applied
sciences
Article
Design of an Atypical Construction of Equipment for Additive
Manufacturing with a Conceptual Solution of a Printhead
Intended for the Use of Recycled Plastic Materials
Jakub Kaščak 1 , Štefan Gašpár 2 , Ján Paško 2 , Lucia Knapčíková 3, * , Jozef Husár 3 ,
Petr Baron 1 and Jozef Török 1






Citation: Kaščak, J.; Gašpár, Š.;
Paško, J.; Knapčíková, L.; Husár, J.;
Baron, P.; Török, J. Design of an
Atypical Construction of Equipment
for Additive Manufacturing with a
Conceptual Solution of a Printhead
Intended for the Use of Recycled
Plastic Materials. Appl. Sci. 2021, 11,
2928. https://doi.org/10.3390/
app11072928
Academic Editor: Francesco Ciardelli
Received: 27 February 2021
Accepted: 23 March 2021
Published: 25 March 2021
Publisher’s Note: MDPI stays neutral
with regard to jurisdictional claims in
published maps and institutional affil-
iations.
Copyright: © 2021 by the authors.
Licensee MDPI, Basel, Switzerland.
This article is an open access article
distributed under the terms and
conditions of the Creative Commons
Attribution (CC BY) license (https://
creativecommons.org/licenses/by/
4.0/).
Appl. Sci. 2021, 11, 2928. https://doi.org/10.3390/app11072928
1 Department of Computer Aided Manufacturing Technologies, Faculty of Manufacturing Technologies with a
Seat in Prešov, Technical University of Košice, Štúrova 31, 08001 Prešov, Slovakia; jakub.kascak@tuke.sk (J.K.);
petr.baron@tuke.sk (P.B.); jozef.torok@tuke.sk (J.T.)
2 Department of Technical Systems Design and Monitoring, Faculty of Manufacturing Technologies with a Seat
in Prešov, Technical University of Košice, Štúrova 31, 08001 Prešov, Slovakia; stefan.gaspar@tuke.sk (Š.G.);
jan.pasko@tuke.sk (J.P.)
3 Department of Industrial Engineering and Informatics, Faculty of Manufacturing Technologies with a Seat in
Prešov, Technical University of Košice, Bayerova 1, 08001 Prešov, Slovakia; jozef.husar@tuke.sk
* Correspondence: lucia.knapcikova@tuke.sk; Tel.: +421-55-602-6407
Abstract: This article presents the variability of Fused deposition modelling (FDM) technology and
the possibilities of its use in the design and implementation of a prototype atypical device. The
assumptions of the behaviour of individual components and subsystems of the design result from an
extensive application of the finite element method and motion analysis of subsystems and various
parts of the structure. The use of this method to such an extent accelerated the design process and its
implementation. The proposal itself reflects the current state of this technology and its focus is on
improving sustainable development. As is generally known, great efforts are currently being made
to reduce plastic waste volume and its environmental burden. The proposed concept is modified to
replace the final treatment of the top layers of the models, called “ironing” by non-planar layering
of material. At the same time, it points out the advantages of this method in reducing energy
requirements and the time required to produce models. The conclusion is a conceptual design of
a printhead for a proposed prototype, designed to use recycled FDM, intending to streamline the
possibility of recycling with little serial and piece production. This process thus closes the circle
of opportunities published by us, which in the future can contribute to the optimisation of this
technology towards increasing the efficiency of resource use, reduction of energy demands and
environmental burden.
Keywords: fused deposition modelling; fused filament fabrication; non-planar printing; plastic
waste; recycling; alternative design
1. Introduction
According to previous surveys and trends for the first quarter of 2019, Fused de-
position modelling (FDM) technology still accounts for most additive manufacturing
technologies, up to 46%. Despite the development of new technologies and designs, FDM
technology increased compared to 2018. Excessive production of plastic waste is currently
a global problem. There are now 12 different basic types of additive devices on the market
(Figure 1). As a result, this technology’s demand, despite its now common occurrence, is
growing in schools or households and various industries [1]. For this reason, the technology
can also be considered as a significant producer of plastic waste, to which its “hobby” use
also makes a significant contribution, which makes it difficult to monitor in this respect [2].
https://www.mdpi.com/journal/applsci
Appl.
Appl. Sci.
Sci.2021,
2021,11,
11,x2928
FOR PEER REVIEW 2 2ofof26
25

50% 0.46

40% 0.36 0.38

0.33 0.33
30% 0.25
0.21
20%
0.13 0.13
0.15 0.07 0.1 0.1
10% 0.08 0.06 0.040.04 0.02
0.12 0.04 0.02 0.02 00.02
0%
FDM SLS SLA DMLS/ Polyjet Multi DLP Binder EBM CLIP/ SDL LOM
SLM jet jetting CDLP
fusion

2018 2019
Figure 1. Additive manufacturing technologies and their share in the industry [1].
Figure 1. Additive manufacturing technologies and their share in the industry [1].
This article closes the imaginary circle of reducing the impact of the environmental
loadThis articleby
produced closes
FDM the imaginaryaddressed
technology, circle of reducing the impactPolylactic
in the publication of the environmental
Acid and Its
load produced
Cellulose BasedbyComposite
FDM technology, addressed
as a Significant Toolinfor
thethe
publication
Production Polylactic
of Optimized Acid Models
and Its
Cellulose
ModifiedBased Composite
for Additive as a Significant
Manufacturing Tool publication
[3]. This for the Production
presented of Optimized Models
the possibilities of
Modified for Additive
using topological Manufacturing
optimisation of models [3].
forThis
FDMpublication
productionpresented
and composite the possibilities
biodegradable of
plastics.
using Another optimisation
topological phase aimed of at models
improving the state
for FDM of sustainable
production development
and composite in FDM
biodegrada-
technology
ble plastics. isAnother
the modification
phase aimedof theatprocess
improving characteristic
the state of
ofthis type of model
sustainable production
development in
and the
FDM recyclingisofthe
technology plastic waste associated
modification with production
of the process [4,5].ofWe
characteristic consider
this type ofcreating
model
an alternative
production andtype of construction
the recycling with
of plastic the possibility
waste associated of integrating
with production a combined
[4,5]. We print
con-
headcreating
sider to be the anmain benefittype
alternative of the ongoing research.
of construction with theAs presented
possibility of in the publication,
integrating a com-
FDM print
bined technology
head toworks
be thewith
main3D objects
benefit of divided
the ongoinginto research.
planes orAs layers. Theseinthen
presented the serve
pub-
as perimeters for creating 3D objects. This research aims to create
lication, FDM technology works with 3D objects divided into planes or layers. These then a prototype device to
finishasFDM
serve technology
perimeters items by
for creating 3Dapplying
objects. Thisnon-planar
researchlayers.
aims toDue to the
create use, recycling
a prototype device of
filaments
to finish FDM andtechnology
failures from FDM
items byproduction, we intendlayers.
applying non-planar that this
Duedevice
to the allows the use
use, recycling
offilaments
of recycled plastic in various
and failures from forms. The integration
FDM production, of thethat
we intend printhead,
this device which,
allowsby the
its very
use
nature, can process such material, has a significant impact on the recycling
of recycled plastic in various forms. The integration of the printhead, which, by its very process itself in
the industry.
nature, can process such material, has a significant impact on the recycling process itself
in theOne of the current trends and at the same time a way to reduce the time required for
industry.
the production of the model
One of the current trendsisandtheatso-called
the samenon-planar
time a waymethod
to reduce of layering the material.
the time required for
the production of the model is the so-called non-planar method of layering the These
We currently encounter this method especially in its application to robotic arms. are
material.
difficult
We to compare
currently encounterwiththis
conventional commercial
method especially FDMs.
in its However,
application their high
to robotic arms.accuracy,
These
speed, rigidity of the entire system and other properties that make
are difficult to compare with conventional commercial FDMs. However, their high accu- them at the forefront in
many fields, are also directly proportional to their price. The article
racy, speed, rigidity of the entire system and other properties that make them at the fore- presents the process of
design and presentation of partial results achieved by the created prototype of the device,
front in many fields, are also directly proportional to their price. The article presents the
the main benefit of which is to make this method of model production available to a wider
process of design and presentation of partial results achieved by the created prototype of
group of users.
the device, the main benefit of which is to make this method of model production availa-
ble
1.1.toNon-Planar
a wider group of users.
Layering of Material
In connection with FDM technology application to robotic arms or other atypical
1.1. Non-Planar Layering of Material
structures, whose structures are inspired by these arms, a simple question arises: whether,
in theIncurrent
connection
state,with FDMmethod
accuracy, technology application
of production andtoimplementation
robotic arms or of other atypical
new materials,
structures, whose structures are inspired by these arms, a simple question
it is necessary or not to approach the production of models differently. Due to current arises: whether,
in the current
trends state, accuracy,
and developments in method of production
this technology, and implementation
improvement of operatingofparameters
new materi- of
als, it is necessary
production and itsorapplication
not to approach the production
to sophisticated of models
equipment differently.
types, innovation Dueisto current
necessary
trends
for theand developments
production process in this[6,7].
itself technology, improvement of operating parameters of
production and its application to sophisticated
One of the directions FDM technology is taking equipment types, innovation
is the change in the sameisapproach
necessaryto
for the production process itself [6,7].
generating printhead paths or changing the material method. The current way of generating
One ofconsists
toolpaths the directions FDMthe
of dividing technology
object to beis taking
createdisinto
the change in the
planes that same approach
correspond to the
to generating
layer’s height.printhead
This means paths
thatoreach
changing
of thethe materialismethod.
perimeters formedThe firstcurrent
in the Xway
andofY gen-
axes,
erating
and only toolpaths
after itsconsists of dividing
completion will there thebeobject to be
a shift created
in the intoThis
Z-axis. planes that correspond
method of layering
Appl. Sci. 2021, 11, x FOR PEER REVIEW 3 of 26

Appl. Sci. 2021, 11, 2928 3 of 25

to the layer’s height. This means that each of the perimeters is formed first in the X and Y
axes, and only after its completion will there be a shift in the Z-axis. This method of lay-
the material
ering has been
the material has used
been from
used the
from beginning of FDM
the beginning of technology
FDM technology development until
development
today.today.
until This process indicates
This process that FDM
indicates thatdevices, in slanginreferred
FDM devices, to as 3Dtoprinters,
slang referred operate
as 3D printers,
realistically
operate in the 2.5inaxes
realistically the during
2.5 axestheir operation.
during Such a method
their operation. Such a of layering
method of the material
layering the
is associated with the print surface characteristic state and their different
material is associated with the print surface characteristic state and their different proper-properties for
their orientation to the device coordination system during printing
ties for their orientation to the device coordination system during printing [8,9]. [8,9].
Nowadays, narrow groups of researchers specialising in FDM technology deal with with
this issue
this issue within
within institutions
institutions andand companies.
companies. Autodesk
Autodesk is is one
one of
of these
these companies.
companies. This
This
company, which
company, which is is one
one of
of the
the leaders
leadersand
andpioneers
pioneersininCAD
CAD// CAMCAM andand CAE
CAE software,
software, has
has
since July 2018 officially registered patent no. US10005126B2. [10]. This
since July 2018 officially registered patent no. US10005126B2. [10]. This patent describes patent describes
the so-called
the so-called“Systems
“Systemsand andmethods
methods forfor
enhanced
enhanced3D 3D
printing”. OneOne
printing”. of these methods
of these uses
methods
a non-planar layering of the material shown in Figure
uses a non-planar layering of the material shown in Figure 2 [8]. 2 [8].

Figure 2. Method of generating individual layers in a planar process of layering [8].

This method of printing

printing involves
involves modifying
modifying the the Slicer
Slicer program.
program. Since, as already
mentioned, the thegeneration
generationofofpathspathsforfor the
the printhead
printhead takes
takes place
place in planar
in planar layers,
layers, it is
it is nec-
necessary
essary to implement
to implement thethe Z-axis’s
Z-axis’s activeparticipation
active participationduring
duringthethe printing
printing process. This
function is only involved in G-code generation in a few situations, such as e.g., approach
to reference points by rapidly moving the device or printing printing in a special mode for creating
thin-walled models through spiralisation continuous printing
thin-walled models through spiralisation continuous printing ofof one
one edge
edge perimeter.
perimeter. The The
necessary function is already implemented within the Slicer program, but it is
necessary function is already implemented within the Slicer program, but it is inactive
inactive in in
the production
the production of models in
of models the usual
in the usual way.
way. Due
Due toto their
their previous
previous research
research andand knowledge
knowledge
in non-planar
in non-planar layering
layering ofof materials
materials to to verify
verify the
the theory,
theory, the
the program
program Slic3r
Slic3r was
was modified.
modified.
The
The software modification itself consisted of several steps related to emulating the Linux
software modification itself consisted of several steps related to emulating the Linux
system, compiling
system, compiling the the already
already existing
existing Slic3r
Slic3r software
software andand adding
adding newnew functions.
functions. After
After
these steps,
these steps, they were able
they were to process
able to process the
the first
first models
models andand test
test their
their implementation
implementation using using
available FDM
available FDM devices.
devices.After
After the
the software
software was was successfully
successfully modified
modified andand the G-code
the G-code was
was generated, it was time to implement them. However,
generated, it was time to implement them. However, the performance itself was the performance itself was
accom-
accompanied
panied by several
by several technical
technical problems.
problems. TheseThese largely
largely resulted
resulted fromfrom the very
the very design
design of
of the
the FDM
FDM device
device andand its printhead
its printhead [11–13].
[11–13].
The first device used was Ender 33 from
The first device used was Ender from Creality. This device
Creality. This device isis aa specific
specific andand cur-
cur-
rently very widespread Cartesian-type device. Due to its shape and construction, several
rently very widespread Cartesian-type device. Due to its shape and construction, several
modifications were necessary at the outset. Since the printhead and its cooling are not
modifications were necessary at the outset. Since the printhead and its cooling are not
adapted to the Z-axis’s active use, it was required to disassemble all the printhead’s cooling
adapted to the Z-axis’s active use, it was required to disassemble all the printhead’s cool-
elements. The resulting model did not meet the required quality. The main reason was the
ing elements. The resulting model did not meet the required quality. The main reason was
fact that the Z-axis of this device is controlled only unilaterally. This fact caused significant
the fact that the Z-axis of this device is controlled only unilaterally. This fact caused sig-
geometric inaccuracies and poor adhesion of non-planar layers in the region of the model,
nificant geometric inaccuracies and poor adhesion of non-planar layers in the region of
which is farthest from the X-axis’s initial position. Due to this fact, a more compact device
the model, which is farthest from the X-axis’s initial position. Due to this fact, a more com-
of the same type was used in the solution. The Anet device, type-designated E12, has
pact device of the same type was used in the solution. The Anet device, type-designated
two guide screws and a sufficient printing volume to carry out non-planar printing. The
E12, has two guide screws and a sufficient printing volume to carry out non-planar print-
successfully created model can be seen in Figures 2 and 3.
ing. The successfully created model can be seen in Figures 2 and 3.
 Appl.Sci.
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2021, 11, 2928
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FORPEER
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REVIEW 44ofof 26
26
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Figure3.3.Method
Figure Methodofofgenerating
generatingindividual
individuallayers
layersininaanon-planar
non-planarmethod
methodofoflayering
layering[8].
[8].
Figure
Figure3.3.Method
Methodofofgenerating
generatingindividual
individuallayers
layersininaanon-planar
non-planarmethod
methodofoflayering
layering[8].
[8].
Duringthe
During themodel
modelmanufacturing
manufacturingprocess, process,bothbothmethods
methodswere wereusedusedto toshape
shapethe thetest
test
During
Duringthe themodel
modelmanufacturing
manufacturingprocess, process,both bothmethods
methodswere wereusedusedto toshape
shapethe thetest
test
specimen
specimen used.
used. Due
Due to
totothethe
the heating
heating pad
pad and
and its
itsitsshape,
shape, the
the model’s
model’s production
production began
began as
as as a
specimen
specimenused.used.Due Dueto theheating
heating pad padandandits shape,
shape,the model’s
the model’s production
production beganbeganas aa
standard
standard planar
planar print.
print. It created the planar basis of the model up to 50% of its height.
a standard
standard planar
planar print.
print. ItIt created
created
It created thethe
the planar
planar
planar basis
basis ofof
basis
of the
thethemodel
model
model up
upup toto50%
to 50%
50%ofofofits
its height.
itsheight.
height.
Subsequently, these
Subsequently, these planar
planar surfaces
surfaces were were usedused asas support
support for for non-planar
non-planar perimeters,
perimeters,
Subsequently,these
Subsequently, theseplanar
planarsurfaces
surfaceswere wereusedusedasassupport
supportfor fornon-planar
non-planarperimeters,
perimeters,
formedin
formed inthe
thehigher
higherlayers
layersof ofthe
themodel,
model,as asshown
shownin inFigure
Figure4.4.An Aninteresting
interestingfeature
featureof of
formedin
formed inthe
thehigher
higherlayers
layers ofof
thethe model,
model, as as shown
shown in in Figure
Figure 4. An
4. An interesting
interesting feature
feature of
this
this type
type
of this type of material
of material
material
of material layering
layering
layering was
was was the
thethe significant
significant
significant saving
saving
saving of
ofof time
time required
required
timerequired
requiredto to
to create
create
tocreate test
test
createtest
test
this type of layering was the significant saving of time
models.With
models.
models. Withthe
With thesame
the sameoperating
same operatingparameters
operating parametersand
parameters andmaterial
and materialconsumption
material consumptiondiffering
consumption differingby
differing byonly
by only
only
models. With the same operating parameters and material consumption differing by only
5%,there
5%,
5%, therewas
there wasaaa30%
was 30%time
30% timesaving
time savingfor
saving foraaamodel
for modelcreated
model createdusing
created usingthe
using thenon-planar
the non-planarmethod.
non-planar method.
method.
5%, there was a 30% time saving for a model created using the non-planar method.

Figure4.4.Display
Figure Display acombination
combination
combinationofof planar
ofplanar and
planarand non-planar
andnon-planar material
non-planarmaterial
material layering
layering (1—non-planar
(1—non-planar layer,
layer,
Figure 4. Display aacombination of planar and non-planar layering
material layering (1—non-planar
(1—non-planar layer,
layer,
2—layer
2—layer
2—layer height,
height,
height, 3—step
3—step
3—step length,
length,
length, 4—extrusion
4—extrusion
4—extrusion width,
width,
width, 5—planar
5—planar
5—planar layers,
layers,
layers, 6—print/object
6—print/object
6—print/object surface)
surface)
surface) [8].
[8].
[8].
2—layer height, 3—step length, 4—extrusion width, 5—planar layers, 6—print/object surface) [8].

Thenature
The natureof ofthe
of theresulting
the resultingsurface
resulting surfaceobtained
surface obtainedby
obtained bythe
by thenon-planar
the non-planarmethod
non-planar methodof
method oflayering
of layering
layering
The nature of the resulting surface obtained by the non-planar method of layering
the materialallowed
thematerial
material allowedbetter
allowed betterprediction
better predictionof
prediction ofmechanical
of mechanicalproperties
mechanical propertiesof
properties ofthese
of thesemodels
these modelscompared
models compared
compared
the material allowed better prediction of mechanical properties of these models compared
to conventional
conventional
to conventional
conventional planar planar
planar models.
models.
planar models.
models. This This obtained
This obtained
obtained resultsresults from
from
results from
from the the
the variable
variable
the variable orientation
orientation
variable orientation
orientation of of
of the
ofthethe
to the
surfaces’ contact
surfaces’ contact surfaces,
contact surfaces, which
surfaces, which
which can can lead
can lead
lead to to a change
change
to aa change
change in in
in the
in thethe distribution
distribution
the distribution
distribution of of
of forces
forces
of forces
forces in in
in the
in the the
the
surfaces’
layers,e.g.,
layers, e.g.,under
undertensile
tensilestress.
stress. Planarregions
stress.Planar regionscreated
createdusing
usingFDM FDMtechnology
technology
technologyare are usually
areusually
usually
layers, e.g., under tensile stress. Planar regions created using FDM technology are usually
lessresistant
less resistant
resistantto to tensile
totensile stress.
stress.ItItfollows
tensilestress. followsfromfrom
fromthethe same
thesame
sameway way
wayof of assembling
ofassembling
assemblingthe the model
themodel
modelfrom from
from
less resistant to tensile stress. It follows from the same way of assembling the model from
planar surfaces.
planarsurfaces.
planar This resistance
surfaces.This resistance is lowest
resistance islowest
lowestin in the
inthe direction
thedirection
directionof of the
ofthe Z-axis.
theZ-axis. Divide
Z-axis.Divide
Dividethem them
theminto into
into aa
planar surfaces. This resistance isis lowest in the direction of the Z-axis. Divide them into aa
mixture
mixture of of tensile
tensileand
of tensile
tensile and shear
andshear forces,
shearforces, and
forces,and
andthe the theoretical
thetheoretical assumption
theoreticalassumption
assumptionof of the
ofthe distribution
thedistribution
distributionof of
of
mixture
these forces and
depending shear
on theforces, and
increased the theoretical
displacement assumption
ofof thethelayers of the
caused distribution
by bystress cancan ofbe
these forces
these forces depending
forces depending
depending on on the
on the increased
the increased displacement
increased displacement
displacement of of the layers
the layers caused
layers caused
caused by stress
by stress
stress cancan
these
seen in Figure 5 [14,15].
beseen
be seen inFigure
in Figure 55[14,15].
[14,15].
be seen in Figure 5 [14,15].

Figure5.5.
Figure Illustrationof
5.Illustration ofthe
theassumption
assumption
assumptionof of the
ofthe change
thechange
changeinin the
inthe shear
theshear force
shearforce component
forcecomponent
componentFS FS as
FSasasaafunc-
function
func-
Figure 5. Illustration of the assumption of the change in the shear force component FS as aafunc-
tion
of
tionofof
the the
ofthe displacement
displacement
thedisplacement of
displacementoftheof the
layers
ofthe layers
thelayers induced
induced by
layersinduced the
inducedby by the forces
forces
bythe during
theforces during
forcesduringthe the tensile
tensile
duringthe test
thetensile test
[15].
tensiletest [15].
test[15].
[15].
tion
Appl. Sci. 2021, 11, x FOR PEER REVIEW 5 of 26
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Appl. Sci. 2021, 11, x FOR PEER REVIEW 5 of 26

1.2. Problems in the Field of Non-Planar Layering of Material by Commercial Equipment

1.2. Problems
1.2.During
Problemsthein the
theField
inclosure ofofofthe
Field Non-Planar
Non-Planar
model using Layering
Layering ofofMaterial
Material
this method, by
byCommercial
several problemsEquipment
Commercial Equipment
arise due to the
During
construction
During ofthetheclosure
the closure of
FDM deviceofthe themodel
and
model theusing this
thismethod,
printhead.
using This is due
method, several
to the
several problems
shape and
problems arise due
duetotothe
individual
arise the
construction
components of the
forming FDM
the device
FDM and
device’s the printhead.
printhead, This
and is
several due
construction of the FDM device and the printhead. This is due to the shape and individual to the
issues shape
arise and individual
connected with
components
the formation forming
components offorming the
non-planartheFDM device’s
layers.
FDM The most
device’s printhead,
important
printhead, and
andseveral
isseveral issues
the shapeissuesofarise connected
the head
arise with
itself and
connected with
the
thethe formation of non-planar layers. The most important is the shape of the head itselfand
formation
individual of non-planar
components layers.
involved The
in most
cooling important
the layers. is the shape
Since the of the
print head itself
activelyand
the
theindividual
engages the Z-axis
individual components
in this process
components involvedin the
involved in
incooling
case
coolingof thethelayers.
layers. Since
non-planar layers,
Since theitprint
the head
returns
print to actively
head places
actively
engages
where
engages the
theZ-axis
individual,Z-axis in in
this
either process
planar
this orinnon-planar,
process the
in case of non-planar
the case perimeters
of non-planar layers, it returns
of a particular
layers, to places
it height
returns to where
have al-
places
individual,
ready been either
formed. planar
This or non-planar,
process often perimeters
causes the of a particular
printhead height
components
where individual, either planar or non-planar, perimeters of a particular height have al- have
to already
collide been
with
formed.
the surface
ready This
been process
of formed.
the often
created
This causesasthe
model,
process printhead
shown
often in Figure
causes components
the 6. The Anet
printhead tocomponents
collide withto
E12 printhead thecollide
surface
and the of
with
the
basic created
geometry model,
of theas shown
print in
nozzle Figure
are 6.
shown The Anet
[16]. E12 printhead
the surface of the created model, as shown in Figure 6. The Anet E12 printhead and the and the basic geometry
of the geometry
basic print nozzle of are
the shown
print nozzle[16]. are shown [16].

Figure 6. The shape of the head and nozzle of the device Anet E12 (a) 42° both sides, (b) 45 and
34°, (c) 126.and
Figure The23°.shapeof
ofthe
thehead
headand
andnozzle
nozzleofofthe
thedevice
deviceAnet
AnetE12
E12(a) ◦ both
(a)4242° bothsides,
sides,(b)
(b)45 and34◦ ,
45and
Figure 6. The shape
34°,
(c) 12(c) 1223
and and
◦ . 23°.
Depending on the print head’s shape, we can observe several shortcomings directly
relatedDepending
to its non-planar
Depending onthe
on printing
theprint
printhead’s application.
head’s shape,we
shape, weGiven the condition
canobserve
can observe severalof
several the heat block,
shortcomings
shortcomings the
directly
directly
nozzle, and
relatedto
related toits the cooling
itsnon-planar location,
non-planarprinting it is
printingapplication.clear that
application. Given its use
Given the in the
thecondition production
conditionof ofthe of
theheat non-planar
heatblock,
block,the the
surfaces
nozzle,will
nozzle, andbe
and the
the significantly
cooling location,
cooling limiteditit[17].
location, As that
isis clear
clear already
thatits mentioned,
itsuse
usein inthe in terms ofofof
theproduction
production cooling the
non-planar
non-planar
layer’s
surfaces
surfaces material,
willbe
will bethis problem is
significantly
significantly easily [17].
limited
limited eliminated.
[17].As AsalreadyBy amentioned,
already simple disassembly
mentioned, interms
in termsof or changing
ofcooling
coolingthe the
the blower’s
layer’s material, shape, we
this increase
problem is the
easily print head’s
eliminated. reach
By
layer’s material, this problem is easily eliminated. By a simple disassembly or changinga in the
simple Z-axis,
disassembly exceedingor larger
changing
height
the differences.
the blower’s
blower’s shape,
shape, we we increase
increase the the print
print head’s
head’s reach
reach in inthetheZ-axis,
Z-axis,exceeding
exceedinglarger larger
Another
height
heightdifferences. problem is the shape of the print nozzle itself. Unlike blowers and other
differences.
printheadAnother
Anothercomponents,
problemthey
problem isisthe
thecannot
shapebe
shape of removed
ofthetheprint or
printnozzle moved.
nozzle itself. AsUnlike
itself. shownblowers
Unlike in Figure
blowers and
and7,other
the
other
shape of thecomponents,
printhead
printhead nozzle itself
components, theyis also
they cannot limiting
cannot be in
be removed creating
removed ornon-planar
or moved. moved.As shownAssurfaces.
in Figure
shown One
in 7, possible
the shape
Figure 7, the
solution
of
shape is the
the nozzle
of use
theitself
nozzle of the
is also
itselfso-called
limiting “Airbrush”
is alsoinlimiting nozzle, non-planar
creatinginnon-planar
creating which
surfaces. consists
One of a sharp
possible
surfaces. One tip. Itis
solution
possible
increases
the use ofthe theoverhang
so-called angles that
“Airbrush” the print
nozzle, head
which can copy.
consists
solution is the use of the so-called “Airbrush” nozzle, which consists of a sharp tip. With
of a these
sharp modifications,
tip. It increases it the
is It
possible
overhang to achieve a significant increase in FDM devices’
increases the overhang angles that the print head can copy. With these modifications, ittois
angles that the print head can copy. With these efficiency
modifications,when printing
it is non-
possible
planar
achieve surfaces.
possible a to However,
significant
achieve increase these
a significant adjustments
in FDM devices’
increase in have their
efficiency
FDM limits.
when
devices’ This limit
printing
efficiency is the
non-planar
when very fact
surfaces.
printing non-
However,
that the print
planar these
surfaces. adjustments
nozzle’s ideal position
However, haveadjustments
these their limits.
during Thistheir
the extrusion
have limit is the
oflimits.
the verylimit
material
This fact that
thethe
is perpendicular
is veryprintfact
tonozzle’s
the surfaceideal of position
the model duringbeing the extrusion
created, of
within the
thematerial
solution
that the print nozzle’s ideal position during the extrusion of the material is perpendicular is perpendicular
of this problem to the
described surfacein
of
thetothe
the model
already
surface being
of thecreated,
mentioned in patent
model within
being the solution
application
created, No.ofthe
within this problem
US10005126B2.
solution described
criticalinlimit
A problem
of this the already
is thein
described
mentioned
the already mentioned in patent application No. US10005126B2. A critical limit value
stated value in
in patent
the range application
of 22.5°–45° No. US10005126B2.
depending on the A critical
direction limit
of the is the
print stated
head move-
is the
in the range of ◦ –45◦ depending on the direction of the print head movement [10]. It
ment [10].
stated value in22.5
It follows thethat,
range inof order further
22.5°–45° to increase
depending onthetheefficiency
directionof ofnon-planar
the print head layering
move-
offollows
material,
ment that,
[10]. in orderisthat,
aItdevice
follows further
required to increase
in orderwhose further thetoefficiency
design allows the
increase of
thenon-planar
printhead
efficiency of layering
to non-planar
be tiltedof material,
partially
layering a
device
[18]. is required
of material, a device whose design allows
is required whosethe printhead
design allowstothe be printhead
tilted partially to be[18].
tilted partially
[18].

(a) (b)
Figure 7. The shape of print
(a) nozzles and their influence on non-planar(b)printing efficiency (a) stand-
Figure 7. The shape of print nozzles and their influence on non-planar printing efficiency (a) standard
ard print nozzle, (b) Airbrush nozzle.
Figure 7. The shape of print nozzles and their influence on non-planar printing efficiency (a) stand-
print nozzle, (b) Airbrush nozzle.
ard print nozzle, (b) Airbrush nozzle.
pl. Sci. 2021,Appl.
11, xSci.
FOR PEER11,REVIEW 6 of 26
Appl. Sci. 2021,
2021, 11, x2928
FOR PEER REVIEW 6 6ofof 26
25

1.3. Current State in the Field of the Use of Non-Planar Layering of Material
1.3.
1.3.Current
CurrentState
Stateininthe
theField
Fieldof
ofthe
the Use
Use of
of Non-Planar
Non-Planar Layering
Layering ofof Material
Material
As already mentioned, each FDM device can perform the simultaneous movement
As
As already
already mentioned, each each FDMFDMdevice
devicecancanperform
performthethesimultaneous
simultaneous movement
movement in
in all three axes. However, due to the shape and nature of FDM devices’ control, it is active
in
allall three
three axes.However,
axes. However,due duetotothe
theshape
shapeand andnature
natureof
ofFDM
FDM devices’
devices’ control, it is active
active
only in specific situations. At present, however, non-planar layering of material is receiv-
only
only inin specific
specific situations. present, however,
situations. At present, however,non-planar
non-planarlayering
layeringofofmaterial
material
is is receiv-
receiving
ing increasing attention
increasing in conventional
attention embodiments
in conventional of plant constructions
embodiments of plant and connect-
constructions and connecting
ing increasing attention in conventional embodiments of plant constructions and connect-
ing with the application
with of this of
the application technology
this to industrial robotic arms arms
(Figure 8). These
ing with the application of technology
this technology to industrial robotic
to industrial robotic (Figure 8). These
arms (Figure create
8). These
create idealideal
conditions for
conditions the
forapplication
the of
application this
of technology.
this technology.
create ideal conditions for the application of this technology.

Figure 8. Application
Figure8. of non-planarof3D
Application
8.Application printing on
non-planar 3Daprinting
robotic arm
printing [19].
onaarobotic
robotic arm
arm [19].
[19].
Figure of non-planar 3D on

In the research
In the presented
the in the publication
research presented “Development of a three-nozzle extru- extrusion
In research presentedin inthe
thepublication
publication“Development
“Development of of
a three-nozzle
a three-nozzle extru-
sion systemsystem
for conformal
for multi-resolution
conformal 3D printing
multi-resolution 3D with a robotic
printing with a manipulator”
robotic [19], [19], we
manipulator”
sion system for conformal multi-resolution 3D printing with a robotic manipulator” [19],
we can see can
the application
see the of this technology
application of this to the robotic
technology to the arm. Toarm.
robotic achieve
To ideal condi-
achieve ideal conditions
we can see the application of this technology to the robotic arm. To achieve ideal condi-
tions for non-planar
for non-planar printing, a separate
printing, reversible
a separate print print
reversible head head
has been designed.
has been The The basic
tions for non-planar printing, a separate reversible print head has designed.
been designed. The
basic principle of operation
principle is to save
of operation is tothe
save maximum time, time,
whichwhich
is achieved by different
basic principle of operation is to the
savemaximum
the maximum is achieved
time, which by different
is achieved layer
by different
layer heights in the in
heights printing processprocess
theinprinting and a combination
and and of non-planar
a combination and planar
of non-planar layers.
andandplanar layers. In
layer heights the printing process a combination of non-planar planar layers.
In essence, this means
essence, that
this the individual
means printheadsprintheads
that the individual have nozzles haveof different
nozzles of diameters.
different diameters.
In essence, this means that the individual printheads have nozzles of different diameters.
These are
These are actively actively interchanged
interchanged during the production
during the production process [19]. process [19].
These are actively interchanged during the production process [19].
Figure 9 showsFigure 9 shows
different different
types types of non-planar
of non-planar surfaces formedsurfaces
by aformed
roboticby a robotic
arm. Their arm. Their
Figure 9 shows different types of non-planar surfaces formed by a robotic arm. Their
basic idea is to create a non-planar base copying the surface
basic idea is to create a non-planar base copying the surface of the support model. Instead of the support model. Instead
basic idea is to create a non-planar base copying the surface of the support model. Instead
of the usualof the usual
Infill, i.e., theInfill, i.e., the percentage
percentage value of the value of known
filling the filling
fromknown from theofcreation
the creation mod- of models
of the usual Infill, i.e., the percentage value of the filling known from the creation of mod-
els by FDMby FDM devices,
devices, a planara laminated
planar laminated
plastic plastic
is usedisinused
this in thisThe
case. case.oneThe one already
already men- mentioned
els by FDM devices, a planar laminated plastic is used in this case. The one already men-
tioned servesserves as a support
as a support for theforupper
the upper non-planar
non-planar surfaces.
surfaces.
tioned serves as a support for the upper non-planar surfaces.

Figure 9.Figure
Demonstration of non-planar
9. Demonstration models models
of non-planar printed printed
by this method
by this [19].
Figure 9. Demonstration of non-planar models printed by method [19].[19].
this method

The application
The application of FDM technology
of FDM technology to robotic
to robotic arms armsatypical
and other and other atypicalisstructures
structures a is a
The application of FDM technology to robotic arms and other atypical structures is a
current topiccurrent topic that significantly
that significantly supports the supports the development
development inof
in this area this area of technology.
technology. Sim- Similar
current topic that significantly supports the development in this area of technology. Sim-
ilar studies studies and conceptual
and conceptual solutionssolutions significantly
significantly contribute
contribute to the increase
to the increase of interest
of interest in in the
ilar studies and conceptual solutions significantly contribute to the increase of interest in
field of non-planar printing. It has an integral place in continuous research
the field of non-planar printing. It has an integral place in continuous research in the field in the field of
the field of non-planar printing. It has an integral place in continuous research in the field
of materials,materials, mechanical
mechanical properties
properties of models,
of models, development
development of structures
of structures and software [20].
and software
of materials, mechanical properties of models, development of structures and software
[20].
[20].
2. Methodology
2. MethodologyWithin the methodology of design of the FDM device design, it is necessary to deter-
2. Methodology
Withinmine and define its required parameters and purpose. Since the work aims to design the
the methodology of design of the FDM device design, it is necessary to deter-
Within
structure the methodology
focused of design
on innovations of the FDM
and current device
trends design,
in the it is one
industry, necessary to deter-
of its priorities
mine and define its required parameters and purpose. Since the work aims to design the
mine and define its required parameters and purpose. Since the work aims to design
is its use. It is well known that recent trends in the use of FDM devices are different. the
Appl. Sci. 2021, 11, 2928 7 of 25

Whether it is the use of printheads installed on robotic arms, or oversized printing used, for
example, in construction, the creation of tissue through the layering of biological material,
or new materials in this area, the devices used in these areas have one thing in common.
They all work on the same principle of layering thermoplastic or other materials in planar
layers [21]. This is based on theoretical assumptions, which form a partial solution related
to the design of an atypical structure for FDM technology. Within the publication, we
focus on a specific construction type, which we consider to be ideal in several ways. It is
well known that compared to serial robots used in conjunction with FDM technology and
conventional 3D printer designs, devices based on the principle of parallel manipulators
are dominant. Due to their availability, it is relatively simple compared to robotic arms, as
well as in regard to speed and dynamic movement. The disadvantage of these devices is
their somewhat complicated operation compared to conventional Cartesian-type construc-
tions and the lower achieved accuracy of component production. In the field of parallel
manipulators, we know several types of constructions, such as tripod-type manipulators,
also used in FDM technology devices, and various other types of constructions based on
the parallel motion [22]. As part of the device’s design, i.e., developing an atypical device,
we encounter a combined Cartesian-type construction with an effector characteristic of
delta devices. This type of device offers new possibilities in terms of system control and
the possibilities of its application. Due to the design and application of the solution to a
specific type of atypical production of models, it is necessary to determine the proposed
equipment’s basic requirements. Given the knowledge already gained related to structures,
control, kinematics and data processing for FDM technology, we can create a list of basic
requirements for creating an atypical structure [23]. These requirements are completed to
develop an atypical device designed for non-planar 3D printing. Partial goals are presented,
as follows:
• Creating a conceptual design.
• Modification of the design based on theoretical knowledge.
• Design of key components of the structure.
• Application of the finite element method to optimise the design of key components.
• Design of construction subsystems.
• Construction assembly and verification.
• Conceptual design of an integrated extrusion system for processing and printing from
recycled material.

2.1. Construction Design Based on Acquired Knowledge

Due to the previous research in types of additive devices, types of their constructions
and application solutions, we have arrived at a possible conceptual design of the structure.
This construction is to be adapted to the models’ production conditions through non-planar
layering of the material. As part of a partial solution, we initially considered a simple
alternative to the Tripteron-type construction, which forms a kind of basis for atypical
devices with untapped potential. From our perspective, this could be used in the printing
of non-planar surfaces [24].
As shown in Figure 10, constructions of this type are designed to combine Cartesian-
type FDM devices. Instead of a standard printhead attached to the X-axis, they have
an effector similar to delta-type devices. Given the theoretical knowledge in the field of
non-planar layering of material, the key is using an effector connected separately to each of
the device axes [25–27].
Appl. Sci. 2021, 11, 2928 8 of 25
Appl. Sci. 2021, 11, x FOR PEER REVIEW 8 of 26

Figure 10. The Tripteron structure used for the initial model for evaluation and design [28].
Figure 10. The Tripteron structure used for the initial model for evaluation and design [28].

However,during
However, duringthetheimplementation
implementation ofof this
this construction,
construction, we we encountered
encountered signifi-
significant
shortcomings. The FDM technology used in the production of key components doesdoes
cant shortcomings. The FDM technology used in the production of key components not
not achieve
achieve the required
the required accuracy,
accuracy, which which
would would not ensure
not ensure the system’s
the system’s sufficient
sufficient accu-
accuracy
racyrigidity
and and rigidity
in theincase
the of
case
theofused
the used transformation
transformation mechanism
mechanism combining
combining linear
linear guid-
guidance
ancetiming
and and timing belt.simple
belt. The The simple
forkedforked
jointsjoints ingested
ingested in theinjoints
the joints
of theofindividual
the individual
armsarms
did
didhave
not not have sufficient
sufficient rigidity,
rigidity, which which
in theinZ-axis
the Z-axis caused
caused the deflection
the deflection of theofentire
the entire arm
arm and
andsubsequent
the the subsequent crossing
crossing of theoflinear
the linear mechanism.
mechanism. BasedBased on facts,
on these these itfacts,
was it was neces-
necessary to
sary to modify the proposal, which
modify the proposal, which will ensure: will ensure:
•• Sufficientrigidity
Sufficient rigidityofofthe
thesystem
systemininthe theZ-axis.
Z-axis.
•• Properplacement
Proper placementofoflinearlinearguides,
guides,guide
guiderodsrodsand
andtransformation
transformationmechanisms.
mechanisms.
•• Correctposition
Correct positionofofthetheeffector
effectorfor
forthe
thedevice
deviceguides
guidesand andthe
theprinting
printing pad.
pad.
•• Proper
Properplacement
placementofofsufficient
sufficientprint
printpads.
pads.
•• Plenty
Plentyofofspace
spacefor arm
for arm movement
movement to to
prevent
prevent collision
collisionwith thethe
with frame when
frame whenlifting in
lifting
the
in Z-axis.
the Z-axis.
• • Design
Designof of the
the arms to tonotnotcollide
collidewith
with thethe machine
machine frame,
frame, the printing
the printing pad or pad or
other
other components.
components.
During
During the
the FDM
FDM device’s
device’s design
design forfor the
the production
productionof of models
models by by non-planar
non-planarlayering
layering
of
of material,
material, wewe relied
reliedon ontheoretical
theoreticalknowledge
knowledge and
and anan overview
overview of theof the current
current state.state.
The
The knowledge
knowledge waswas subsequently
subsequently applied
applied to antoexisting
an existing kinematic
kinematic modelmodel of the
of the Tripteron
Tripteron de-
device. With
vice. With the
the helpofofvarious
help varioustypestypesand
andmodifications
modificationsnecessary
necessary forfor realising
realising 3D
3D printing
printing
on
on such
such aa device,
device, this
this process
process achieved
achieved its its design
design ofof an
anatypical
atypicalconstruction
construction of of an
anFDMFDM
device. As already mentioned, the proposed device has all the characteristic
device. As already mentioned, the proposed device has all the characteristic elements of elements
of
thethe construction
construction usedused by additive
by additive production
production devices
devices FDM.FDM. Itsisbase
Its base is an“L”
an open open “L”
shaped
shaped frame. It has sufficient space to place the printing plate, lines,
frame. It has sufficient space to place the printing plate, lines, drives and other elements drives and other
elements
[26–28]. [26–28].
2.2. Layout Design of the Construction Frame
2.2. Layout Design of the Construction Frame
The resulting device concept is designed for non-planar 3D printing, because the
The resulting device concept is designed for non-planar 3D printing, because the con-
conventional design of the FDM device, controlled in three axes, is unsatisfactory in non-
ventional design of the FDM device, controlled in three axes, is unsatisfactory in non-
planar printing due to insufficient extrusion of the material at an elevation of more than
planar printing due to insufficient extrusion of the material at an elevation of more than
22.5◦ . A new concept is proposed for the possible extension, which will allow it to work in
22.5°. A new concept is proposed for the possible extension, which will allow it to work
more than three axes. It is, therefore, a matter of connecting two types of devices in series.
in more
This fact than three
harms axes. It is,
the stability of therefore,
the system,a matter
as wellofasconnecting two types
other parameters. Forofthis
devices in
reason,
aseries.
frameThis
of afact harms
smaller the stability
height of the
(Figure 11), andsystem, as base,
a larger well as other
was parameters.
chosen, For this
which partially
eliminates the negative vibrations in the frame caused by the movement of the arms. par-
reason, a frame of a smaller height (Figure 11), and a larger base, was chosen, which
tially eliminates the negative vibrations in the frame caused by the movement of the arms.
 Appl. Sci. 2021, 11, 2928 9 of 25
Sci. 2021, 11, x FOR
Appl. Sci.PEER
2021, REVIEW
11, x FOR PEER REVIEW 9 of 26 9 of 26

Figure 11. Layout design

Figure
Figure 11. of the frame
11. Layout
Layout structure
design
design of the
of withstructure
the frame
frame a description
structure withof
with the axes. of
aadescription
description ofthe
theaxes.
axes.

The device’s Theframe is made

Thedevice’s
device’s of aluminium
frame
frame madeofofprofiles
isismade aluminium
aluminium measuring 20
profiles
profiles × 20 and 2020
measuring
measuring × 40
× ×20 mm.
20 and2020×× 40
and 40 mm.
mm.
The orientation
Theoforientation
The these profiles
orientation of is adapted
of these
these profiles
profiles sois
isthat, due to
adapted
adapted sothe
so device’s
that,
that, due to
due tocomplicated
the device’s
the kine-
device’s complicated
complicated kine-
kine-
matic, there are no there
matic,
matic, collisions
there are of collisions
are no
no the arms and
collisions of the
of carriages
the arms and
arms in carriages
and the individual
carriages inthe
in axes,
the with the
individual
individual axes, with
axes, withthethe
frame of the structure
frame (Table
frame of the 1). Another
structure
structure (Table
(Table influence
1).Another
1). on the
Another orientation
influence
influence onon
theof
thethe profilesofisthe
orientation
orientation also
of the profiles
profiles is
is also
also
used by the used used by
usedconnecting the
by the used used
parts, connecting
i.e., clamps,
connecting parts,
parts,which i.e., clamps,
ensurewhich
i.e., clamps, which
the mutual
ensureensure the
position mutual
of indi-
the mutual position
position of indi-of
vidual shapesindividual
and ensure
vidual shapes
shapes the and
whole
and ensure
ensure the the
frame’s whole
stability.
whole frame’s
frame’s stability.
stability.

Table 1. Dimensional
Table1.1.characteristics
Table Dimensional
Basic of the proposed
characteristics
dimensions of the offrame.
frame. the proposed frame.

Basic Dimensions Basicof

Basic the Frameofofthe
Dimensions
Dimensions theFrame
Frame
Frame lengthFrame
in the Y-axis
length in the Y-axis
Frame length in the Y-axis 570 [mm] 570[mm]
570 [mm]
Frame lengthFrame
in the length
Frame X-axis
length ininthe
theX-axis
X-axis 500 [mm] 500[mm]
500 [mm]
Maximum size of 2] × 2
Maximum size of the base
Maximum ofthe
area
size thebase
basearea
area 285 × 103 [mm 285
285 × 103
103[mm
[mm]2]
Maximum frameMaximum frame height
height frame height
Maximum 390 [mm] 390 [mm]
390 [mm]

The constructionThe of FDM devices

The construction
construction ofFDM
of is relatively
FDM devicesundemanding.
devices isisrelatively The models have
relativelyundemanding.
undemanding. been have
Themodels
The models havebeen
been
adapted to beadapted
fixed using
adapted to
tobebesimple
fixed
fixedusing connections
using simple
simple of M3 screws
connections
connections and
of of
M3 M3 “T”
screws matrix.
screwsandand Various
“T” matrix.
“T” vari-
matrix.Various variants
Various vari-
ants of cornerof corner
brackets
ants brackets
served
of corner asserved
brackets setting aselements
served setting elements
for the
as setting for the
frame
elements offrame
forthe of theofstructure.
thestructure.
frame The device
Thestructure.
the device was
The device
was designeddesigned
so that
was soassembly
its
designed thatso itsthatassembly
requires
its assembly requires
minimal minimal
requiresinterventions
minimalinterventions
in the frame
interventions in thein frame
structure.
the frame structure. In
structure.
connection
In connectionInwith with
the assignment’s
connection the assignment’s solution,
solution, a virtual
with the assignment’s solution, a virtual
model model
of the model
a virtual of the
whole assemblywhole
of the whole assembly and
andassembly and all
all components components
all was created.
components wasThe created.
was body
created.The
of thebody
The of the
system
body system
itself
of the was
systemitself waswas
relatively
itself relatively
simple. The
relativelysimple.
use
simple.TheThe
useuse
of
fasteners
of fasteners andof fasteners andand
individual individual
elements
individual elements
in a elementsin ainpredetermined
predetermined location on
a predetermined location
the on the
frame
location frame
wasthe
on seam- waswas
frame seamless.
seam-
The
less.negative
less. The negative factors
The factors
were the
negative were
factors the
assembly
wereassembly of plastic
of plastic
the assembly parts partsthe
of with
plastic with thewith
help
parts help
of of screw
screw
the con-ofconnections,
help screw con-
nections, the the mechanical
mechanical
nections, properties
theproperties
mechanical of the
of properties
the materials
materials used
of the used
andand
materialsthethe deviations
deviations
used and the of the
of deviations
the equipment
equip- used
of the equip-
to
ment used toment produce
produce components.
usedcomponents.
to produce components.When mounted
When mounted When on a metal
on mounted frame,
a metal frame, they caused
they caused
on a metal the
frame, the plastic element
they caused the
plastic elementto deform.
to deform.
plastic Other
element Other
tonegative
negative
deform. effects were
effects
Other shown
were
negative during
shown
effects the shown
during
were commissioning
the commissioning
during the of individual
commissioning axes.
These
of individual ofaxes. negative
These negative
individual factors,
axes. These extremely
factors, complicating
extremely
negative factors, complicatingthe design of the structure
the design of the design
extremely complicating itself, caused
struc- of the struc-
the
tureaccumulation
ture itself, caused itself, causedofthe
the accumulation largeof amounts ofofplastic
large amounts
accumulation waste,
of plastic
large amounts which
waste, resulted
which
of plastic in the
resulted
waste, need to recycle
in resulted
which in
the
the need to recycle failures.
the The
failures.criticalThe components
critical were
components the bearings
were the of
the need to recycle the failures. The critical components were the bearings of motors, motors,
bearings drives
of and
motors, lead screws,
drives and leadwhich
drives can
andbe
screws, leadseen
which in Figures
can
screws, seen12
bewhich and
incan 13.seen
Figures
be Modifying
12 in
and 13. these
Figures designs
Modifying
12 and using
these
13. the finite
designs
Modifying theseelement
designs
method
using the finite element
using greatly
method
the finite accelerated
element greatly this process
accelerated
method and
greatlythis reduced
process and
accelerated the amount
thisreduced of
process the plastic
andamount waste
reduced the generated,
amount
resulting
of plastic wasteof plastic from
generated,waste the high failure.
resulting
generated, from the highfrom
resulting failure.the high failure.

Figure 12. Detail

Figure 12.ofDetail
Figure the12.
keyof components
Detail
the of the
key ofcomponents
key the X-axis
components of theguide
of theand
X-axis drive
X-axis
guide housing.
guide
and andhousing.
drive drive housing.

Due to these Due

deformations, e.g., to offset e.g.,
to these deformations, the guide barthe
to offset andguide
guidebar
screw. This misa-
and guide screw. This misa-
lignment waslignment
measurable
wasinmeasurable
millimetres,in which is unacceptable
millimetres, for the smooth
which is unacceptable forrunning
the smooth running
 or rod caused an extreme deflection of the flexible coupling, which could not compensate
for this deformation. As a result of these shortcomings, the engines overheated, and the
truck stopped unintentionally at a greater distance. Due to the dispositional solution of
the device frame and the lack of space for alternative possibilities of mutual storage of
these subsystems, the need arose on the device to create models common for the storage
Appl. Sci. 2021, 11, 2928 10 of 25
of components in both axes. As shown in Figure 13, the Y-axis drive mount is also the
opposite component for the X-axis bearing, guide screw and guide rod mount.

FigureFigure
13. Detail
13. of key of
Detail components of bearings
key components guidedguided
of bearings and drives in the Y-axis.
and drives in the Y-axis.

These defectsDue arose on alldeformations,

to these key components e.g.,used to mount
to offset drives
the guide bar and
and linear
guide technol-
screw. This misalign-
ogy on the device.
ment was As ameasurable
solution toin this situation in
millimetres, commercially
which used FDM
is unacceptable for the devices,
smoothap- running of the
drives and
plying the so-called freethe endtrolley’s
of leadmovement
screws. It with means thethat
arm.theThe
endmisalignment
of the lead screw of the is
lead screw or
rod caused
housed in clearance an extreme
housing. This play deflection
subsequently of the allows
flexiblecompensation
coupling, which could not compensate
in non-coaxial
movement offor thethis deformation.
lead screw and linear As a result of these
technology, andshortcomings, the engines
there is no bending overheated, and the
and negative
forces. Such truck stopped
a solution unintentionally
is unacceptable due to at athegreater
naturedistance. Due to the dispositional
of our construction. In this case, solution of
the loose endstheofdevice
the guide frame and would
screws the lack of space
cause otherfor alternative
unwanted possibilities
vibrations of mutual storage of
and vibrations
of the system,these
whichsubsystems, the need arose
would negatively affecton thethe device
prints’ to create
quality. Asmodels
a solutioncommon
to thesefor the storage
problems, weofusedcomponents
the so-called in both axes. As
application ofshown in element
the finite Figure 13, the Y-axis
method beforedrive mount is also the
the model
oppositeThis
production process. component
solutionfor the X-axis
consisted bearing,of
of analyses guide screw and
the model’s guidewithin
location rod mount.
the
virtual subsystem and subsequent simulation of the effects acting on individualand
These defects arose on all key components used to mount drives linear technology
compo-
nents [27,28].on the device.
Individual As a of
values solution
deviationsto thisfromsituation in commercially
the initial position can be used FDM
seen devices, applying
in Tables
the so-called
2 and 3. Repeated free end of
measurements of real
leadmodels,
screws. modifications
It means that the end ofmodels
of CAD the lead andscrew
cor- is housed in
clearance and
rection of dimensions housing.
geometryThis play subsequently
of components wereallows
done.compensation
In essence, it in wasnon-coaxial
a matter movement
of measuringofthe themagnitude
lead screw of andthelinear technology,
angular deformation and there
of theis drive
no bending
bearing and negative
after fixing forces. Such
a solution is unacceptable due to the nature of
the plastic component to the metal frame and comparing it with the simulation. Subse-our construction. In this case, the loose
ends of the guide screws would cause other unwanted
quent deformation was implemented in a CAD model, which served as a template for a vibrations and vibrations of the
system, which would negatively affect the prints’
new part. This process was applied to each bearing of the drive and the lead screw endquality. As a solution to these problems,
we used
element. Gradual the so-calledand
measurements application
adjustments of thehave
finitesucceeded
element method beforethis
in reducing the nega-
model production
tive factor toprocess.
a minimum, This solution consisted
thus ensuring smoothof analyses
movements of theinmodel’s
all axes.location within the virtual sub-
system and subsequent simulation of the effects acting on individual components [27,28].
Individual
Table 2. The result of the Xvalues of deviations
and Y axes from the initial position can be seen in Tables 2 and 3.
drive displacement.
Repeated measurements of real models, modifications of CAD models and correction
Placement
of dimensions and geometry X of
[mm]components were done. YIn[mm] essence, it was a matter of
Nema 17 (holding
measuring screw the1)magnitude of the 2.907angular deformation of the2.583 drive bearing after fixing the
plastic component
Nema 17 (holding screw 2) to the metal1.13 frame and comparing it with the simulation. Subsequent
1.066
deformation
Z axis deformation was implemented in
0.054 a CAD model, which served
0.048 as a template for a new
Combined part. This process was applied0.018
deformation to each bearing of the drive and the lead screw end element.
0.008
Gradual measurements and adjustments
(torque, force) have succeeded in reducing this negative factor
to a minimum, thus ensuring smooth movements in all axes.

Table 2. The result of the X and Y axes drive displacement.

Placement X [mm] Y [mm]

Nema 17 (holding screw 1) 2.907 2.583
Nema 17 (holding screw 2) 1.13 1.066
Z axis deformation 0.054 0.048
Combined deformation 0.018 0.008
(torque, force)
ci. 2021, 11, Appl.
x FORSci.
PEER2021, 11, x FOR PEER REVIEW
REVIEW 11 of 26 11 of 26
Appl. Sci. 2021, 11, 2928 11 of 25

Tablecharacteristics
Table 3. Dimensional 3. Dimensionalofcharacteristics
the proposed of the proposed frame.
frame.
Table 3. Dimensional
Placementcharacteristics of the proposed
Z [mm]frame. Z′ [mm]
Placement Z [mm] Z′ [mm]
Nema
Nema 17 (holding 17 (holding
screw 1) screw
Placement 1)
1.650 1.650 1.940
Z [mm] 1.940
Z0 [mm]
Nema
Nema 17 (holding 17 Nema
screw (holding screw 2)
2) 17 (holding 0.761
screw 1)
0.761 0.667
1.650
0.667
1.940
X axisNema
X axis deformation deformation 0.004
17 (holding screw 2) 0.004 0.008
0.761 0.008
0.667
Y axis deformation
Y axis deformation 0.013
X axis deformation 0.013 0.009
0.004 0.009
0.008
Y axis
Combined deformation
Combined deformation deformation 0.013 0.009
0.018 force) 0.018
Combined deformation (torque, 0.008
0.018 0.008
0.008
(torque, force) (torque, force)

The
The second
The second problem second
was the problem
problem was
wasthe
implementation theimplementation
of the shapes of
implementation ofthe
theshapes
other shapes of
ofother
components otherin components
componentsin in
the design of the
the design
new design
models.of new
ofAsnew models.
models.
shown As
As shown
in Figure shown in
in Figure
14, the Figure
mounting 14,
14, the
the mounting
mounting
of motors andofof motors
motors and
linear andlinear
linear
technology
technology oftentechnology
interfered often
withinterfered
often interfered
the proposed with the
theproposed
withmodels, proposed models,
models,not
not excluding notexcluding
the that allthe
excluding
fact the fact
thesefactthat
thatall
allthese
these
models had tomodels
models
correlate had
had to
tocorrelate
with correlate
the with
withthe
aluminium the aluminium
aluminium
profiles profiles
profiles
and their and
andtheir
grooves’ theirgrooves’
grooves’
dimensions. dimensions.
dimensions.This
This This
fact required afact
fact required
set ofaathe
required
specific specific
specific set
setof
parameters ofthe of parameters
the parameters
printing and of printing
printingand
ofextrusion and
of extrusion
extrusion
the of
equipment’s ofthe
theequipment’s
equipment’s
material
material
material on which on
onwhich
whichthe
the production ofproduction
the production
models wasofofmodels
models
carried was
was
out. carried
We carried out.
achievedout.We
an achieved
We achieved
ideal mate-an anideal material
ideal mate-
extrusion with
rial extrusion
rial extrusion with the right
with the which
the right settings, settings,
right settings, which
allowedwhich allowed
allowed
us to create us to create
us to create
components components
a non- withaa non-
components
with with non-
conflicting
conflicting shape and the shape
conflicting shapeand
correct and the
thecorrect
dimensions.correct dimensions.
dimensions.
These componentsThese
These components
components
then then
thenin
easily landed easily
the landed
easily landedin inthe
the
specified
specified place,specified place, in
incorrelation
place,with
in correlation correlation with
the developed withthethe
CADdeveloped
model. CAD
developed CADmodel.
model.

FigureFigure 14. Figure

14. DetailDetail 14.
of the of
key Detail
key of the key
components
the components
of the
components guide
of andof the guide
drive
the guide and andindrive
bearings
drive thein
bearings bearings
Z-axis. in the Z-axis.
the Z-axis.

During
During the
During the structure’s the structure’s
structure’s
design process, design
design
we did process,
process,
not workwe
we did
didnot
only not
withwork
work only
only
static with
withstatic
models, staticmodels,
as models,asas
was
was interpretedwas interpreted
interpreted
in the in
deformation the
in the deformation
deformation
shown in Figures shown
shown in
12–14, Figures
in Figures 12–14,
but we also12–14, but we
butthe
used also
also used theso-called
used
weso-called the so-called
motion
Due analysis.
motion
motion analysis. analysis.
to Due
the arms’Due to
to the
the arms’
arms’ arrangement,
arrangement, arrangement,
the types of linesthe
the types of
typesand
used oflines
lines used
usedand
the possibleandthe
thepossible
possible
negative
negative
negative phenomena phenomena
phenomena
resulting fromresulting
resulting from
the individualfromthethe individual
individualthe
subsystems, subsystems,
subsystems, the
thestatic
static analysis aloneanalysis
static analysisalone
alone
was
was
was insufficient. Theinsufficient.
device is The
insufficient. The device
divided intoisisseveral
device divided
divided into
intoseveral
smaller several smaller subsystems,
smallerwhich
subsystems, subsystems,
reduced which
whichreduced
reduced
the
the time
the time required time required
for eachrequired for
analysisforeach
eachanalysis
run. analysis
One run. One
One of
run.subsystems
of these of these
these subsystems
wassubsystems was
was also
also the already also the
the already
already
mentioned
mentioned
mentioned X-axis X-axis line,
X-axiswith
line, together together
line, its
together with its key
with its key
key component. component.
Thecomponent. The
whole partThe whole
whole
of the part of the construction
part of the construc-
construc-
tion was used was
for used
tionthewas for the
used
simulationforsimulation
the itself,itself,
simulation
itself, as shown as
inshown in
15.Figure
as shown
Figure 15. 15.
in Figure

Figureof
Figure 15. Illustration
Figure 15.
15.theIllustration
subsystem
Illustration ofused
of thesubsystem
the subsystem used
by the motion
used bythe
themotion
analysis.
by motionanalysis.
analysis.

After
After definingAfter defining
all thedefining all the
connections andconnections
supplementing
connections and
andsupplementing the
thestructural
the structural elements
supplementing elements
such as
structural elements such as
such
screw
screw connections
as screwconnections
and and
andbearings
bearings from
connections the from
library
bearings the
of the
from library
theused of
of the
the used
program,
library the location
program,andthe location
the locationand
and
type of electric motor used were defined. The advantage of this type of analysis is that it
 Table 4. Definitions used in the X-axis motion analysis subsystem.

Detail of Analysis
Ground Aluminium Frame (Profiles 20 × 20, 20 × 40)
Element size [mm] 1.4
Appl. Sci. 2021, 11, 2928 12 of 25
Motor speed [mm/s] 60
Material of analysed part Polylactic acid (PLA)
Elastic modulus [MPa] 3500
is not necessary to explain ratio
Poisson’s all the factors operating on the subsystem. 0.300 The definition of
these factors results from[g/cm3]
Density the CAD model itself, the relationships between1252 the individual
components, the selected types
Yield stress [MPa] of materials, etc. The starting curve of the electric motor
59
(Figure 16) during the analysed load is decisive for us. This was adjusted according to
the assumed
Theseoperating
operatingparameters
parametersofarethe proposed FDM
unsatisfactory duedevice. In Table
to the design. An4,intense
we canincrease
see
the individual parameters
in the carriage speed indefining the course
the X-axis causes of simulation
undesired of the subsystem
oscillations betweenmotion
the leadandscrew
its analysis.
and the lead bar, transmitted by the carriage’s work with the arm attached (Figure 16).

Figure
Figure16.
16.Description
Descriptionofofthe
thestarting
startingcurve
curveof
ofthe
theelectric
electricmotor
motor determined
determined according
according to
to the
standard printing speed.
the standard printing speed.

Due to the motion analysis result, we assumed this negative phenomenon at each
Table 4. Definitions used in the X-axis motion analysis subsystem.
acceleration, deacceleration or change of the orientation of the print head movement in
the X and Y axes. In extreme cases, forofexample,
Detail Analysis it manifests itself only by breaking the
contact of the print head with the printout. The solution to eliminating this problem was
Ground Aluminium Frame (Profiles 20 × 20, 20 × 40)
to activate the so-called jerk settings. This function is one of the options related to control-
Element size [mm] 1.4
ling the speed of the production process implemented in the used software for model
Motor speed [mm/s] 60
preparation. This parameter
Material of analysed part is also known from the field of machine tools. By activating
Polylactic acid (PLA)
it, we partially limit the starting
Elastic modulus [MPa] speeds to a specific value, from
3500 which the speed subse-
quently increases until
Poisson’s ratioit reaches the required operating value.
0.300 The use of the “jerk set-
Density [g/cm3] 1252
ting” function could be explained as follows. If the device has a set maximum speed v =
Yieldanstress
60 mm/s, and [MPa] a = 20 mm/s2, the device reaches this
acceleration 59 speed in three jumps in

These operating parameters are unsatisfactory due to the design. An intense increase
in the carriage speed in the X-axis causes undesired oscillations between the lead screw
and the lead bar, transmitted by the carriage’s work with the arm attached (Figure 16).
Due to the motion analysis result, we assumed this negative phenomenon at each
acceleration, deacceleration or change of the orientation of the print head movement in the
X and Y axes. In extreme cases, for example, it manifests itself only by breaking the contact
of the print head with the printout. The solution to eliminating this problem was to activate
the so-called jerk settings. This function is one of the options related to controlling the
speed of the production process implemented in the used software for model preparation.
This parameter is also known from the field of machine tools. By activating it, we partially
limit the starting speeds to a specific value, from which the speed subsequently increases
until it reaches the required operating value. The use of the “jerk setting” function could
be explained as follows. If the device has a set maximum speed v = 60 mm/s, and an
acceleration a = 20 mm/s2 , the device reaches this speed in three jumps in 3 s after start-up.
If we set the value “jerk”, or jerks to j = 10 mm/s, we spread the first jump at acceleration
and the last at de-acceleration to 2 s. It means a rise from speed from 0 to 10 mm/s and a
 3 s after start-up. If we set the value “jerk”, or jerks to j = 10 mm/s, we spread the first jump
at acceleration and the last at de-acceleration to 2 s. It means a rise from speed from 0 to
Appl. Sci. 2021, 11,10
2928
mm/s and a subsequent increase by leaps according to the corresponding acceleration 13 of 25
value up to the required value v = 60 mm/s. This method of eliminating undesired oscil-
lations is suitable as a temporary solution for the production of test specimens.
Due to thesubsequent
excessive increase
scope ofbyapplying
leaps according to the corresponding
this method acceleration
to all components of the value up to the
device,
we list only a few of the most critical ones. By repeatedly combining FEM, measurementssuitable
required value v = 60 mm/s. This method of eliminating undesired oscillations is
and correctionsasofa temporary
CAD models, solution for theachieved
we have production
theofcorrect
test specimens.
placement of each axis and
Due to the excessive scope of applying this method to all components of the device,
the components stored on it. This correlated with the standard deviation of the equipment
we list only a few of the most critical ones. By repeatedly combining FEM, measurements
on which they and were manufactured, i.e., ± 0.01 mm. The finite element method allowed us
corrections of CAD models, we have achieved the correct placement of each axis and
to reduce the plastic waste produced
the components significantly,
stored on it. but
This correlated dozens
with of defective
the standard pieces
deviation of thewere
equipment
produced despite this reduction. As a result of the increased volume of failures,
on which they were manufactured, i.e., ±0.01 mm. The finite element method it was allowed
necessary to recycle the waste
us to reduce thus produced.
the plastic waste produced significantly, but dozens of defective pieces were
produced despite this reduction. As a result of the increased volume of failures, it was
2.3. Recycling ofnecessary to recycle
Plastic Waste fromthe waste thus produced.
Design
Due to the2.3.
accumulation of plastic
Recycling of Plastic Wastewaste and its inherent negative impact on the en-
from Design
vironment, the recycling
Due to of theplastics in additive
accumulation production
of plastic waste andisits necessary. There are
inherent negative cur- on the
impact
rently many studies and publications dealing with this issue. We most often
environment, the recycling of plastics in additive production is necessary. There are encounter
material recycling with many
currently conventional
studies and FDM equipment.
publications Their
dealing simple
with versions,
this issue. which
We most have
often encounter
only one print material
head, produce
recycling a relatively large amount
with conventional of plastic waste,
FDM equipment. not just
Their simple in the area
versions, which have
only one
of failures. Because theprint
deviceshead, produce
use only one a relatively
type oflarge amount
material of plastic
in their waste, not
operation, thejust in the area
mate-
of failures. Because the devices use only one type of material
rial used to support the printing of individual models has a majority share in the produc- in their operation, the material
used to support
tion of waste. Equally problematicthe printing
are theoffilament
individual modelswhich,
residues, has a majority
due to share in the production
the insufficient
of waste. Equally problematic are the filament residues, which, due to the insufficient
volume, have no use in larger components. Due to the waste produced in this way, several
volume, have no use in larger components. Due to the waste produced in this way, several
devices are used in this technology, which enable the recycling and reuse of material. In a
devices are used in this technology, which enable the recycling and reuse of material. In a
relatively simple cycle, simple
relatively the material is material
cycle, the crushedisinto granules
crushed of a specific
into granules size,size,
of a specific andand
thenthen this
this granulate is introduced
granulate into a specialised
is introduced extruder.
into a specialised It works
extruder. It on the on
works principle of a plas-
the principle of a plastic
tic injection chamber,
injectionwith
chamber,the difference that thethat
with the difference melt
theismelt
notisinjected intointo
not injected the the
mould.
mould.TheThe melt
passes through
melt passes through a nozzlea nozzle of a specific
of a specific diameter
diameter andand is then
is then cooledand
cooled and wound
wound on ona aroll. We
schematically
roll. We schematically see process
see this this process
shownshown in in Figure17.
Figure 17.

Figure 17.Figure
Equipment for the for
17. Equipment production of filament
the production fromfrom
of filament recycled granulate
recycled [29].
granulate [29].

Due toinaccuracies
Due to deficiencies, deficiencies, inaccuracies
and variousand various
types types of influences,
of external external influences,
which can which can
significantly affect the production of models using FDM technology, the presentation will will
significantly affect the production of models using FDM technology, the presentation
always contain a certain percentage of failures. This failure, which is characteristic in
always contain a certain percentage of failures. This failure, which is characteristic in par-
particular of the initial stages of prototype production and the changes resulting from there,
ticular of the initial stages of in
is predominant prototype production
plastic waste generation. and the changes
Given resulting
that this article fromthe
presents there,
design and
is predominantmanufacture
in plastic waste generation.
of atypical Given that
FDM equipment, it isthis article
obvious presents
that the design
it was necessary and this
to address
manufacture ofissueatypical
duringFDM equipment,
its production. The it is obvious
application thatfinite
of the it was necessary
element methodto address
(FEM) technology
this issue during its production.
in designing The application
key components of thereduced
has partially finite element method
this failure. (FEM) tech-
Nevertheless, due to the
inaccuracies
nology in designing and deviations
key components hasofpartially
the FDM reduced
devices, the thisproblem
failure.ofNevertheless,
storing the different
due types
of materials
to the inaccuracies used, and
and deviations of the
the mechanical
FDM devices, properties of the of
the problem prints themselves,
storing this design
the different
did not go without plastic waste accumulation. Due to this
types of materials used, and the mechanical properties of the prints themselves, this de- fact and the amount of waste
produced, the recycling of the produced plastic waste was implemented in this activity.
sign did not go without plastic waste accumulation. Due to this fact and the amount of
The design has also been extended to include a separate printhead concept, designed to
waste produced, the recycling of the produced plastic waste was implemented in this ac-
work directly with recycled granulate. The recycling of waste from FDM production and
tivity. The design has as
industry also
suchbeen
is ofextended to include
interest to many studies. a separate
The issue ofprinthead concept,
partial recovery de- from
of waste
individual sectors is also addressed in the publication “Evaluation of the Circularity of
l.
pl.Sci.
Sci.2021,
2021,11,
11,xxFOR
FORPEER
PEERREVIEW
REVIEW 1414ofof2626

signed totowork
workdirectly
directlywith
withrecycled
recycledgranulate.
granulate.The Therecycling
recyclingofofwaste
wastefromfromFDM FDMpro-
Appl. Sci. 2021, 11, 2928 signed pro- 14 of 25
duction
duction and industry as such is of interest to many studies. The issue of partialrecovery
and industry as such is of interest to many studies. The issue of partial recovery
ofofwaste
wastefrom
fromindividual
individualsectors
sectorsisisalso
alsoaddressed
addressedininthe thepublication
publication“Evaluation
“Evaluationofofthe the
Circularity
Circularity of Recycled PLA Filaments for 3D Printers” [30]. The subject ofthis
of Recycled PLA Filaments for 3D Printers” [30]. The subject of thispublication
publication
isisthe
theuse
useofofRecycled
plastic
plasticimpact
PLA from
impact fromvarious
Filaments for industries
various 3D inina[30].
Printers”
industries apredefined ratio.
The subject
predefined ofAt
ratio. the
this
At thesame
sametime,
publication
time,is the use of
ititpoints out the
plasticimportance
impact fromand method
various of circulation
industries in a of these
predefined materials
ratio.
points out the importance and method of circulation of these materials in productionAt in
the production
same time, it points out
(Figure 18).
(Figure 18). the importance and method of circulation of these materials in production (Figure 18).

Figure
Figure18.
18.Demonstration
Demonstrationof
ofFDM
FDMproduction
productionwaste
wastebefore
beforeprocessing
processinginto
intogranulate
granulateform.
form.
Figure 18. Demonstration of FDM production waste before processing into granulate form.

The
Theoverall
overallrecycling
recycling
The overall process
process isisnot
recycling not complicated.
complicated.
process Essentially,
Essentially,plastic
is not complicated. plasticfailures,
Essentially, failures, filament
plastic filament
failures, filament
residues and
residues and supporting
residues material
and supporting
supporting material areare crushed
material
crushed into
areinto granules.
crushed It is
into granules.
granules. then processed
It is then Itprocessed bybyaade-
is then processed de-by a device
vice
viceworking
working ononthe
working theprinciple ofofplastic
on the principle
principle plastic ofinjection. The
Thedifference
plastic injection.
injection. isisthat
The difference
difference thatinstead ofofinjecting
is that
instead instead
injectingof injecting
the
themelt
meltinto the
into the
the mold,
melt
mold,intothe
the filament
the mold, the
filament isisextruded
filament through
extruded isthrough
extruded aanozzle
through
nozzle ofofthe
athe desired
nozzle
desired of diameter,
the desired diameter,
diameter,
the filament
the filament is
the cooled
is filament
cooled andand then
is cooled wound
and then
then wound on a roll.
on wound Thanks
on a roll.
a roll. Thanks to this
Thanks
to this process,
to this
process, it is
ispossible
it process,
possible ittois
topossible to
recycle most of
recyclethe plastic
most ofwaste
the produced.
plastic waste At present,
produced. however,
At
recycle most of the plastic waste produced. At present, however, this step is beginning to present, this step
however, is beginning
this step tois beginning
seem redundant,
to seemespecially
redundant, in the piece
especially or small
in the series
piece production
or small
seem redundant, especially in the piece or small series production area. Implementing the area.
series Implementing
production area. the
Implementing
granulate
granulateprocessing
the granulate
processing mechanism
processing
mechanism into the
theprinthead
mechanism
into printhead itself
into the will
willallow
printhead
itself us
itself
allow totoreduce
uswill allow
reduceus these
to reduce these
these
steps with a
steps with steps low degree
a low with degree of
a low production load.
degree of production
of production As
load. As can can be
load. seen
As can
be seen in the publication
be seen
in the “Towards
in the publication
publication “Towards “Towards
Distributed Recycling
Recyclingwith
DistributedDistributed Additive
Recycling
with Additivewith Manufacturing ofofPET
Additive Manufacturing
Manufacturing PETFlake Flake ofFeedstocks”
PET [31].
[31].The
Flake Feedstocks”
Feedstocks” The [31]. The
extrusion system works on the principle of two differently
extrusion system works on the principle of two differently oriented screws, which are are used
extrusion system works on the principle of two oriented
differently screws,
oriented which
screws, are
which
used
usedtotomove
moveto thethegranulate
move through
the granulate
granulate through the
theprint
through thehead.
print printBy
head. Byapplying
head. By applying
applying heat
heatand heat
and pressure
and pressure
pressure inindif-
dif-in different
ferent areas, the
areas, melt
the reaches
melt a
reachesstate a that
state is identical
that is to the
identical fibre
to the
ferent areas, the melt reaches a state that is identical to the fibre state during the extrusion state
fibre during
state the
during extrusion
the extrusion of the
ofofthe filament by
filament a conventional
by a conventional printhead.
printhead. As already
As already
the filament by a conventional printhead. As already mentioned, the combination of mentioned,
mentioned, the combination
the combination of of the finite
the
thefinite
finiteelement
element
element method
method
method used,
used,measurements,
used, measurements,repeated
measurements, repeatedcorrection
repeated correctionof
correction ofCAD
of CADmodels
CAD modelsand
models andsubsequent
subsequent printing caused the accumulation of unnecessary waste during the atypicalstructure’s
subsequent printing
printing caused the accumulation of unnecessary waste during the atypical
atypical
structure’s prototyping.
structure’sprototyping.
prototyping.In In combination
Incombination
combinationwith with
withthe so-calledcommon
theso-called commonwaste
common wastefrom
waste fromFDM
from FDMproduction,
FDM pro-
pro- such
duction, suchas asexcess
excess support,
support, cuttings
cuttings and
and ends
ends of filaments
of filaments
duction, such as excess support, cuttings and ends of filaments significantly affect the di- significantly
significantly affect
affect the
the direction
di- of the
rection of design
the design of ofthe
the structure
structure (Figure
(Figure 19).
19). InInthe
thebeginning,
beginning,
rection of the design of the structure (Figure 19). In the beginning, the excess and non-gift the
the excess
excess andand non-gift
non-gift material was
material recycled and processed into a filament. Thisprocess process hasproven proven efficientbut but relatively
materialwas wasrecycled
recycledand andprocessed
processedinto intoaa filament.This This processhas has provenefficientefficient but
relatively lengthy and inefficient due to the production batch [32,33].
relativelylengthy
lengthyand andinefficient
inefficientdue duetotothe theproduction
productionbatch batch[32,33].
[32,33].

Figure 19. Demonstration

Figure of the cycle of recycling plastic models from the design of the structure.
Figure19.
19.Demonstration
Demonstrationofofthe
thecycle
cycleofofrecycling
recyclingplastic
plasticmodels
modelsfrom
fromthe
thedesign
designofofthe
thestructure.
structure.

Due Duetheto this fact,was

the design was extended by the creation of an effector with a separate
Duetotothis
thisfact,
fact, thedesign
design wasextended
extendedby bythe thecreation
creationofofan
aneffector
effectorwith
withaaseparate
separate
extrusion extrusion mechanism integrated directly into it. The print head designed in this way will
extrusionmechanism
mechanismintegrated
integrateddirectly
directlyinto
intoit.it.The
Theprint
printhead
headdesigned
designedininthis
thisway
waywill
will
then allow us to skip some of the steps necessarily associated with recycling. We also
consider it another of the necessary steps to improving the state of long-term sustainable
development in connection with this type of technology.
 sider it another of the necessary steps to improving the state of long-term sustainable de-
velopment in connection with this type of technology.

2.4. Guide Design in Y and X Axes

Appl. Sci. 2021, 11, 2928 15 of 25
Each functional structure must have suitable lines, drives and transformation mech-
anisms. Due to the creation of the system, which is formed by the series connection of two
instruments, the work pays increased attention to lines and transformation mechanisms.
2.4. Guide Design in Y and X Axes
It is known that most commonly available FDM devices work with extreme clearances
Each functional structure must have suitable lines, drives and transformation mecha-
[34]. This includes
nisms.e.g.,
Due free ends
to the of theoflead
creation screws which
the system, in theisZ-axis,
formedwhichby the are also
series visible, of two
connection
e.g., on Zmorph SX or Creality CR-Max devices. These are considered upper
instruments, the work pays increased attention to lines and transformation mechanisms. It and middle
class in terms ofis price
known andthatquality of available
most commonly FDM equipment.
available FDM devicesA frequent
work recommenda-
with extreme clearances [34].
tion of these devices’ intermediaries
This includes is not
e.g., free ends to tighten
of the lead screws the in
screw connections
the Z-axis, which are to the
alsostop.
visible, e.g.,
This fact, combined with the mechanisms’ serial involvement, played an important role class
on Zmorph SX or Creality CR-Max devices. These are considered upper and middle
in the design. in terms of price and quality of available FDM equipment. A frequent recommendation
of these
By successive devices’we
selection, intermediaries
have eliminated is not tothetighten the screwmechanisms
conventional connections toused the stop.
to This
fact, combined with the mechanisms’ serial involvement, played an important role in
move the FDM device’s components. Due to previous experience and the device’s con-
the design.
ceptual design, instruments with V-shaped wheels and timing belts have been excluded.
By successive selection, we have eliminated the conventional mechanisms used to
When moving,move the mechanism
the FDM device’s controlled
components.by theDue timing belts was
to previous unsatisfactory.
experience Theyconcep-
and the device’s
often wear out tual
anddesign,
loosen,instruments
resulting in inaccurate
with V-shaped movement of the belts
wheels and timing arms. This
have beencanexcluded.
lead to When
a collision or damage to the effector. The mechanism moving using
moving, the mechanism controlled by the timing belts was unsatisfactory. They rubber wheels in the
often wear
shape of a “V” out
hasand
been loosen, resulting
eliminated duein inaccurate
to the frequentmovement of the arms.
loosening This cannuts,
of eccentric lead to a collision or
which
damage
subsequently cause to the effector.
a change The mechanism
in the components’ moving In
position. using
the rubber
case ofwheels in the
the series shape of a “V”
connec-
has been eliminated due to the frequent loosening
tion of the newly designed structure’s arms, this fact would lead to the accumulation of eccentric nuts, which subsequently
of
cause a change in the components’ position. In the case of the series connection of the
negative forces caused by the truck’s incorrect position relative to the machine coordina-
newly designed structure’s arms, this fact would lead to the accumulation of negative
tion system. The deflection of these arms would subsequently cause the linear guide and
forces caused by the truck’s incorrect position relative to the machine coordination system.
the lead screwThe to deflection
cross, thus preventing
of these arms would the carriage
subsequently from moving
cause andguide
the linear damaging
and the the
lead screw
drive. As part toof cross,
our proposal, we chose two variants of the solution
thus preventing the carriage from moving and damaging the drive. applied to the
As XY
part of our
and ZZ′- axes. The first variant
proposal, we choseistwo a combination
variants of the ofsolution
a guideapplied
rod and to athe
guide
XY and ZZ0 - axes. The first
screw.
The lines of the devices
variant in the X of
is a combination and Y axes
a guide rodareandessentially identical (Figure 20). The
a guide screw.
The lines of the devices in the X and Y axes
drive of the entire line is provided by the Nema 17 motor (3), which is connected are essentially identical (Figure
to the20). The
lead screw (5) using flexible coupling (4). The carriage movement (10) is ensured through to the
drive of the entire line is provided by the Nema 17 motor (3), which is connected
lead screw (5) using flexible coupling (4). The carriage movement (10) is ensured through a
a guide screw and a nut (9) which drives the carriage in the Z-axis. A guide rod’s combi-
guide screw and a nut (9) which drives the carriage in the Z-axis. A guide rod’s combination
nation provides its exact position with a diameter of 8 mm (6) with a linear ball bearing
provides its exact position with a diameter of 8 mm (6) with a linear ball bearing (8). The
(8). The linear bearing and guide
linear bearing nut are
and guide nuthoused
are housedin thein carriage, ensuring
the carriage, ensuring thethe
transmission
transmission of the
of the guide movements to the first stage of the arm in the Y-axis and
guide movements to the first stage of the arm in the Y-axis and its correct its correct orientation
orientation for
for the device’sthecoordination system. system.
device’s coordination

Figure 20. Figure

Drive, 20. Drive, transformation
transformation mechanism
mechanism and device
and device guidance
guidance in Y-axis.
in the the Y-axis.

The line used in the X-axis is similar to the first line. The elements of its construction
The line used in the X-axis is similar to the first line. The elements of its construction
and the principle of operation remain unchanged. The only change is component No. 2.
and the principle
Thisofkey
operation
component, remain
whichunchanged.
is common toThe only and
the X-axis change is secures
Y-axis, component No. 2.position
the motor’s
This key component, which is common to the X-axis and Y-axis, secures the motor’s posi-
in the Y-axis. These components ensured the relative place of the drives, transformation
tion in the Y-axis. These components
mechanisms ensured
and lines. Since the relativewere
these components place ofcreated
to be the drives,
using transfor-
FDM technology
mation mechanisms
as partand lines.
of the Since these
conceptual components
solution, were towas
their production be accompanied
created usingbyFDMthe already
mentioned complications and the need for frequent model modifications.
technology as part of the conceptual solution, their production was accompanied by the
already mentioned complications and 0the need for frequent model modifications.
2.5. Line Design in Z and Z Axes
Another of the device design’s key components is the mechanism ensuring movement
in the Z and Z0 axes. Due to its orientation and the fact that it is to be loaded with two arms
Sci. 2021, 11, x FOR PEER REVIEW 16 of 26

Appl. Sci. 2021, 11, 2928

2.5. Line Design in Z and Z′ Axes 16 of 25

Another of the device design’s key components is the mechanism ensuring move-
ment in the Z and Z′ axes. Due to its orientation and the fact that it is to be loaded with
two arms stagesstagesandanda printhead
a printhead effector, it isitobvious
effector, is obvious thatthat
its construction
its construction waswas moremorede- demanding
manding than thanwith
withmechanisms
mechanismsininthe theXXand
andYY axes.
axes. The
The first change
change fromfromthe theoriginal
originalproposal was
proposal wasthe theuse
useofoftwo
twoinstruments.
instruments.This Thisstepstepdistributed
distributedthe theload
loadbetween
betweenthe thetwotwomechanisms,
mechanisms,whichwhichfacilitated
facilitatedthethedrives’
drives’operation
operation and
and contributed
contributed totothethe stability
stability of of
thethe
structure. The
second step was to use linear guides instead
structure. The second step was to use linear guides instead of guide rods. of guide rods.
Both designsBoth designs
in the Z and in Z′ the
axesZare Z0 axes are conceptually
andconceptually similar (Figure similar (Figure
21). The 21). The movement
movement
is ensured byistheensured
Nemaby 17the Nema
motor (5),17 motor
fixed (5),frame
to the fixed through
to the frame through
a plastic a plastic(1,2).
component component (1,2).
Subsequent transmission
Subsequent transmission of torque to the of torque
guide to rod the
(7)guide rod (7)by
is ensured is aensured
flexibleby a flexible coupling
coupling
(6). The linear(6).guide
The linear guidetoisthe
is attached attached
frame to thethree
with framebrackets
with three
thatbrackets
providethat provide its position
its position
and stability. The trolley (8) is supplemented with
and stability. The trolley (8) is supplemented with bearings of type 608 2Z (9) and bearings of type 608 its
2Z (9) and its
movement is excited thanks to the guide nut, which
movement is excited thanks to the guide nut, which ensures the transformation of the ensures the transformation of the
rotational movement of the guide screw into a sliding
rotational movement of the guide screw into a sliding movement of the linear guide. The movement of the linear guide. The
opposite endopposite end screw
of the lead of the is
lead screwin
housed is ahoused
bearing in 608
a bearing 608 2Z
2Z located inlocated in the (11,
the housing housing (11, 12).
It is attached
12). It is attached to the
to the frame frame
with with standard
standard hexagonhexagon socketand
socket screws screwsM3 and M3 threads.
threads.

Figure 21. Drive,21.

Figure transformation mechanism
Drive, transformation and device
mechanism andguidance in Z-axis.in Z-axis.
device guidance

0
The Z -axis consists
mechanism consists
The Z′-axis mechanism of the sameofcomponents
the same components andof
and principle principle
operationof operation as
the mechanism
as the mechanism for movement
for movement in theThe
in the Z-axis. Z-axis. The difference
difference is thein
is the change change in the dimensions
the dimen-
of components
sions of components 9 and 2).
9 and 2).

2.6. Design of2.6.

the Design
X, Y andof Z-Axis
the X, YArmandSystem
Z-Axis Arm System
Due to the complicated solution associated with the series connection of the individual
Due to the complicated solution associated with the series connection of the individual
elements of the four arms located on the device. It was necessary to pay increased attention
elements of the four arms located on the device. It was necessary to pay increased attention
to the so-called “Trolleys” moving along a guide bar and a linear guide. They are based on
to the so-called “Trolleys” moving along a guide bar and a linear guide. They are based on
a solid trolley in which all the necessary components are stored. In the case of carriages in
a solid trolleythe
in Xwhich
and Y allaxes,
the necessary components
these components are bearings
include stored. Inofthetypecase of2Z
608 carriages in are used to
(1), which
the X and Y axes, these components include bearings of type 608 2Z (1), which are
support the 1st stage arm (Figure 22). They also participate in its rotational motion. The used to
support the 1st stage arm has
construction (Figure
two 22). They alsowhich
components, participate in itsincreased
required rotationalattention
motion. in Theterms of their
construction has two components,
relative position and whichcoaxial. required increased attention
These components, i.e., theinlinear
termsball
of their rel- (4) and the
bearing
ative positionguide
and coaxial.
nut (2),These components,
are fastened to the i.e., the linear
carriage bodyball bearing
through (4) and
screw the guide(5 and 3). In
connections
the casetoofthe
nut (2), are fastened a linear bearing,
carriage body the screwscrew
through connection is realised
connections (5 and on3).
theInhousing
the case (8) in which
the bearing
of a linear bearing, is located.
the screw Figure
connection is 22b shows
realised onthe
the“trolley” of the
housing (8) Z and the
in which Z’- bearing
axes. Its design was
modified due to the need to reduce the weight of the whole
is located. Figure 22b shows the “trolley” of the Z and Z’- axes. Its design was modified mechanism. The difference is
due
Appl. Sci. 2021, 11, x FOR to the
PEER need to reduce the weight of the whole mechanism. The difference is also an- in 17
REVIEWalso anchoring on the linear guide realized through M3 screws (5). The change theoftype
26
of line was necessary due to the increase required in the system’s
choring on the linear guide realized through M3 screws (5). The change in the type of line stability and rigidity in
the Z-axis, which supports the effector’s entire weight.
was necessary due to the increase required in the system’s stability and rigidity in the Z-
axis, which supports the effector’s entire weight.

Figure
Figure22.
22.(a)(a)Design
Designofofthe
thetruck
truckininthe
theXXand
andYYaxes;
axes;(b)
(b)The
The“trolley”
“trolley”ofofthe
theZZand
andZ´-axes
Z´-axes.

The arm of the first stage of the proposed construction consists of a ridge hinge (1),
fixed to the carriage through a screw and a nut M8 and six corresponding washers (Figure
23a). The arm further consists of a 20 × 20 mm aluminium profile (6), screws (7), washers
(8) and “T” shaped nuts ensuring the position and stability of both end elements. The
arm’s opposite side is formed by a hinge (10) with bearings that allow arm 2. The second
component of the arm in the X and Y axes is the second stage arm (Figure 23b).
Appl. Sci. 2021, 11, 2928 17 of 25

Figure 22. (a) Design of the truck in the X and Y axes; (b) The “trolley” of the Z and Z´-axes

The arm of The arm stage

the first of theoffirst stage of the
the proposed proposed consists
construction construction consists
of a ridge of (1),
hinge a ridge hinge
fixed to the(1), fixedthrough
carriage to the carriage
a screwthrough
and a nuta M8
screw
andand a nut M8 and six
six corresponding corresponding
washers (Figure washers
(Figure
23a). The arm 23a).
further The arm
consists of afurther
20 × 20consists of a 20 ×profile
mm aluminium 20 mm(6), aluminium
screws (7),profile (6), screws (7),
washers
washers (8) and “T” shaped nuts ensuring the position and stability
(8) and “T” shaped nuts ensuring the position and stability of both end elements. The of both end elements.
arm’s opposite side is formed by a hinge (10) with bearings that allow arm 2. The secondarm 2. The
The arm’s opposite side is formed by a hinge (10) with bearings that allow
componentsecond component
of the arm in the X of
andtheYarm
axesinisthe
theXsecond
and Y stage
axes isarm
the(Figure
second 23b).
stage arm (Figure 23b).

Figuredesign
Figure 23. Structural 23. Structural
of the X,design
Y, Z andof the X, Y,arm.
Z´ axis Z and
(a)Z´ axis
The arm.
arm of (a)
theThe
firstarm
stageofof
thethe
first stage ofconstruction;
proposed the pro- (b)
posed construction; (b) the 0second
the second stage arm; (c) trolley in Z and Z axes. stage arm; (c) trolley in Z and Z′ axes.

This arm
This arm provides theprovides
connection the ofconnection of the
the first arm firsteffector.
to the arm to The the method
effector. ofThein- method of
interconnection and transformation of motion is the same
terconnection and transformation of motion is the same as in the previous step. It means as in the previous step. It means
that the component has a comb hinge, this time rotated by 90 ◦ (2), and an aluminium
that the component has a comb hinge, this time rotated by 90° (2), and an aluminium pro-
profile
file with a 20 × 20 mmwith a 20 × 20
diameter, mm is
which diameter,
connected which
to theiseffector
connected holderto the
(7). effector holder (7). It is
It is attached
attached
to the aluminium frameto the aluminium
through screwframe through
connections screw connections
consisting of a screw (7),consisting
a washer of (8)
a screw (7), a
and a “T” shaped nut. The different shape of the end component is adapted so that it does is adapted
washer (8) and a “T” shaped nut. The different shape of the end component
not collide so thatthe
with it does not through
effector collide with whichthe M8
effector through
threaded which
screws M8 threaded
connect it during screws
the connect it
movement of the arms in the X and Y- axes. The correct position of the screw connectionof the screw
during the movement of the arms in the X and Y- axes. The correct position
connection
and the bearings’ and themovement
trouble-free bearings’ trouble-free movement
is ensured through is ensured
washers (9). through washers (9).
As for the connecting element, trolley in Z and Z 0 axes, its design is smaller and more
As for the connecting element, trolley in Z and Z′ axes, its design is smaller and more
compact, ascompact,
shown inas shown
Figure in ItFigure
23c. 23c. compact
is a more It is a more
designcompact
due todesign due toweight
the heavier the heavier
of weight
of the linear guide housing, which the drive must handle
the linear guide housing, which the drive must handle during the device’s operation. The during the device’s operation.
componentsThe of components
these structural of these
elementsstructural elementsHere
are similar. are similar.
is a ballHere is a ball
bearing, bearing,
which was which was
replaced by a linear guide house. The trolley is attached to it through M3 screws (4). Other
replaced by a linear guide house. The trolley is attached to it through M3 screws (4). Other
elements of this construction are bearings type 608 2Z, which are used to fasten the arm’s
elements of this construction are bearings type 608 2Z, which are used to fasten the arm’s
first stage using a screw and nut with an M8 thread. The last element is the guide nut (3),
first stage using a screw and nut with an M8 thread. The last element is the guide nut (3),
which ensures, as with other components, the transformation of the rotational movement
which ensures, as with other components, the transformation of the rotational movement
of the guide screw into a sliding movement of the house along with the linear guide. The
of the guide screw into a sliding movement of the house along with the linear guide. The
lead nut is attached to the component with M4 screws (5). The arm’s second stage in the Z
lead nut is attached to the component with M4 screws (5). The arm’s second stage in the
and Z0 axes is substantially identical to the X and Y-axes arm. The only difference is the
Z and Z′ axes is substantially identical to the X and Y-axes arm. The only difference is the
different orientation of the swivel joint connecting the arm to the effector. This component’s
different orientation of the swivel joint connecting the arm to the effector. This compo-
shape is then adapted so that it does not collide anywhere with the effector or other arms
nent’s shape is then adapted so that it does not collide anywhere with the effector or other
during movement.
arms during movement.
2.7. Design of Other Components of The Structure
Based on a theoretical analysis dealing with FDM technology, we know that key
components characterize each device’s design. In our case, the following features are the
effector with the print head, the Bowden extrusion system and the print pad. The design of
the printing pad is based on knowledge from the field of FDM technology. The designed
printing pad has a relatively simple manual positioning system (Figure 24). This is based
on the principle of tightening the screw (5) and the “T” nut (8) located at the top of the
printing pad (1). By turning the screw, we derive the pressing force, which moves one of
the corners of the printing pad downwards or upwards when it is released. By positioning
each corner of the pad in this way, we then achieve the base’s correct position for the
 ponents characterize each device’s design. In our case, the following features are the ef-
fector with the print head, the Bowden extrusion system and the print pad. The design of
the printing pad is based on knowledge from the field of FDM technology. The designed
printing pad has a relatively simple manual positioning system (Figure 24). This is based
on the principle of tightening the screw (5) and the “T” nut (8) located at the top of the
Appl. Sci. 2021, 11, 2928 18 of 25
printing pad (1). By turning the screw, we derive the pressing force, which moves one of
the corners of the printing pad downwards or upwards when it is released. By positioning
each corner of the pad in this way, we then achieve the base’s correct position for the
printing
printing process. Dueprocess. Due to the series-connected
to the series-connected design useddesign
and theused
fact and
that the
ourfact that our proposed
proposed
solution
solution is based is based
on the on the
principle of aprinciple
kinematic of amodel
kinematic model
that has not that has not
yet been yet been
tested, it wastested, it was
not our
not our intention intention tothe
to complicate complicate
solution the
usingsolution usingcalibration
automatic automatictools.
calibration tools. Their simple
Their simple
design
design and the and the
principle of principle
operationofwereoperation
based were based onthe
on averaging averaging
positionthe position
of the limit of the limit
switch during calibration. In the case of larger deviations, it would
switch during calibration. In the case of larger deviations, it would average a value higher average a value higher
thanheight
than the layer’s the layer’s
duringheight during
printing. printing.
This This cause
fact could fact could cause insufficient
insufficient or no adhesionor no adhesion of
theto
of the material material to thesubstrate
the printing printing substrate in this design.
in this design.

Figure 24. The design

Figureproposal for theproposal
24. The design printing for
padthe
solution.
printing pad solution.

The conclusionThe of conclusion

the design ofisthe design is solutions
conceptual conceptual of solutions
the effector of the
andeffector and the system
the system
for material extrusion. These devices form one unit and are located at the end of the X,end
for material extrusion. These devices form one unit and are located at the Y, of the X, Y,
Z and Z 0 axes. The effector has six joints for the joints, which were created to verify the
Z and Z′ axes. The effector has six joints for the joints, which were created to verify the
kinematics of kinematics
the six-axisof the six-axis
device anddevice and as elements
as support support elements
that would that be
would
neededbe needed
when when using
aluminium
using aluminium profiles profiles
in the in the and
arms armstoand to verify
verify the kinematic
the kinematic modelmodel and possible
and possible col- collisions.
A Bowden
lisions. A Bowden material
material extrusion
extrusion system
system waswas chosen
chosen in inthethe design
design totoreduce
reducethe the weight of
the effector. It is basically a standard system with commonly
weight of the effector. It is basically a standard system with commonly available compo- available components. It
is based on the Nema 17 (9) drive, which ensures the
nents. It is based on the Nema 17 (9) drive, which ensures the fibre’s extrusion. Extruderfibre’s extrusion. Extruder design
that provides
design that provides the pressure
the pressure requiredrequired to extrude
to extrude the material
the material (Figure (Figure
25). The25). The material is
mate-
moved through a pneumatic coupling (10) in which
rial is moved through a pneumatic coupling (10) in which a PTFE tube (11) is fixed from a PTFE tube (11) is fixed from the
the extruder.extruder.
Inside, the Inside, the material
material slides the
slides toward toward
printtheheadprint head
(12). (12).it There
There it isto
is heated heated to the
the desired temperature and is subsequently extruded in the form of a molten fiber through a
desired temperature and is subsequently extruded in the form of a molten fiber
nozzle(13).
through a nozzle (13).An An atypicalnozzle
atypical nozzlewaswaschosen
chosenfor forthe
thedesign,
design,which whichwillwillallow
allowthe the creation of
creation of non-planar surfaces on a larger scale. The effector (2), i.e., a key component ofthe proposed
non-planar surfaces on a larger scale. The effector (2), i.e., a key component of
the proposeddevice,
device,consists
consistsofofbearings.
bearings.AAmovable
movablejointjointisisformed
formedbetweenbetweenthe theeffector
effectorand the end
element of the arms X and Y of the second stage after the screw connection has been formed.
and the end element of the arms X and Y of the second stage after the screw connection
The bearings are positioned within the effector so that their axis is always parallel to the
has been formed. The bearings are positioned within the effector so that their axis is al-
axis of the lead screw of the respective axis. Other elements of this printing set are fans
ways parallel to the axis of the lead screw of the respective axis. Other elements of this
used as standard. A 20 × 20 × 10 mm centrifugal fan (7) for cooling the passive cooling of
printing set are fans used as standard. A 20 × 20 × 10 mm centrifugal fan (7) for cooling
the print head and a 40 × 40 × 10 mm axial fan (3) for cooling the layer of material on the
the passive cooling of the print head and a 40 × 40 × 10 mm axial fan (3) for cooling the
printing pad. Both of these components are fixed to the effector body through standard
layer of material on the printing pad. Both of these components are fixed to the effector
screws (4, 6). The last component of this assembly is the blower used to direct the airflow
body through standard screws (4, 6). The last component of this assembly is the blower
under the nozzle.
used to direct the airflow under the nozzle.
The application of theoretical knowledge to designing a device for printing non-planar
surfaces can be seen in Figure 26. The resulting device consists of two pairs of identical
arms that connect the individual axes with the end effector. The base frame is made of
aluminium profiles measuring 20 × 20 and 20 × 40 mm. Its L-shaped arrangement has
enough space for the movement of all four arms. The design consists of two types of guides,
and the first is located in the X and Y axes, is based on the principle of a combination of a
lead screw, nut and lead bar. The guides in the Z and Z0 axes consist of linear guides and
lead screws with nuts. These guides and transformation mechanisms provide the system
with sufficient rigidity and fluidity of movement.
Appl.
Appl.Sci.
Sci.2021,
2021,11,
11,x2928
FOR PEER REVIEW 1919ofof26
25

Figure 25. Display the effector of the proposed device and the Bowden extension system.

The application of theoretical knowledge to designing a device for printing non-pla-

nar surfaces can be seen in Figure 26. The resulting device consists of two pairs of identical
arms that connect the individual axes with the end effector. The base frame is made of
aluminium profiles measuring 20 × 20 and 20 × 40 mm. Its L-shaped arrangement has
enough space for the movement of all four arms. The design consists of two types of
guides, and the first is located in the X and Y axes, is based on the principle of a combina-
tion of a lead screw, nut and lead bar. The guides in the Z and Z′ axes consist of linear
guides and lead screws with nuts. These guides and transformation mechanisms provide
Displaythe
theeffector
effectorof
ofthe
theproposed
proposeddevice
deviceand
Figure25.
Figure 25.Display
the system with sufficient rigidity and fluidity ofand theBowden
the Bowdenextension
movement. extensionsystem.
system.

The application of theoretical knowledge to designing a device for printing non-pla-

nar surfaces can be seen in Figure 26. The resulting device consists of two pairs of identical
arms that connect the individual axes with the end effector. The base frame is made of
aluminium profiles measuring 20 × 20 and 20 × 40 mm. Its L-shaped arrangement has
enough space for the movement of all four arms. The design consists of two types of
guides, and the first is located in the X and Y axes, is based on the principle of a combina-
tion of a lead screw, nut and lead bar. The guides in the Z and Z′ axes consist of linear
guides and lead screws with nuts. These guides and transformation mechanisms provide
the system with sufficient rigidity and fluidity of movement.

Figure 26.Design
Figure26. Designof
ofatypical
atypicalconstruction
constructionof
ofFDM
FDMadditive
additiveproduction
productionequipment.
equipment.

The
Theresult
resultof ofthe
theuseuseof ofFEM
FEMcancanbebeseen
seenininFigure
Figure26. 26.AAfully
fullyfunctional
functionalFDM FDMdevice
device
has
has all the relevant components characteristic of FDM technology. The end effectorallows
all the relevant components characteristic of FDM technology. The end effector allows
the
the storage
storage ofof aa tip-shaped
tip-shapedprint printhead
headadapted
adapted forfor
thethe non-planar
non-planar surface
surface production
production pro-
process.
cess. Its Its movement
movement is ensured
is ensured bybythethe transmission
transmission of of
thethe carriages’
carriages’ sliding
sliding movementin
movement
in
thethe
X, X,
Y, Y, Z and
Z and Z0 axes
Z′ axes through
through arms.arms.
ThisThis movement
movement is derived
is derived from thefrom the rotational
rotational move-
movement
ment of the Nema 17 motors and its transformation into a rectilinear sliding motion
of the Nema 17 motors and its transformation into a rectilinear sliding motion
through
through aaleadleadscrew
screwand andaanut.nut.The
Theimplementation
implementationof ofthe
theproposal
proposalitself itselfconsisted
consistedof
of
several steps. The first step was to create a request based on the
several steps. The first step was to create a request based on the theoretical knowledge theoretical knowledge
gained26.inDesign
Figure the previous
of atypicalchapters. The of
construction design (Figure production
FDM additive 27) was created to apply theoretical
equipment.
knowledge and design requirements for the printing of non-planar surfaces. The result of
this The
creative activity
result of the was
use ofa conceptual
FEM can bedesignseen inofFigure
a device 26.working in three axes.
A fully functional FDM However,
device
this original concept did not have good features. We created the prototype
has all the relevant components characteristic of FDM technology. The end effector allows of the atypical
FDM
the device
storage of presented
a tip-shaped in the article.
print The existing
head adapted type
for the of Tripteron
non-planar construction
surface productioninspires
pro-
the design of the device. The main purpose and reason for the creation
cess. Its movement is ensured by the transmission of the carriages’ sliding movement in of this construction
areX,the
the Y, intention
Z and Z′ axes to move
through in the field
arms. Thisofmovement
this technology
is derivedtowards
from thethe rotational
developmentmove-of
equipment, which allows the production of prints created by a non-planar method. We
ment of the Nema 17 motors and its transformation into a rectilinear sliding motion
consider this type of construction to be ideal for many reasons. One of them is the possibility
through a lead screw and a nut. The implementation of the proposal itself consisted of
of expanding the number of axes and drives in these constructions, which subsequently
several steps. The first step was to create a request based on the theoretical knowledge
allows active tilting of the effector. We consider this fact to be one of the unique advantages
 FDM device presented in the article. The existing type of Tripteron construction inspires
the design of the device. The main purpose and reason for the creation of this construction
are the intention to move in the field of this technology towards the development of equip-
ment, which allows the production of prints created by a non-planar method. We consider
Appl. Sci. 2021, 11, 2928 this type of construction to be ideal for many reasons. One of them is the possibility 20 of
of 25
expanding the number of axes and drives in these constructions, which subsequently al-
lows active tilting of the effector. We consider this fact to be one of the unique advantages
of the chosen structure. For this reason, a new, conceptual version of the device has been
of the chosen structure. For this reason, a new, conceptual version of the device has been
created. Due to the continuity and ideology of the RepRap project, the structure’s individ-
created. Due to the continuity and ideology of the RepRap project, the structure’s individual
ual components were designed so that they can be manufactured using FDM technology.
components were designed so that they can be manufactured using FDM technology. The
The third step was the procurement of elements characteristic of FDM devices, fasteners
third step was the procurement of elements characteristic of FDM devices, fasteners and
and subsequent structure implementation.
subsequent structure implementation.

Figure 27. Implemented design of atypical equipment of additive manufacturing technology FDM.
Figure 27. Implemented design of atypical equipment of additive manufacturing technology FDM.
The presented construction of a prototype FDM device is characterised by a combi-
The presented construction of a prototype FDM device is characterised by a combi-
nation of characteristic elements of several devices connected in series. Due to this fact,
nation of characteristic elements of several devices connected in series. Due to this fact,
we tried to adapt the operating parameters for the test samples as much as possible to
we tried to adapt the operating parameters for the test samples as much as possible to
commercially available FDM equipment. The print settings for printing test samples can
commercially available
be seen in Table 5. FDM equipment. The print settings for printing test samples can
be seen in Table 5.
Table 5. Print settings used to print test samples.
Table 5. Print settings used to print test samples.
Print Settings First Layer Print Settings
Print Settings First Layer Print Settings◦
Bed temperature [◦ C] 50 Bed temperature [ C] 70
BedExtruder
temperature [°C] [◦ C]
temperature 50 195 Bed temperature [°C]
Extruder temperature [◦ C] 70 210
Extruder temperature
Extrusion [°C]
width [mm] 195 0.45 Extruder temperature
Extrusion width[°C][%] 210 115
Layer height
Extrusion width [mm] [mm] 0.45 0.264 Layer height
Extrusion width [%] [%] 115 90
Default print
Layer height [mm] speed [mm/s] 0.264 60 First layer print
Layer height [%] speed [%] 90 35
Infill density [%] 100
Default print speed [mm/s]
Infill pattern [–]
60 Grid First layer print speed [%] 35
Infill densityspeed
Perimeter [%] [%] 100 40
Infill
Nozzlepattern [–] [mm]
diameter Grid 0.4
Filamentspeed
Perimeter diameter
[%][mm] 40 1.75
Extrusion multiplier [–] 1.05
Nozzle diameter [mm] 0.4
Extruder type [–] Bowden
Filament diameter [mm] 1.75
Extrusion multiplier [–] 1.05
In termstype
Extruder of accuracy
[–] andBowden
speed of production of this device, it was initially our
intention to approach commercially available FDM devices. However, because this is a
prototype, the construction of a combination of two devices connected in series, we initially
expected and observed a significant deterioration of accuracy. Our next intention was the
gradual identification and elimination of these shortcomings. The operating parameters of
the device with which it can operate in the current state are identical to the device settings
when printing test samples.
As already mentioned, due to the selected operating parameter and the device’s design
character, we observed the common types of defects (Figure 28).
 • Deflection occurring at the end of the arms with the effector.
In Figure 28 it can see the selection with several shortcomings caused by the negative ef-
fects. As shown in the figure, the main negative of the construction is the poor adhesion of
the layers. It causes incorrect adhesion of the material to the printing pad (Figure 28a),
defects in the individual layers (Figure 28b), or sealing of the print head to the model (Fiu-
Appl. Sci. 2021, 11, 2928 21 of 25
ure 28c). All these shortcomings can be attributed to the arm system’s undesirable vibra-
tion, which proved to be the majority problem in the solution.

Figure 28.design
Figure 28. Implemented Implemented design
of atypical of atypical
equipment equipment
of additive of additivetechnology
manufacturing manufacturing
FDM.technology FDM.
(a) incorrect adhesion of
(a) incorrect adhesion of the material to the printing pad; (b) defects in the individual layers;
the material to the printing pad; (b) defects in the individual layers; (c) sealing of the print head to the model. (c)
sealing of the print head to the model.
Among the most problematic were:
Minor defects and shortcomings are characteristic of all FDM devices. There are a
• Incorrect positioning/position of linear technology and transformation mechanisms.
relatively large number of technological and other factors that can affect the final quality
• Oscillations of the system during acceleration and de-acceleration.
of prints, whether with conventional or atypical FDM equipment. In this case, however,
• Deflection occurring at the end of the arms with the effector.
it is possible to observe a majority of defects caused by poor adhesion in the layers. These
errors are found In Figure 28 the
throughout it can see
test the selection
sample withlocations.
at specific several shortcomings
These places caused by the negative
are charac-
effects. As shown in the figure, the main negative of the construction is the poor adhesion
terised by the fact that the individual circumferential perimeters begin and end in them.
of the layers. It causes incorrect adhesion of the material to the printing pad (Figure 28a),
It is well known that these places are critical in conventional planar printing. For example,
defects in the individual layers (Figure 28b), or sealing of the print head to the model
samples used for mechanical tensile testing, produced on FDM equipment, accumulate
(Fiuure 28c). All these shortcomings can be attributed to the arm system’s undesirable
defects, especially in this area, which leads to undesired weakening of the samples at spe-
vibration, which proved to be the majority problem in the solution.
cific locations. We attribute this undesirable accumulation of defects and their majority
Minor defects and shortcomings are characteristic of all FDM devices. There are a
representation to the unwanted oscillating system of arms, resulting from the will and
relatively large number of technological and other factors that can affect the final quality of
minor inaccuracies in the design. This undesired oscillation is reduced in the design by
prints, whether with conventional or atypical FDM equipment. In this case, however, it is
flexible couplings located between the drive motors and the lead screws, changing the
possible to observe a majority of defects caused by poor adhesion in the layers. These errors
starting speeds for the perimeter perimeters and installing dampers on the NEMA17 step-
are found throughout the test sample at specific locations. These places are characterised
per motors. Despite this step, however, undesired oscillations occur. For this reason, in
by the fact that the individual circumferential perimeters begin and end in them. It is
another areawellof research,
known that we these
will focus onare
places changing
critical the design of subsystems
in conventional providing
planar printing. For example,
transformation and transmission of motion on individual axes of the device.
samples used for mechanical tensile testing, produced on FDM equipment, accumulate
Despitedefects,
these visible shortcomings,
especially measures
in this area, which were
leads taken in Simplify3D
to undesired to allow
weakening the samples at
of the
creation of aspecific
non-planar sample.
locations. We Based on this
attribute it, we were able accumulation
undesirable to analyse the of
device’s
defectscurrent
and their majority
state and the impact of its shortcomings on the quality of prints. In
representation to the unwanted oscillating system of arms, resulting Figure 28, we can
from seethe will and
the selectionminor
with inaccuracies
several defects caused by negative effects. The main negative of the
in the design. This undesired oscillation is reduced in the design
by flexible couplings located between the drive motors and the lead screws, changing
the starting speeds for the perimeter perimeters and installing dampers on the NEMA17
stepper motors. Despite this step, however, undesired oscillations occur. For this reason, in
another area of research, we will focus on changing the design of subsystems providing
transformation and transmission of motion on individual axes of the device.
Despite these visible shortcomings, measures were taken in Simplify3D to allow the
creation of a non-planar sample. Based on it, we were able to analyse the device’s current
state and the impact of its shortcomings on the quality of prints. In Figure 28, we can see
the selection with several defects caused by negative effects. The main negative of the
construction, as shown in Figure 28, the adhesion of the layers is poor. It causes incorrect
adhesion of the material to the printing pad (Figure 28a), defects in the individual layers
(Figure 28b) or sealing of the print head to the model (Figure 28c). All these shortcomings
can be attributed to the arm system’s undesirable vibration, which proved to be the majority
problem in the solution. Given the purpose for which the device was created, i.e., the
production of non-planar samples, we can say that the device fulfilled its purpose. After
modifying the settings, it was possible to partially suppress some negative aspects resulting
from the series-connected design’s nature. Given that the change and implementation
of corrections negatively affect the equipment’s production time, we recommend a few
necessary proposals to streamline production. These proposals include:
• Use of more precise transformation mechanisms in the X and Y axes.
 After modifying the settings, it was possible to partially suppress some negative aspects
resulting from the series-connected design’s nature. Given that the change and implemen-
tation of corrections negatively affect the equipment’s production time, we recommend a
few necessary proposals to streamline production. These proposals include:
Appl. Sci. 2021, 11, 2928 • Use of more precise transformation mechanisms in the X and Y axes. 22 of 25
• Use of more specific connecting components and mating pins.
• Streamlining of drives, which is necessary with the increasing weight of the effector.
• Ultimately, after the end of the prototype phase, the replacement of plastic compo-
• nents.
Use of more specific connecting components and mating pins.
• Streamlining of drives, which is necessary with the increasing weight of the effector.
• TheUltimately,
main benefit of using non-planar layers is clear time-saving. According to the
after the end of the prototype phase, the replacement of plastic components.
data available from the preparation of a planar and non-planar sample by the same device,
The main
a non-planar benefit
sample savesofup
using non-planar
to 15% layers is clear
of time compared time-saving.
to a planar model. According to the
data available from the preparation of a planar and non-planar sample by the same device,
2.8.aConceptual
non-planarDesign
sample of saves up to 15%
an Alternative of time compared to a planar model.
Printhead
AsConceptual
2.8. mentioned, the prototype
Design device Printhead
of an Alternative has relatively high ambitions due to its charac-
teristic shape of structure.
As mentioned, the However, the justified
prototype device benefit ofhigh
has relatively the ambitions
non-planardue method of lay-
to its character-
ering materials can still be emphasised. Several steps can reduce the recycling
istic shape of structure. However, the justified benefit of the non-planar method of layering of the plas-
tic materials
waste produced
can still be emphasised. Several steps can reduce the recycling of the plastic the
in FDM production by integrating the extrusion mechanism into waste
device’s printhead.
produced in FDM Several researches
production are currently
by integrating theunderway
extrusion related
mechanism to theinto
interconnec-
the device’s
tionprinthead.
of these two mechanisms
Several researchesandarethecurrently
effect of direct extrusion
underway relatedof to
plastic granulation on of
the interconnection
thethese
prints’ final
two quality. One
mechanisms andofthe
these
effectresearches is the effort
of direct extrusion to create
of plastic an instrument
granulation on thewith
prints’
its extrusion process principle applied to the industrial robotic arm ABB IRB 140
final quality. One of these researches is the effort to create an instrument with its extrusion [35]. This
concept
processis constantly under development,
principle applied to the industrialflowrobotic
analysis and
arm ABBheat distribution.
IRB 140 [35]. ThisSimultane-
concept is
ously, the research is devoted to the simulation of movements and
constantly under development, flow analysis and heat distribution. Simultaneously, possible collisionsthe
when hittingisthis
research device
devoted to on
theasimulation
robotic arm. of Based on theand
movements facts and data
possible collected
collisions so far,
when a
hitting
conceptual
this devicedesign
on aof the effector
robotic for theondevice
arm. Based created
the facts and by
datauscollected
was created, as ashown
so far, in
conceptual
Figure 29. of the effector for the device created by us was created, as shown in Figure 29.
design

Figure 29. 29.

Figure Integration andand
Integration schematic representation
schematic of aofplastic
representation granulate
a plastic extruder
granulate in ainprinthead.
extruder a printhead.

As can be seen, when designing the effector itself, we assumed a significant increase in
weight due to the mechanism of the print head. For this reason, support can be seen in the
effector design in the form of the placement of clamps for the six joints. These are primarily
intended to ensure the rigidity of the entire system, even with its increased weight. At
the same time, their location is positioned to allow active tilting of the effector during
subsequent modifications of the structure. It is inevitable when the device is intended to
be used in connection with a non-planar printing method. It is necessary to ensure the
printing nozzle’s axis to the printout’s surface.
In Figure 29, we can see that the extrusion system is integrated directly into the
already designed printhead. However, unlike the common components of the “Hotend”
and “Bowden” system, it has a reduced version, similar to the large-capacity device used
to process the granulate into a filament. The design of the structure consists of an electric
motor (3), which transmits the torque to the feeder screw (8) via a flexible coupling (4). It
has a check valve (12) at its end. It is designed to close when the nozzle becomes clogged or
 sure the printing nozzle’s axis to the printout’s surface.
In Figure 29, we can see that the extrusion system is integrated directly into the al-
ready designed printhead. However, unlike the common components of the “Hotend”
and “Bowden” system, it has a reduced version, similar to the large-capacity device used
to process the granulate into a filament. The design of the structure consists of an electric
Appl. Sci. 2021, 11, 2928 23 of 25
motor (3), which transmits the torque to the feeder screw (8) via a flexible coupling (4). It
has a check valve (12) at its end. It is designed to close when the nozzle becomes clogged
or too high in the injection chamber’s overpressure to prevent the melt from running back
too highAinhopper
into the printhead. the injection
formschamber’s overpressure
its other parts to prevent
for granulate the meltcooling
(5), passive from running
(9) back into
placed so as to ensure the correct course of temperatures during the extrusion of granulate (9) placed
the printhead. A hopper forms its other parts for granulate (5), passive cooling
or melt. The so as to ensure
heating systemthe(10)correct course
is located at of
thetemperatures during theand,
end of the printhead extrusion
unlikeof granulate or melt.
a com-
The heating system (10) is located at the end of the printhead
monly used heater, is in the form of a hoop. It is used due to the need to achieve higher and, unlike a commonly used
temperatures in the processing of recycled plastics. The mechanism is terminated bytemperatures
heater, is in the form of a hoop. It is used due to the need to achieve higher an in
the (11),
airbrush nozzle processing of recycled
the shape of whichplastics. The mechanism
is more suitable is terminated
for non-planar layeringbyofan airbrush nozzle
mate-
rial. (11), the shape of which is more suitable for non-planar layering of material.
The presentedThe presenteddesign
conceptual conceptual design
(Figure (Figure 30) this
30) eliminates eliminates
device’s this
usedevice’s use by eliminating
by eliminat-
ing the use of this device and the granulate is processed directly in the print head. head.
the use of this device and the granulate is processed directly in the print

Figure 30.
Figure 30. Detailed Detailed of
description description of the
the proposed proposed
extrusion extrusion mechanism.
mechanism.

Bythis
By integrating integrating
system this
into system into the
the device, we device,
expect we expect
up to a 20%upreduction
to a 20% reduction
in time in time for
low-capacity
for low-capacity productionproduction
compared compared to therecycling
to the regular regular recycling plastic
plastic waste waste method.
method.
3. Conclusions
3. Conclusions
The article informs about the current state of additive FDM technology, its current
The article informs about the current state of additive FDM technology, its current
direction and trends in this industry. It presents the characteristic types of structures in
direction and trends in this industry. It presents the characteristic types of structures in
this industry and analyses the individual elements of their construction in detail. After
this industry and analyses the individual elements of their construction in detail. After
analysing the particular types of construction and an overview of the current state, the
analysing the particular types of construction and an overview of the current state, the
work deals with a possible design of the structure or an alternative to current trends in the
work deals with a possible design of the structure or an alternative to current trends in
field of additive technologies. In the individual chapters, the article presents the gradual
the field of additive technologies. In the individual chapters, the article presents the grad-
design of the FDM device’s key components and the gradual creation of design subsystems.
ual design of the FDM device’s key components and the gradual creation of design sub-
It informatively describes designing key features using this technology and the method
systems. It informatively describes designing key features using this technology and the
and use of FDM devices’ characteristics. The result of creative activity is developing a
method and use of FDM devices’ characteristics. The result of creative activity is develop-
CAD model of an atypical device of additive technology FDM. This device is modified to
ing a CAD model
be as of an atypical
adapted device to
as possible of developments
additive technology FDM. This
in non-planar deviceof
layering is materials
modi- by FDM
fied to be as technology.
adapted as possible to developments
It thoroughly describes thein issues
non-planar layering
addressed of materials
during by
the implementation of
the structure. This is based on the shortcomings of the production of key components
using FDM technology and the impact of these shortcomings on the equipment’s operation.
One of the main deficiencies addressed during applying plastic parts was the angular
deformations and misalignment of linear components and transformation mechanisms. The
work also presents a solution method by using the finite element method and measurement
of negative and positive catches in the production of parts as a suitable solution to eliminate
these shortcomings. The work’s conclusion consists of evaluating the design and creating
a conceptual design of the printhead with an integrated extrusion system. We assume
that this concept will enable streamlining and improving the overall situation of the use
and processing of plastic granulate with this technology. It also applies to ordinary users
located outside the monitored spectrum of plastic waste producers from this production.
The use of new types of constructions for additive manufacturing and the competitiveness
of the design in case of further development is one of the presented solutions’ strengths, as
with the use of atypical equipment in various areas, such as in the educational process, the
Appl. Sci. 2021, 11, 2928 24 of 25

automotive industry or FDM technology. It can figure as an economically available device

capable of working in multiple axes, whether for the production of models using planar
or non-planar layering of material. Such a device can therefore be considered as a more
economically affordable variant of the robotic arms, which uses in connection with FDM
technology and production accuracy between 0.1–0.4 mm we consider not available to all
consumer groups.
As part of another solution after the end of the prototype development phase, we
plan to deal with the possibilities of recycling ABS waste in this area, e.g., from the
automotive industry. This type of plastic waste has a majority in the automotive industry.
In the case of its efficient recycling of used plastic in non-planar printing, we expect a
significant improvement in prototypes’ quality and efficiency in this area. We consider the
demonstrable improvement of a specific type of prints’ surface quality and mechanical
properties as another step towards production efficiency. The integration and use of
recycled plastic during construction and the creation of the extrusion system concept can
significantly impact reducing the environmental burden produced by a relatively large
group of unmapped users in this type of production.

Author Contributions: Conceptualization, J.K.; methodology, J.K.; software, J.K., P.B. and J.T.;
validation, Š.G., J.P. and J.H.; formal analysis, J.K.; investigation, J.K.; resources, J.H.; data curation,
Š.G.; writing—original draft preparation, J.K.; writing—review and editing, L.K.; visualization, J.T.;
supervision, L.K.; project administration, J.K. and Š.G.; funding acquisition, Š.G. All authors have
read and agreed to the published version of the manuscript.
Funding: This paper is a part of the project VEGA n. 1/0116/20—Research of Application of
Structural Topology in a Structure of New Generation of Moulds by 3D Printing Technology.
Conflicts of Interest: The authors declare no conflict of interest.

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