from passing through. That particular rectangular area appears blank.

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As shown in the table below, eight of the pins are data lines (pins 7-14), two are for
power and ground (pins 1 and 16), three are used to control the operation of LCD (pins 4-
6), and one is used to adjust the LCD screen brightness (pin 3). The remaining two pins
(15 and 16) power the backlight. The details of the LCD terminals are as follows:
Fig.no.4.6.2.Pin Diagram of 16x2 LCD
Features of 16×2 LCD module
 Operating Voltage is 4.7V to 5.3V

 Current consumption is 1mA without backlight
 Alphanumeric LCD display module, meaning can display alphabets and numbers
 Consists of two rows and each row can print 16 characters.
 Each character is build by a 5×8 pixel box
 Can work on both 8-bit and 4-bit mode
 It can also display any custom generated characters
 Available in Green and Blue Backlight
Fig.no.4.6.3.LCD Screen & Arduino Module

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4.2.7. Mother Board- Mega Aurdino
What is Arduino?
Arduino is an open source electronics platform accompanied with a hardware and

software to design, develop and test complex electronics prototypes and products. The
hardware consists of a microcontroller with other electronic component which can be
programmed using the software to do almost any task. The simplicity of the Arduino
language makes it very easy for almost everyone who has an interest in electronics to
write programs without the understanding of complex algorithms or codes.
Arduino is intended for an artist, tinker, designer or anyone, interested in playing with
electronics without the knowhow of complex electronics and programming skills.
Arduino is an excellent designed open source platform. It has specially designed boards
which can be programmed using the Ardunio Programming Language (APL).
The presence of Arduino is not only spreading between hobbyists, but it has also
expanded its roots in industries and used by experts for making prototypes of commercial
products. Arduino takes off the efforts required in complex coding and designing
hardware.
The open source nature of Arduino has been the main reason for its rapid horizontal
growth. Since it is an Open Source project, all the files related to hardware and software
is available for personal or commercial use. The development cost of the hardware is
very small as against the costly similar proprietary products by the industrial giants. The
open source nature doesn‘t require any licenses to develop, use, redistribute or even sell
the product. But the Arduino name is trade mark protected (Arduino) i.e., you are free to
sell the Arduino board under any other name however in order to sell it under the name
―Arduino‖ you need to take permission from the founders and follow their quality terms.
The Software files which includes all the source code library are also open sourced. A
user can modify them to make the project more versatile and improve its capabilities.
This provides a strong online community support.

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Concept of Arduino
The root of Arduino goes deep down to the development of Processing Language by MIT
researchers. Processing language is an open source language designed to introduce the
software development environment for the artistic people without the need of deep
knowledge of programming of algorithms. Processing is based on java. In early year of
21st century, designing an electronics gadget was nearly impossible for a common man.
The requirement of specific skill set and hefty prices of software and hardware created a
full stop in the path of their creativity. In year 2003 Hernando Barragan, a programmer
developed an open source electronics development platform with software IDE, where
anyone with a small knowledge in electronics and programming could use his project to
give wings to their creativity. His focus was to reduce the burden of complexity in
designing electronics hardware and software. The project was named as Wiring. The
software IDE of the Wiring used processing language to write the codes.
Arduino Mega (R3)
Arduino
Board Processor Memory Digital I/O Analogue I/O
Arduino 16MHz 8KB SRAM,

Mega ATmega2560 256KB flash 54 16 input, 0 output
Table no. 2 Specifications of Aurdio Mega
The Arduino Mega is a microcontroller board based on the ATmega2560. It has 54

digital input/output pins (of which 14 can be used as PWM outputs), 16 analog inputs, 4
UARTs (hardware serial ports), a 16 MHz crystal oscillator, a USB connection, a power
jack, an ICSP header, and a reset button. The Arduino Mega2560 can be powered via the
USB connection or with an external power supply. The power source is selected
automatically. External (non-USB) power can come either from an AC-to-DC adapter

25
(wall-wart) or battery. The adapter can be connected by plugging a 2.1mm center-positive

plug into the board's power jack. Leads from a battery can be inserted in the Gnd and Vin
pin headers of the POWER connector. The board can operate on an external supply of 6
to 20 volts. If supplied with less than 7V, however, the 5V pin may supply less than five
volts and the board may be unstable. If using more than 12V, the voltage regulator may
overheat and damage the board. The recommended range is 7 to 12 volts. The Mega2560
differs from all preceding boards in that it does not use the FTDI USB-to-serial driver
[4]
chip. Instead, it features the Atmega8U2 programmed as a USB-to-serial converter.
The power pins are as follows:
• VIN: - The input voltage to the Arduino board when it's using an external power source
(as opposed to 5 volts from the USB connection or other regulated power source). You
can supply voltage through this pin, or, if supplying voltage via the power jack, access it
through this pin.
• 5V: - The regulated power supply used to power the microcontroller and other
components on the board. This can come either from VIN via an on-board regulator, or
be supplied by USB or another regulated 5V supply.
• 3V3: - A 3.3 volt supply generated by the on-board regulator. Maximum current draw is
50 mA.
• GND: - Ground pins.
Fig.no.4.7.Mega Aurdino

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4.2.8. Linear bearing
Linear bearings generally use a pad, bushing, or roller system to carry a load on a rail that
need not be a straight line. The rail can be most any length, although that dimension is
limited by the actuator. The durability of the bearing is determined by the load and
required speed
 linear-motion bearing
A linear-motion bearing or linear slide is a bearing designed to provide free

motion in one direction There are many different types of linear motion bearings.
Motorized linear slides such as machine slides, XY tables, roller tables and some
dovetail slides are bearings moved by drive mechanisms. Not all linear slides are
motorized , and non-motorized dovetail slides, ball bearing slides and roller slides
provide low-friction linear movement for equipment powered by inertia or by
hand. All linear slides provide linear motion based on bearings, whether they
are ball bearing dovetail bearings, linear roller bearings magnetic or fluid
bearings XY Tables, linear stages, machine slides and other advanced slides use
linear motion bearings to provide movement along both X and Y multiple axis
 What is the function of a bearing?

Generally speaking, a bearing is a device that is used to enable rotational or linear
movement, while reducing friction and handling stress. Resembling wheels,
bearings literally enable devices to roll, which reduces the friction between the
surface of the bearing and the surface it's rolling over.
 How bearing work?

In order to serve all these functions, bearings make use of a relatively simple
structure: a ball with internal and external smooth metal surfaces, to aid in rolling.
The ball itself carries the weight of the load—the force of the load‘s weight is
what drives the bearing‘s rotation. However, not all loads put force on a bearing
in the same manner. There are two different kinds of loading: radial and thrust.

27
A radial load, as in a pulley, simply puts weight on the bearing in a manner that
causes the bearing to roll or rotate as a result of tension. A thrust load is
significantly different, and puts stress on the bearing in an entirely different way.
If a bearing (think of a tire) is flipped on its side (think now of a tire swing) and
subject to complete force at that angle (think of three children sitting on the tire
swing), this is called thrust load. A bearing that is used to support a bar stool is an
example of a bearing that is subject only to thrust load. [3]
Fig.no.4.8. Linear bearing
 Specifications
Important specifications to consider when selecting linear bearings include the

bearing width, length, inside diameter, and dynamic load capacity. The bearing
housing can be flanged, none or open, rectangular, and pillow block. The bearing
may be open or closed.

28
4.2.9. Motor pulley
A pulley is a wheel on an axle or shaft that is designed to support movement and change
of direction of a taut cable or belt, or transfer of power between the shaft and cable or
belt. In the case of a pulley supported by a frame or shell that does not transfer power to a
shaft, but is used to guide the cable or exert a force, the supporting shell is called a block,
and the pulley may be called a sheave.
A pulley may have a groove or grooves between flanges around its circumference to
locate the cable or belt. The drive element of a pulley system can be a rope, cable, belt,
or chain.
Hero of Alexandria identified the pulley as one of six simple machines used to lift
weights.[1] Pulleys are assembled to form a block and tackle in order to
provide mechanical advantage to apply large forces. Pulleys are also assembled as part
of belt and chain drives in order to transmit power from one rotating shaft to another.
 Why do we use a pulley?
Well, pulleys help us by changing the direction of the force we use to lift an
object. ... The real mechanical advantage of a pulley is in using many pulleys at
once. Using multiple pulleys decreases the amount of force necessary to move an
object by increasing the amount of rope used to raise the object.
 Choosing belt and pulley
Generally speaking, for best performance you want at least 6 teeth in contact with the
pulley at any given time. That minimizes the chance of the belt slipping, and helps
reduce backlash even further. In practice that means you want a minimum of a 12
tooth pulley, and I usually try to get at least 18 teeth. Beyond that minimum, fewer
teeth are generally better than more teeth, since a smaller pulley gives both more
torque and more resolution. You get more torque because the longer your "arm", the

29
less torque you have (Imagine the load is mounted on an arm the length of the radius
of the pulley, the shorter that arm, the easier it is to lift the load), and you get higher
resolution, since you have a fixed number of steps per revolution, and a smaller
pulley moves a shorter linear distance per step. [4]
I recommend GT2, 2mm pitch, but you can also use GT3 3mm pitch. A finer pitch is
preferable for the type of movement we do, and the belts are cheaper, but if you find the
2mm belts or pulleys are out of stock, you can go to 3mm pitch without any significant
downsides. If you do choose 3mm pitch pulleys, be sure to get 3mm pitch belts as well.
Fig.no.4.9. Motor pulley
4.2.10. Power supply
 What is power supply?

Power supplies, or PSUs (power supply units), are usually clunky metal boxes
with a row of screw terminals or a bundle of wires at one end and a fan on the
side. Also within a PSU is a rectifier circuit, which converts the wall's AC current
to the DC current a 3D printer needs.
 Requirement of Power supply to the 3d printer.

PSUs tend to contain a transformer (or a series of transformers), which receives
the 110 to 240 volts from the wall and steps them down to a more

30
reasonable 12to 24 volts. Also within a PSU is a rectifier circuit, which converts
the wall's AC current to the DC current a 3D printer needs.
Watts = Volts x Amps
 Heat bed 200x200 MK3 = 120W (12V 10A)

 Hot end, generic = 40W (12V 3.3A)
 Hot end, E3D = 30W (12V 2.5A)
 Motors NEMA17, four of = 25W (3.75V 1.5A each, typical estimate)
 Arduino Mega = 2.5W (0.5A 5V)
 Fans, two of = 3.2W (0.15A 12V each, high estimate)
Fig.no.4.10. Power supply
So without a heat bed you need about 75W (12V 6.25A) which includes a little
overhead. With a heat bed you need at least 200W (12V 16.7A). It's fairly common to
run the electronics on one supply and the heat bed on another supply especially if
using 12V electronics and 24V heat bed
 Power brick

31
Switchable aftermarket laptop power bricks are available in a selection of fixed

wattages, notably 90W and 120W. For variable voltage supplies, check it can
actually supply sufficient current at 12V, some have a high current rating overall
but can only do a lower current at 12V Probably better to over-rate this because
China. AU$15 to AU$35 on Ali express and eBay, search 12v 120w power
supply. Variety of barrel jacks. XBox 360 Slim power brick 135W. 129W 12V
10.83A and 5W 5Vsb 1A. About AU$25 dual barrel connector. [4]
4.2.11. Extruder nozzle

 What is the function of the extruder in a 3d printer?
The filament extruder on a FDM printer is the part that extrudes the
plastic filament in a liquid form and deposits it on a printing platform by adding
successive layers. The printing head is made of many distinct parts including a
motor to drive the plastic filament and a nozzle (or extruder) to extrude the plastic
 What does an extruder do?

Plastics extrusion is a high-volume manufacturing process in which raw plastic is
melted and formed into a continuous profile. Extrusion produces items such as
pipe/tubing, weather stripping, fencing, deck railings, window frames, plastic
films and sheeting, thermoplastic coatings, and wire insulation.
 Extruder: essential part of a 3D Printer.

The 3D extruder is the part of the 3D printer that ejects material in liquid or semi-
liquid form in order to deposit it in successive layers within the 3D printing
volume. In some cases, the extruder serves only to deposit a bonding agent used
to solidify a material that is originally in powder form. Let's discover the function
of the 3D printer extruder, a little but essential part, required for some additive
manufacturing processes.

32
Fig.no.4.11. Extruder nozzle

 Which nozzle should select for 3D printer?
The melted material flows out (or more precisely: is squeezed out) through the
nozzle, which is the tip of the extruder and the printer itself. Nozzles have various
diameters, depending on their intended application. For example, a larger nozzle
is useful, if the model needs to be ready quicker. The layer of material coming out
of the 3d printer nozzle will be thicker and thus there fewer layers will be needed.
Thicker layers also have a larger surface area to be able stick to the filament
applied beforehand. What‘s also important is that when the printing is shorter,
there is less likelihood of something going wrong during the process. But
sometimes smaller diameter nozzles are necessary. This is because a thinner layer
of material allows for better details in the model. Therefore, if you want to print
quicker and with less hassle, pick a thicker nozzle. But if you value precision, a
narrow nozzle is the right choice for you. [4]
Nozzle Sizes, Materials, and Shapes for 3D Printer.
1. Nozzle diameter.
The diameter of the nozzle is, perhaps, the most important factor when choosing a nozzle.
This is because of how much it affects the resolution of the print. The size directly
dictates the horizontal resolution and affects the layer thickness, which determines
vertical resolution.

33
2. Standard Sized Nozzles.
The most common nozzle size, which is included with most printers, is .4 mm. This size
is a good trade-off between resolution and speed. As a nozzle gets larger, the layer
thickness increases, which decreases resolution but increases the print speed. As a nozzle
gets smaller, the layer thickness decreases, which increases resolution but decreases print
speed. A .4 mm nozzle rests between these two sides, which gives it both decent print
3. Nozzle Materials.
Another important factor in the selection of 3D printer nozzles is the material that the
nozzles are made from. Some of the most popular options are brass and steel, but there
are also other options.
4.2.12. Cooling fan
A cooling fan is crucial for good overhang performance on a PLA 3D printed product.
Cooling reduces the level of adhesion to the bed surface, so the fan should not be used
while the first few layers of the item are built up
 Use of cooling fans for printing.
Though 3D printing has been around since the 1980s, the process has only just begun to
enter mainstream society. A 3D printer works by depositing material, such as PLA
thermoplastics, in layers until it has built up a physical object based on a digital file. In
the past, these printers have been used to create jewelry, prototypes, industrial parts and
more. As an increasing number of manufacturers, hobbyists and companies experiment
with the potentials of this process, they‘ve also developed new methods to improve the
quality of the end product. One of those methods is to use a cooling fan to improve
bridging and overhang performance.
A cooling fan is crucial for good overhang performance on a PLA 3D printed product. It
can be programmed to operate at different speeds during the printing process, which has

34
several desirable consequences. Running a fan constantly during printing is detrimental to

the final product. It can cause stringing, a defect in which ―small threads of plastic are
trailed into undesirable areas.‖ Stringing occurs when the machine is unable to remove
the force that pushes the thermoplastic filament out of the nozzle quickly enough. Using a
fan at different speeds also makes the quality of a 3D print more consistent and less
dependent on the temperature of the environment at the time.
There are several other factors to consider when implementing a PLA cooling fan.
Cooling reduces the level of adhesion to the bed surface, so the fan should not be used
while the first few layers of the item are built up. It must also not be directed toward the
hot end of the printer, as this will naturally alter the temperature of the nozzle and thus
affect the heated PLA material. Lastly, fans should not be used when printing items with
ABS, another commonly used thermoplastic material used in 3D printing. This is because
ABS is prone to cracking when cooled.
Before embarking on a 3D printing project that requires the printer to print across gaps or
create overhangs at sharp angles, you might consider the use of a cooling fan. For 3D
prints made of PLA material, a cooling fan can be a crucial factor in obtaining high-
quality prints. When used correctly, a fan will reduce stringing, thus helping you achieve
a cleaner, more appealing final product. [3]
Fig.no.4.12. Cooling fan

35
4.2.13. Timing belt
3D printers are driven by stepper motors in the X and Y dimensions via timing belts and
pulleys. Timing belt drives are a cost effective, low maintenance drive alternative that are
especially suited for linear movement and positioning applications such as those used
in 3D printers.
 Timing belts and its component for 3D printer.
Many of the current 3D printers on the market include timing belt drives. 3D
printers are driven by stepper motors in the X and Y dimensions via timing belt
and pulleys. Timing belt drives are a cost effective, low maintenance drive
alternative that are especially suited for linear movement and positioning
applications such as those used in 3D printers. The drives most commonly used in
3D printing include the T2.5, T5, and Gates Power Grip GT2 2mm pitches.
RepRap is a project founded in 2005 to develop 3D printers that can print most of
their own components. In 2005, RepRap was founded by Dr. Adrian Bowyer, a
senior Lecturer in mechanical engineering in the United Kingdom. There are
currently four RepRap 3D printers: Darwin, Mendel, Prusa Mendel and Huxley
which was released in 2010.[7]
RepRap building has grown within the technology and engineering communities,
but it also now has a growing hobbyist community. Many commercial derivatives
have also surfaced in the past year, including some companies which offer kits
that include all or some of the parts needed to get started with your own 3D
printer. Timing pulleys such as 16-2P06M6CA5 and 20-2P06M6FA5 and timing
belts such as 1164-2P-06 are popular choices because of their early adoption and
cost effective design.

36
Fig.no.4.13. Timing belt
Belt Materials & Sizing.
Belts for 3D printers can be made of a variety of materials, with the most common
being some form of rubber. Many OEM belts are made of rubber, and have a
specific length. When closed, the length is usually exact, or slightly longer than
expected, so that it can be adjusted to the appropriate tension. The same goes with
unclosed belts. Extra space is usually given so that they can be adjusted in the
connector, or attached to a tensioner.
Many belts also have reinforcement, though this isn‘t standard. Though the most
common and most widely appreciated type of reinforcement is fibre glass, other
types of reinforcement can work well, too. Other reinforcement materials include
steel or even nylon. When it comes to belt dimensions, they are often measured in
millimeters, as with most elements in 3D printing. Closed belts have
measurements of thickness, width, and circumference. Unclosed belts have the
same measurements, except they use the term length instead of circumference. [3]
4.2.14. Limit switch

 What is function of limit switch?
The limit switch then regulates the electrical circuit that controls the machine and
its moving parts. These switches can be used as pilot devices for magnetic starter

37
control circuits, allowing them to start, stop, slow down, or accelerate

the functions of an electric motor.
 Limit switch.
In electrical engineering a limit switch is a switch operated by the motion of a

machine part or presence of an object.
Fig.no.4.14. Limit switch
They are used for controlling machinery as part of a control system, as a

safety interlocks, or to count objects passing a point.[1] A limit switch is an
electromechanical device that consists of an actuator mechanically linked to a set
of contacts. When an object comes into contact with the actuator, the device
operates the contacts to make or break an electrical connection.
Limit switches are used in a variety of applications and environments because of

their ruggedness, ease of installation, and reliability of operation. They can
determine the presence or absence, passing, positioning, and end of travel of an
object. They were first used to define the limit of travel of an object; hence the
name "Limit Switch".
Standardized limit switches are industrial control components manufactured with

a variety of operator types, including lever, roller plunger, and whisker type.
Limit switches may be directly mechanically operated by the motion of the

38
operating lever .A reed switch may be used to indicate proximity of a magnet

mounted on some moving part. Proximity switches operate by the disturbance of
an electromagnetic field, by capacitance, or by sensing a magnetic field. Rarely, a
final operating device such as a lamp or solenoid valve will be directly controlled
by the contacts of an industrial limit switch, but more typically the limit switch
will be wired through a control relay, a motor contactor control circuit, or as an
input to a programmable logic controller.
Miniature snap-action switch may be used for example as components of such

devices as photocopiers, computer printers, convertible tops or microwave ovens
to ensure internal components are in the correct position for operation and to
prevent operation when access doors are opened. A set of adjustable limit
switches are installed on a garage door opener to shut off the motor when the door
has reached the fully raised or fully lowered position. A numerical
control machine such as a lathe will have limit switches to identify maximum
limits for machine parts or to provide a known reference point for incremental
motions. [6]
4.3. Assembly of FDM Printer
Nozzle size: 0.4mm
Nuild area: 200 x 200 x 240mm
Print speed: 20 to 100mm/s
Software: Cura
Compatible materials: PLA and ABS
Posibilty of printing offline: yes.

39
Assemble the frame by inserting the nut into the slot and then binding with screws.
Tedious is an understatement, especially when a nut falls out. The bottom of the frame is
held together with threaded screws and opposing nuts. Measure to make certain they are
equally aligned. The front smaller frame unit has a roller bearing for a drive belt. In the
back center, we have the motor mount. The bottom of the frame is held together with
threaded screws and opposing nuts. Measure to make certain they are equally aligned.
The front smaller frame unit has a roller bearing for a drive belt. In the back center, we
have the motor mount. Y-Axis motor is mounted on a flat plate on the back bottom of the
frame. The limit switch is also mounted here.
To the front and back of the lower frame, we attach these small keepers. A rail will be
placed in the small hole that is under this keeper. These two smooth rods are the Y-Axis
rails. On each of them we put 2 linear bearings. On each front side of the frame, build a
small box that will hold the 2 z-axis drive motors. On both the right and left sides, install
the Z-Axis stepper motors under the newly built support boxes. They screw in from the
top. Assemble the z-axis limit switch with 2 plastic spacers and the switch. This is bolted
onto the left frame side. Use the limit switch with the shortest wire. Push the two x-axis
rails through the white holders (located on the z-axis drive). Make certain they are
parallel. [5]
Also we place 2-linear bearings on the top railand 1 on the bottom rail. Bolt the extruder
u-shaped carriage to the linear bearings on thex-axis rods. Also we have move the
assembly a few times to ensure parallel movement before tightening. Bolt on the cooling
fans .One with a heat sink on the left side (to cool the filament) and one on the front to
freeze the deposited filament. The heated build bed is made of the black aluminum sheet
with tape, 4-srews and the heating board. Tape the contractors on heated board with
electrical tape before assembly. We install the build bed onto the build bed frame by
using the 4 screws. We will later use these screws to level the build platform relative to
the extruder nozzle (with 1 mm of spacing). Install the x-axis limit switch by the x-axis
drive motor. This is the longest switch wire. Also, feed the x-axis drive belt around the
motor and the slip bearing on the right of x-axis holder.

40
Tighten the belt to the belt holder at the back of the extruder carriage. Install the control
board at the top of the frame with 4 screws, 4 plastic spacers and a few leveling nuts.
There is also a backing plastic sheet for protection. Connect wires to power supply and
attach to right side of the frame. Install the control board to the left side of the frame. Use
the wire wrap to tidy up the wires. Match the connectors and plug in everything. The
included Cura slicer software had a test part. It seemed to work alright. The white air
scoop is to direct cooling air at the part to help the plastic freeze. [5]
Fig.no.4.15.After Assembly Printer
4.4. Testing of Printer
3d printers are quite dumb as far as electronics go in the sense that there is a lot going on
during a print which is assumed by the electronics. 99% of the time the electronics are
assuming incorrectly.
So for the better prints, we have tune our printer to filament. Ideally we would do most of
these steps for every print or every individual roll of filament. If we use a single brand we
could setup profiles for each material, if we use a single brand and single material we
could do this once. we should do this for every spool of filament or every print. In a our

41
printer we have used single material so we have set printer initially once at a 1st time.At
the 1st time when we have produced part or model there are some defects & error occurs
so for minimizing such errors we have done some following steps –
Step 1: Calibrating the extruder.
 Disconnect hotend from the extruder.

 Cut the filament and repeat this procedure
Step 2: calibrate z height and first layer.
Step 3: Calibrate fan speed.
After completing above mentioned step we have get fine product as designed on CAD
software.
Fig.no.4.16.3D Printed product

42
5. Cost Estimation of 3D printer
3D Printer Specifications:-
 Printing dimensions – 200 x 200 x 240mm

 PLA & ABS can be printed
 Sd card support
 Reprap smart controller
Cost Estimation of 3D printer components:-

Sr. Components Quantity Price Per Unit Total
no. Price
1 Extruded aluminium 2020 6 Mtr 500per/mtr 3000
2 Linear bearing SC8UU 8 300 2400
3 Smooth rod HRC60 3 600per/mtr 1800
4 Rod holder 8mm 12 180 2160
5 Lead screw 8mm (300mm) 2 600 1200
6 Timing belt GT2 2 Mtr 350per/mtr 700
7 Stepper motor – Nema 17- 1.8 5 950 4750
degree
8 Motor pulley -16 teeth 2 250 500
9 Lead screw bearing (8mm) 2 350 500
10 MK 8 Extruder 1 600 600
11 Stepper motor coupler 2 250 500
12 Arduino mega mother board 1 900 900
13 RAMPS -1.4 shield 1 600 600
14 A4988 motor driver ic 5 200 1000
15 E3D hot End 1 1025 900
16 Power supply 240 watt 1 1150 1150
17 Heat bed 1 1339 1339
18 Reprap smart controller display 1 1350 1200
19 12*12 fan 2 200 400
20 Extruder pipe 1 Mtr 350 350
21 Nozzle 3 500 500
22 M6 allen bolts 30 mm 80 3.5 280
23 M3 allen bolts 40 2 80
24 M3 nuts 40 1 40
25 M6 nuts 40 2.5 60
26 PLA 1 1200 1200
27 Stepper motor mount 5 200 1000
28 Limit switches 3 150 350

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29 cables , couplers 7, 7 500 300

30 Heat sink tube ,spiral 2, 2 200 200
Total 29,959
31 3 Printer Manufacturing & Service 6000 6000
Total Cost Estimation 35,959
Table no.3 Cost Estimation of 3D printer

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6. APPLICATIONS
Three-dimensional printing makes it as cheap to create single items as it is to produce

thousands and thus undermines economies of scale. It may have as profound an impact
on the world as the coming of the factory did Just as nobody could have predicted the
impact of the steam engine in 1750 or the printing press in 1450, or the transistor in 1950
. It is impossible to foresee the long-term impact of 3D printing. But the technology is
coming, and it is likely to disrupt every field it touches.
Additive manufacturing's earliest applications have been on the tool room end of the
manufacturing spectrum. For example, rapid prototyping was one of the earliest additive
variants, and its mission was to reduce the lead time and cost of developing prototypes of
new parts and devices, which was earlier only done with subtractive tool room methods
(typically slowly and expensively). With technological advances in additive
manufacturing, however, and the dissemination of those advances into the business
world, additive methods are moving ever further into the production end of
manufacturing in creative and sometimes unexpected ways. Parts that were formerly the
sole province of subtractive methods can now in some cases be made more profitably via
additive ones.
Standard applications include design visualization, prototyping/CAD, metal casting,

architecture, education, geospatial, healthcare, and entertainment/retail.
3D printer came with immense number of applications. All the traditional methods of
printing causes wastage of resources. But 3D printer only uses the exact amount of
material for printing. This enhances the efficiency. If the material is very costly, 3d
printing techniques can be used to reduce the wastage of material.
Consider printing of a complex geometry like combustion chamber of a rocket engine.

The 3D printing will enhances the strength and accuracy of the object. Conventional

45
methods use parts by parts alignment. This will cause weak points in structures. But in
the case of 3D printed object, the whole structure is a single piece. [7]
 Aerospace and Automotive sector
With the help of 3-D-printed components which are used for aircrafts and parts are 70%
less weighing but identically tough as conventional parts, indicating cost reduction and
carbon reduction and emissions of unwanted particle. It uses less raw constituents and
manufactures parts which are less weight, complicated but possess more strength [4].
 Medicine
Medical sector is one of the most promising areas of usage. It is being applied to face
many medical situations, and develop medical research, also combining the field of
―regenerative medicine‖. In 2012, using a 3-D printer, engineers and doctors at Hasselt
successfully experimented the very first patient-specific instrument of prosthetic jaw
transplant.
 Rapid Manufacturing
Advancements in Rapid Prototyping have presented materials those are necessary for
final manufacturing, leading to the possibility of manufactured finished components and
parts.
 Mass Customization
Many industries have provided services where people can recreate their desirables
implementing simple web-based customizing software. This now enables customers to
replicate cases of their mobiles. Nokia has displayed the 3D designs of their mobiles so
that owners will be able to recreate their own phone case.

46
7. ADVANTAGES & DISADVANTAGES
 Create anything with great geometrical complexity.
 Ability to personalize every product with individual customer needs.
 Produce products which involve great level of complexity that simply could not
be produced physically in any other way.
 Additive manufacturing can eliminate the need for tool production and therefore
reduce the costs, lead time and labour associated with it.
 3D printing is an energy efficient technology.
 Additive Manufacturing use up to 90% of standard materials and therefore

creating less waste.
 Lighter and stronger products can be printed.
 Increased operating life for the products.
 Production has been brought closer to the end user or consumer.
 Spare parts can be printed on site which will eliminate shipping cost.
 Wider adoption of 3D printing would likely cause re-invention of a number of

already invented products. [6]

47
DISADVANTAGES
 Since the technology is new, limited materials are available for printing.
 Consumes more time for less complicated pats.
 Size of printable object is limited by the movement of extruder.
 In additive manufacturing previous layer has to harden before creating next layer.
 Curved geometry will not be much accurate while printing. [6]

48
8. Conclusion
Though 3D printing is still a growing technology, it already has many benefits and
drawbacks. While many people agree that this technology could change the world,
there are also those who believe it could have extreme consequences if it is not
researched and tested thoroughly. As the technology beings to grow more and more
throughout the next couple of years there will be more information and data that
will determine whether it is a technology that is here to stay or it is something that
will simply not make it
In medicine, hospitals are already printing structural body components. In labs they
are working on printing out organs, though it will be a while before this becomes
common. Due to the price it's access to world is very limited but through this
project there will be an increase in the access of 3D printers. We made our own 3D
printer with a price of just 35000 Rs. It is comparatively low to market price. We
can use this for many purpose such as making models, in automotive & aerospace,
also in medical sector.

49
9. References
[1] Bradshaw, B. (2011, May 1) The evolution of rapid prototyping. Rapid Prototyp Jr ;
15: 216-225.
[2] Guo, N. & Leu, M.C. (2013) Schmitt SM. Rapid prototyping in dentistry &
automotive : Technology and application. Int J AdvManufTechnol ; 29: 317-35.
[3]Price Waterhouse Cooper. (2013) Rapid Prototyping in Europe and Japan. 1977
Loyola College of Maryland, Baltimore, MD, 5-20.
[4]Price Waterhouse Cooper. (2013) Three-dimensional rapid prototyping technologies

and key.
[5] S. Bradshaw, A. Bower, and P. Haufe. ―The Intellectual Property Implications of Low-
cost 3D printing,‖ SCRIPTeD, vol. 7, (1), 2010, pp. 5-31, doi: 10.2966/scrip.070110.5.
[6] H. Lipson and M. Kurman, Factory at Home: The Emerging Economy of Personal
Manufacturing. Washington: U.S. Office of Science and Technology, 2010, n.p
Internet:-
[7] https://en.wikipedia.org/wiki/3D_printing
[8] https://www.3dhubs.com/knowledge-base/introduction-fdm-3d-printing

50

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Savitribai Phule Pune University

3D printing or additive manufacturing (AM) is any of various processes for making a

AM technologies found applications starting in the 1980s in product development, data

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

medical industries, biotech (human tissue replacement), fashion, footwear, jewellery,

1.1 Problem Statement

1. Study the 3D printing technology

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

4. To study and fabricate (Assemble) 3d printer

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

The step by step methodology of project development is as per following:

Fig.no.1.2. Process flow chart

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

3. FUSED DEPOSITION MODELEING

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

3.1 PROCEDURES FOR PRINTING

Fig.no.3.2 - Printing process

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

3.2 Designing using CAD

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

3.3 Conversion to STL file format

An STL file is a triangular representation of a 3D surface geometry. The surface is

The native STL format has to fulfill the following specifications:

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

Fig.No.3.3 Pre-process for 3D Printing

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

3.4 Rapid prototyping

Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

4.1 Components are used for assembly

4.2 Components & there specifications

4.2.1 Stepper motor –Nema 17

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

Stepper Motor Specifications

Fig.no.4.1 Stepper Motor –Nema 17

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

4.2.2 Hard chrome bar

External Diameter Accuracy: f8

Fig.no.4.2. Hard chrome bar

4.2.3. Lead screw

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

An important advantage of the screw-rail configuration for controlling linear motion in

Fig.no.4.3 Lead Screw

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

4.2.4. Motor coupler

Fig.no.4.4 Motor Coupling

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

4.2.5. Hot bed

 WHY HOT BED USED?

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

 What is the function of hot bed in 3D printer?

 Heat beds have two purposes:

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

Fig.no.4.5. Hot Bed

4.2.6. Graphic display

Fig.no.4.6.1. LCD Layered Diagram

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)

 How LCDs Work?

TSSM‘S BSCOER, NARHE, B.E. (MECHANICAL)