Methodology

STEP 1: Designing parts

There are various steps involved in the process of printing of a part or model using a 3D Printer. here
all the steps involved in the printing process in our 3D Printer are explained in detail.

The first and foremost step in the process of 3d Printing is to design the part or model to be
Printed in any of the 3D Modelling Software’s such as Fusion 360, Cura, Xloader, pronterface…etc.
I. In our case we had used Solidworks 3D Modelling Software to design a part for example
in this case a Twisted Hexagon with a circular cut in between.
II. Required dimensions for the part to be printed is decided in the design stage for
example the height of this hexagon is 15mm.

STEP 2: Assembly or Saving the Design in. STL format

I. The designed file is saved as. STL format (Stereolithography). This file format is
supported by many software packages; it is widely used for rapid prototyping, 3D
printing and computer-aided manufacturing.
II. An STL file describes a raw unstructured triangulated surface by the unit normal and
vertices (ordered by the right-hand rule) of the triangles using a three dimensional
Cartesian coordinate system.
STEP 3: Installation Firmware

( Slicer Software)

(Part Print View)

I. The. STL file is opened in Slic3r Software where the view of the object or the position
in which the object would be printed can be seen.
II. After checking the view, the G-code of the design in this case a Twisted Hexagon can
be generated by clicking on the option ‘Export G-Code’.
 STEP 3: Importing the G-code file and Printing in Pronterface Software

Fig: Pronterface Software

I. The file created is then loaded in the pronterface which connects Arduino with the
computer.
II. From the pronterface software we can give print command. The Arduino mega will
thus send command to the stepper motor & we get a 3D model.
III. Figure above is a snap shot of pronterface software showing the wagon wheel through
which the motions of the 3D printer can controlled.

After printing:
 Actual 3D printed object

How does firmware work?

The firmware is the software that runs on the 3D printer’s microcontroller. Its purpose is to translate
the contents of a G-code file into electrical signals that activate or deactivate 3D printer
components. Briefly, the G-code file is a list of commands and coordinates that describes the 3D
model to be printed. The G-code is generated on a computer by a program known as a slicer based
on the desired 3D model. The ins and outs of this process are discussed in a separate section
(see: Slicers). But back to talking about G-code. 99% of the G-code is made up coordinates that look
something like the following:

G1 X50 Y20 E15

We can dissect this code by looking up the G-code commands. G1 instructs the microcontroller to
prepare for a linear movement. Then the new coordinates, which are X = 50, Y = 20, and E = 15, are
read in by the firmware. For 3D printers, the E stands for the extrusion drive. When an E is present in
a G code coordinate then either filament is being deposited or retracted. At this point the firmware
needs to perform some basic calculations to determine how far off each carriage is from the
required positions. After determining directions and distances the microcontroller will send step
pulses to the stepper drivers, which will move the appropriate stepper motors.
The above sequence of events relies on the assumption that the firmware understands the setup of
the 3D printer that it is controlling. A printer motherboard can be used in a variety of different 3D
printer builds or even non-3D printer builds, like laser cutters and CNC routers. Therefore, it is critical
that the firmware understands the exact configuration of the 3D printer down to the transmission
specifications for each axis and extrusion drive(s).

CONFIGURATION VARIABLES

The appropriately named configuration variables are where your printer’s specific information
is stored. These variables are typically located in an accessible file known as a configuration
file. Way back in the day you had to understand C/C++ in order to program a custom 3D
printer. Today, that is certainly not the case and very little if any coding experience is needed
to setup up the firmware. Prior to looking up the configuration variables, it’s a great exercise
to brainstorm what these variables might be. Imagine that you are the microcontroller for a
3D printer, and you have a long list of G-code that you need to turn into a physical 3D object.
Design and Analysis of 3D printer:

Fig. 1. Diagram showing FDM 3D- printer schematic

Fig. 2. FDM 3D- printer CAD model

3D printer uses a combination of components that operate simultaneously to provide the

manufacturer with required output using the input digital file, the basic components are listed
below:
A. Print Bed (Tray):
The flat surface where the filament is layered during printing is Print bed. It is used at required
temperature as per the need of filament used for printing. The heat bed is used to maintain the
temperature of the printed section for layering of the next layer.
B. Extruder:
It is the component that ejects and supply the plastic filament (or any suitable filament) into the
‘hot-end’. Extruders are typically fixed into the hot-end, pushing the filament inside a tube, into
the hot-end by use of a simple two gear mechanism. Sometimes a dual extruder is used, when
there is need to print two different materials simultaneously.
C. Hot-end:
A hot-end is consists of a temperature sensing device, heat source and an extrusion tip where
plastic filament is fed through to deposit molten material. The size of slot hole varies typically
from 0.2mm to 0.8mm. Smaller size hole increases the detailing of the produced print resulting
in increased print time.
D. Filament:
It is the material which is heated in order to print 3D solid object. It ejects from the nozzle in the
form of semi-solid thermoplastic.

Analysis of printer:
There are three types of motion of the extruder i.e., in X, Y, Z directions. Horizontal direction are
X, Z directions while vertical motions is Y axis motion.
Design Calculation:
1) Horizontal Frame (Static Load Analysis)
Analysis for horizontal rail for three position of extruder.
S. No. Parameters Value
1 Load due to weight of W1 =
frame 2.94N
2 Load due to extruder W2 =
assembly 2.94N
For center position of extruder:
Total weight acting = W1 + W2 = 5.88 N
W1= W2 =2.94N
𝐵𝑀𝐴=- (2.94 ×350) + (5.88 × 175)
=0
𝐵𝑀𝑐 = (𝑅𝐴 × 175) = 514.5Nmm

For extruder at 87.5mm from the left side:

 For extruder at 87.5mm from the right side:

On calculating the bending moments we came to know that the maximum deflection occurs at
the center position of extruder. So the design of the frame is done for the center position of
extruder.
2) Heat analysis of the extruder:
CAD assembly (Nozzle, pipe and Heat Sink):

Creating Contact region between the assembly parts:

Creating mesh of total body and Contact surface:

Temperature increased to 240 C due to heating rod in the nozzle.

Convection of Brass (Nozzle). Input (film coefficient)- 105 W/C-m2

Resultant FEA for assembly at 240C

 The extruder head was designed and analyzed to ensure a better heat concentration only in
the area of the nozzle, avoiding as much as possible dissipation of heat to the aluminum frame
or to the environment. Furthermore, lowering temperature of the ABS material pas-sage,
improves the sliding of the material, because it is heated only in the area of extrusion, where it is
needed.

Future Scope and Applications:

40 % of 3D printing patent applications are medical. A Process called bio texture modeling allows us
to print stimulated organs with texture & wetness of real things.

3D Scans of patients can help create custom built prosthetic and face prosthetics.

Customized bone replacements can be executed 3D printing.

Orthodontic appliances, temporary teeth, dental crowns can be 3D printed.

Bio printing is the process of printing out organic tissue which could facilitate
organ transplants.
Conclusion:
a) We get high precision regardless of uneven heating or bowed build plate.
b) Sensors ensure the print head is always moving parallel to the build plate.
c) No wasting time fiddling with the bed and Z height. It’s easy of for
inexperienced machinists to use it .
d) Use of filament effective reduces the wasting of filaments.
e) Hence we are intended to produce a low cost 3D printer for all with an
estimated cost of 11000 INR.

Abbreviations:
i. STL: stereo lithography
ii. CAD: Computer aided designing
iii. ABS: Acrylonitrile butadiene styrene
iv. BMD: Bending moment diagram
v. SFD: Shear force diagram
vi. BM: Bending moment