A

Dissertation Report
on
“Design and development of additive manufacturing system for
manufacturing multilayer structures”

Submitted in partial fulfillment of the requirement for

The Degree of
MASTER OF TECHNOLOGY
IN
MECHANICAL-DESIGN ENGINEERING
SUBMITTED
By
Mr. Aniket Dnyandeo Jadhav
(Roll No: 19271212)
Under the Guidance of
Prof. V. S. Jadhav
Government College of Engineering, Karad

Department of Mechanical Engineering

Government College of Engineering, Karad
(An Autonomous Institute of Govt. of Maharashtra)
2020-2021
 CERTIFICATE

DEPARTMENT OF MECHANICAL ENGINEERING

This is to certify that, Mr. Aniket Dnyandeo Jadhav has satisfactorily completed the dissertation
work entitled, “Design & Development of additive manufacturing system for manufacturing
multilayer structures” This work is being submitted in partial fulfillment for the award of degree
of Master of Engineering in Mechanical (Design Engineering) to Shivaji University, Kolhapur,
under my guidance and supervision.

Prof. V. S. Jadhav Dr R. K. Shrivastava

Guide Professor & HOD
Associate Professor, Dept. of Mechanical Engineering,
Dept. of Mechanical Engineering, GCE, Karad
GCE, Karad

Principal Examiner
Dr. A. T. Pise
Govt. College of Engineering, Karad
 DECLARATION

I hereby declare that the dissertation entitled, “Design & development of additive
manufacturing system for manufacturing multilayer structures” was carried out and
written by me under the guidance of Prof. V. S. Jadhav, Associate Professor of
Mechanical Engineering Department, Government College of Engineering, Karad. This
work has not been previously formed the basis for the award of any degree nor has been
submitted elsewhere for the award of any degree.

Place: Karad

Date: Mr. Aniket Dnyandeo Jadhav

 DISSERTATION APPROVAL SHEET

Mr. Aniket Dnyandeo Jadhav has done the appropriate work for the award of Master of
Technology in Mechanical - Design Engineering of Government College of Engineering,
Karad, affiliated to Shivaji University, Kolhapur Maharashtra state India.

Guide: Prof. V. S. Jadhav

External Examiner:

Place: Karad

Date:
 ACKNOWLEDGEMENT

I have great pleasure in presenting this project report entitled “Design & development of
additive manufacturing system for manufacturing multilayer structures”, for partial
fulfillment of the degree of Master of Technology.

I would like to express my deep and sincere gratitude to my Guide Prof. V. S. Jadhav,
Associate Professor of Mechanical Engineering Department, GCE, Karad. It was my
privilege and pleasure to work under his able guidance. I am indeed grateful to him for
providing helpful suggestion, from time to time. Due to his constant encouragement and
inspiration, I am able to present this dissertation.

We express our deep gratitude to Dr. R. K. Shrivastava Head of Mechanical Engineering

Department and Dr. S. P. Deshmukh Co-Ordinator M-Tech Design Engineering, for their
valuable guidance and constant encouragement.

I would also like to thank Lab Assistant Mr. V. K. Jadhav and Peon
Mr. Nikam of Mechanical Engineering Department,

I express my deep gratitude to (Dr.) A.T. Pise, Principal, Government college of

Engineering, for his valuable guidance and constant encouragement.

Last but not least, it would not have possible for me to resume the prolonged work of project
without support of my family members. Constant encouragement and support of my family
made me possible to complete the work.
 ABSTRACT

From the automobile industry to ceramics, the demand for additive manufacturing is
continuously increasing. In more conventional fields such as prototyping using plastics,
however, the largest part remains. While 3D printing brings benefits, such as being quicker
and less expensive than conventional production, it also makes it easier to manufacture on
demand. The concern is that the bulk of the printed material employed is still plastic, which
is among the most harmful environmental materials. This was also obvious to us, so we
wanted to know why there were no more environmentally friendly 3D printing materials.
This enabled us to research a technique for 3d printing that uses wastepaper, as a raw
material. The Paper Printer is a 3D printer that uses plastic to replace wastepaper. The
content market is broadly growing and there are many other alternative sources for your
prints that you can choose from. Many of the others, however, are still composite materials
using PLA as a basis. We crossed paths with 3D modelling and additive processing at the
early stage. Through this approach, we found the troubling amount of plastic being used in
the process and began looking to substitute it with a more sustainable material. We chose to
study with this unnecessary and hugely used material because the amount of paper waste per
person is about 80 kg per year.

Key Words: Layer, Rapid prototyping, SDL, SLS, STL.

 Title of Contents

Chapter No Title Page No

List of figures
List of Tables
List of Graphs
List of Abbreviations

1 Introduction 1-3
1.1 Introduction 1
1.2 3D Printer basic principals 1
1.3 Selective Deposition Lamination 2
1.4 Green, Safe and Easy to Use 3
1.5 Problem Statement 3
1.6 Objectives 3

2 Literature Review
2.1 Introduction 4
2.2 Review of Research Papers 4
2.3 Concluding Remarks 9
2.4 Identified gaps in the literature 9

3 Design and Experimentation 10-31

3.1 Experiment and Methodology 10
3.2 Flow chart 10
3.3 Selection of process 12
3.4 Characterization of process 12
3.5 Selection of mechanism 13
3.6 Electronics section 14
3.6.1 Controller 14
3.6.2 Stepper motor 15
3.6.3 End stops 17
 3.6.4 Stepper drivers 18
3.6.5 Display Board 18
3.6.6 Thermistor 19
3.6.7 Power supply 20
3.7 Software’s 20
3.7.1 CAD Tools 20
3.7.2 CAM Tools 22
3.8 Conceptual Design 26
3.9 Working of machine 27
3.10 Detailed Design 28
3.11 Bearings 29
3.12 Paper feeding 30
3.13 Paper gluing 31

4 Result and Discussion 32-43

4.1 Introduction 32
4.2 Static Structural Analysis 32
4.2.1 Meshing 33
4.2.2 Static Structural Analysis Results 34
4.3 Optimization of Paper adhesive 41
4.4 Specialization of final product 42
4.5 Results 43
4.5.1 Results of ALM System 43
4.6 Concluding Remarks 43

5 Conclusion 44

References
 List of Figures
S
Fig. No. Name of figure Page No.

Figure 1.1 Basic 3D Printing 1

Figure 3.1 3D printer design 10
Figure 3.2 Paper feeding mechanism 10
Figure 3.3 Flow chart 11
Figure 3.4 Cartesian type mechanism 14
Figure 3.5 MKS GEN V1.4 Motherboard 15
Figure 3.6 NEMA-17 stepper motor 16
Figure 3.7 NEMA-17 stepper motor 3D view 16
Figure 3.8 END stops 17
Figure 3.9 END stops 3D view 17
Figure 3.10 A4988 Stepper driver 18
Figure 3.11 A4988 with Arduino interfacing 18
Figure 3.12 Display board 19
Figure 3.13 Thermistor 19
Figure 3.14 Power supply 20
Figure 3.15 Design in CATIA 21
Figure 3.16 Cura slicing 23
Figure 3.17 Program of Arduino 25
Figure 3.18 Conceptual view 26
Figure 3.19 Mechanism of Z-Axis movement 28
Figure 3.20 Bed support 28
Figure 3.21 Bed support 29
Figure 3.22 Ball Bearing 29
Figure 3.23 Paper feeding mechanism 30
Figure 3.24 Paper gluing mechanism 3D design 31
Figure 3.25 Paper gluing mechanism model 31
Figure 4.1 Meshing of components 33
Figure 4.2 Fixed support 34
Figure 4.3 Total Deformation of PLA 34
Figure 4.4 Total Deformation of PETG 35
I
Figure 4.5 Total Deformation of ABS 35
Figure 4.6 Equivalent stress of PLA 36
Figure 4.7 Equivalent stress of PETG 37
Figure 4.8 Equivalent stress of ABS 37
Figure 4.9 Equivalent strain of PLA 38
Figure 4.10 Equivalent strain of PETG 39
Figure 4.11 Equivalent strain of ABS 39

II
 List of Tables

Table Name of Table Page

No. No.
3.1 A4 Size Paper properties 13
3.2 Specification of Ball Bearing 30
4.1 Mechanical properties of material 32
4.2 compressive strength and adhesive strength of 41
deferent stick adhesives
4.3 Specifications of final product 42

Graph Name of Graph Page

No. No.
4.1 Total Deformation Distributions 36
4.2 Equivalent stress Distributions 38
4.3 Equivalent Elastic Strain Distributions 40
4.4 Adhesive strength comparison of different adhesives 41
4.5 Compressive strength comparison of adhesive 42

LIST OF ABBREVIATIONS

Symbol Name

RP Rapid Prototyping
STL Standard Triangle Language
FDM Fused Deposition Modeling
SLA Stereolithography
SDL Selective Deposition Lamination
LOM Laminated Object Manufacturing
DTP Direct Tool Production
3DP 3d Printing

III
 CHAPTER 1

INTRODUCTION

1.1. Introduction
For centuries, 3D printers have been around us, regularly converting 3D computer designs
into complex physical artifacts for product development, educational, architecture,
healthcare, mapping, historical preservation, and other applications. In a variety of
materials, such machines produce templates, including plastic, plaster, and photopolymers,
metal and sometimes even fruit. Depending on your application, each of these materials
brings inherent benefits and drawbacks. One more thing to consider: paper. It is a bit
disappointing to create additive parts using ordinary paper as the construction material. On
the one side, you assume that such a 3D printed item may not be able to cope with the
possible wear and tear to which you may expose it. On the other side, you are almost
returning ordinary paper to its original wood type with the right binders and sealing
materials, with all the durability, strength, and ruggedness of wood-based items.

1.2 3D printer's basic principles

Forget all about printing, processing, constructing, and developing objects that you think
you know. In such a way that it disrupts any part of traditional product production, the world
of 3D printing has evolved. The underlying 3D printing concepts and the printers
themselves are progressing towards a cohesive state of turn-key development restricted only
by our creativity.

Figure 1.1 Basic 3d printing

Government College of Engineering, Karad Page 1

 CHAPTER 1

The maximum critical detail to be understood as a personal person tool concerning 3D

printing or 'additive printing' is its operation. although the various fashions of 3D printers
work in distinctive ways, they are all based totally on a basic idea. because the word
"additive printing" suggests, 3-D printers work together to generate an object by way of
"adding" layers of print material. The number one technique of operation of any 3D printer
is to convert a software-based totally template into separate 2d layers or slices that are
"printed" and bonded to each other produce a 3-d object. Imagine a dot of glue being put on
a sheet of paper. Now, imagine applying layer upon layer of glue in a precise and adhesive
way to that dot. The dot will expand into the third dimension from the two-dimensional page
and become a cylinder with the original dot 's diameter. Another example: a single sheet of
paper would be two-dimensional, but it would be rendered three- dimensional by a stack of
papers. In the very same way, 3D printers produce 3D structures to achieve a three-
dimensional product by printing layer upon layer of a variety of materials. Any 3D printer’s
overall workflow is geared towards achieving the objective of transforming a software-
generated 3D design into a hardcopy version. While the methods used by various printer
models differ, all of them are based on the same workflow type. Let 's look at this workflow
and then explore the various styles of 3D printers available on the market to dig deeper into
the world of 3D printing.

1.3 Selective Deposition Lamination (SDL)

Dr. Conor and Fintan McCormack invented Selective Deposition Lamination (SDL) or 3D
Paper Printing in 2003. Dr. McCormack noticed 3D printing in 1986 for the first time. The
technology caught his imagination like cars, rockets, computers, and space travel. Most
technologies manufacture replicas from expensive plastic or chemically infused powder,
while 3D SDL printers use ordinary, inexpensive paper for building materials. The old,
laminated object (LOM) technology should not be confused with SDL. LOM uses a laser,
laminated paper, and glue to gather all the material around the model. The excavation was
an oddity, sometimes leading to a 3D split. SDL uses a blade for cutting and selectively
positions the 3D printer on the adhesive only where necessary. This paper describes how a
paper-based 3D printer uses the SDL process to create a concrete 3D model.

Government College of Engineering, Karad Page 2

 CHAPTER 1

1.4 Green, Safe and Easy to Use

In non-industrial settings, such as universities, medical laboratories and professional design
offices, the chance to use your 3D printer is another comfort. This doesn't really mean that
chemicals, gases or dust or toxic heat or light are dangerous. SDL fluid products are mostly
water-based and non-toxic, such as glue and ink. No infiltration is required for SDL models.
The SDL technique is green and harmless: you could go directly into the paper recycling bin
when you finished using the model.
1.5 Problem Statement:
In 3D printer raw material is costly and need to prepare dimensions and particular shape
(wire of diameter). Waste papers are easily available and need not any pre operations also
comparing the cost of paper is cheaper than PLA and other materials used for 3D printer.

1.6 Objectives

1. Design and development of Z-axis and its interfacing.

2. Design and development of paper feeding mechanism.

3. Optimization of paper adhesive for paper gluing mechanism.

4. Design and development of paper gluing mechanism.

Government College of Engineering, Karad Page 3

 CHAPTER 2

LITERATURE REVIEW
2.1 Introduction

Additive manufacturing (AM) is the process of creating 3D object from computer

designs, it’s also known as 3D printing. We can create a 3D object from different materials
like plastic, metal, chocolate etc. In concerned with proposed dissertation work, following
research papers have been reviewed as follows

2.2 Review of Research Papers

Jing Zhan et al. [1] achieved selective metal formations in 3-D-printed plastic systems
without the standard trendy remedy, including facial implants, which frequently contain
poisonous chemicals, and lubricants, wi-fi implants are universal for FFF 3-d printing. ABS
cord containing Pd ions (catalyst precursor for electroless plating) became a custom-made
using ABS acsone solution and PdCl2. A double-layered FFF 3-d printer become identified
for developing a 3D-published ABS layout with PSCl2-loaded ABS set up in selected areas
of hobby. the main element is manufactured from a single pipe using a fashionable ABS
cable (natural ABS without PdCl2), and ABS layers loaded with PdCl2 are inserted into
selected interest areas via a 2d microphone using ABS cable with Pd ions or ABS and
PdCl2 acetone answer. An ABS with PdCl2 loaded with ABS was then immersed in a non-
electrified Ni tub. it's far ensured that Ni was mounted in decided on regions and adhered
strictly to the ABS. This demonstrates that the proposed 3-D printing technique generally
based on non-electric powered plating enables metallization selectively. This technology
offers many blessings as it does no longer require (i) a custom FFF 3-d printer (provided
industrial integration), (ii) landscaping or immersion (no harm to 3-d-printed shape), or (iii)
poisonous chemical compounds, such as chromic acid, which is typically used for the set-up
of ABS operations on gasoline-free plating. due to the fact many metals as well as their
alloys can be established without an electrical installation, the proposed 3-d printing
technology is extensively used inside the creation of -3D with various metallic capabilities,
together with circuits, steel factors, sleek appearance.

Government College of Engineering, Karad Page 4

 CHAPTER 2

Anton Wiberg et al. [2] reviewed lots of publications in Additive Manufacturing design
field, Additive Manufacturing design automation, and optimization. Using a systematic
approach, the publications are sorted by sequence and finally written extensive reviews
based on over 100 pages. According to the review, a new detailed DfAM process and
proposed design support map design was developed in the form of methods, guidelines,
software tools, and design tools. In addition, recommendations are given on which types of
tools and methods are most suitable for the various stages of the design process. Finally, he
proposed a new type of additional production design process aimed at achieving an
automated Additive Manufacturing design process. The framework demonstrates the ability
to reduce the replication function within the construction process. The proposed
mechanization process is presented at the standard level and is linked to existing literature.

Thomas duda et al. [3] described a rich area of available technology and materials to
produce metal products. The range of existing materials is already vast, from titanium alloys
and nickel alloys to stainless steel steels and is growing rapidly. Additive manufacturing
Technology that offers free product complexity but requires new product design for AM.

Nico Helpesrieder et al [4] proposed method, enabling the production of LLM components
designed to measure medium size from TO using internal ports. To get started, we have
implemented various features of Free CAD, which can be fully utilized with Python
algorithms. The parts are cut and supplied with the same grid, suitable for production. The
stiffness generated from the TO is inserted between the line at UMG and is measured by the
corresponding holes. All model layers are finally integrated and can be exported to the same
CAD file formats. To ensure its effectiveness, this method has been applied to two parts of
the model industry. The application is fingerprinted in Fig. 6 shows that this method does
not work very well in parts with multiple working areas in different areas. Promising results
are achieved with a ball screw axis block. Parameter studies have shown that especially
large bridge spans lead to very poor results However, comprehensive parameter studies will
be conducted in order to make reliable statements on the optimal combination of production
parameters. In addition, the reconstruction of construction should be improved to exclude
large areas with low cost in modeling. Based on these findings, an LLM blockchain will be

Government College of Engineering, Karad Page 5

 CHAPTER 2

developed and used on a ball screw drive test bench to investigate its impact on the overall
behavior of the system. In addition, the water-repellent properties of LLM bonds and their
specific system will be investigated.

Meisam Askari et al. [5] introduced metamaterial exhibition systems other than those
depicted with ordinary items in commonplace conditions. This has been investigated by way
of theoretical have a look at and via the examiner of length. in lots of instances the know-
how of the bodily aid of metals has some distance surpassed our capability to create current
structures. but, the improvement of extra manufacturing strategies gives new opportunities
for the development of complicated metamaterial structures, a lot of which aren't to be had
through conventional methods of manufacturing. The literature thus far consists of
contributions from a various organization of researchers from the herbal sciences,
arithmetic, and era to create metamaterials for electromagnetic, acoustic, and mechanical
applications. it's far counseled that additional production consists of the important thing to
recognizing the capacity of this research network and to permit for the creation of recent
paradigms in the basic structures but additionally for exploitation thru utility. To this quit, a
assessment of the literature identifies great tendencies in metamaterials alongside
accelerated productivity and introduces new possibilities for researchers to collaborate on
internal / disciplinary studies to find frameworks that mirror unusual behavior. This review
represents a whole account of the country of the art inside the production of such substances
the usage of complementary manufacturing techniques and scenarios, which, based totally at
the practices recognized in the literature, are suitable for in addition research and require
concerted effort on behalf of the above fields to expand current art.

Naira Dias Pinheiro et al. [6] prepared disposable, reasonably priced and smooth-to-use
optoelectronic nose with 1. Five µL of 15 exclusive air dyes the discharge of 5 sorts of
thermoplastic fibers all through the printing of 3-d systems. Two metalloporphyrin’s, 5 pH
indicators, five solvatochromic dyes, redox the dye and single-decided on solvent form the
perfect and awesome digital fingerprints of the sensor listing after the random release of
every thread. Similarly, the paper-based nostril has created a stigma of internal
contamination, which may be a useful device for tracking offices under 3-d printers. all the

Government College of Engineering, Karad Page 6

 CHAPTER 2

Results described here have shown the first-rate performance of the optoelectronic nostril to
identify the supply of capability resources of indoor air pollution. Even though easy, the
toughest step of our approach is the manual training of each colorimetric sensor. Leasing
hoses can drastically reduce preparation time. The automatic system can be helpful in
reducing the duration of color information extraction from a high wide variety of dye stains
and duplication; but it is able to additionally lessen duplicate since absorption of dye into
the filter out paper can be caused by the heterogeneity of the cellulose fibers of the paper. A
growth in the wide variety of recurring gadgets can reduce the external percentage without
defects in the facts release period. We count on a totally transportable air excellent monitor
to update a flatbed scanner with a virtual based totally pictures tool.

Fabio Giudice et al. [7] proposed the environmental sustainability of metal add-on
processes has so far been investigated to a limited extent, and inadequate in the design of
Design for Additive Manufacturing, as they do not allow for any interaction between the
natural functioning of the additive process, and design variables.

Christoph Klahn et al. [8] chosen the design strategy also has an impact on the process of
identifying components and elements for additional performance. In a design strategy driven
by production strategies, product performance is impartial of the production process.
Consequently, the enterprise case of the choice manner calls for simplest the cost and lead
time of the production tactics. The case of an enterprise-pushed layout enterprise ought to
remember, that the structure and function of the product will significantly trade all through
the improvement process. This makes preceding estimates of production charges hard, and
improved performance also can generate greater sales. Cognizance of very distinct design
strategies input production will help the designer make knowledgeable selections about the
development technique.

Lim Chin Hwa et al. [9] introduced 3D printing, next to the rapidly evolving field of
molded clay, has recently become the epitome of what lies ahead. In this paper, 3D printing
technology is tested for its compatibility with porous clay materials, due to the competitive
process in terms of speed and the use of certain tools, especially high-quality manufacturing.

Government College of Engineering, Karad Page 7

 CHAPTER 2

This paper reviews the capabilities of these new technological processes in the production of
porous beauty. The basic technology is 3D printing techniques, which are used to make
parts of blue-green clay later made sintered. Different types of pottery are tested and
categorized into different powders according to their 3D printing quality and the materials
being studied. Discussion of the 3D printing process depending on the physical
characteristics of the particles such as particle size, flow and water is also discussed.
Examines the relationship between the different 3D printing parameters and the final print
result.

Vranic et al. [10] explained the technological benefits offer extra freedom in the
manufacturing of complicated formulas, top-notch compliant components, mold industry
gear, prosthetics, and medical implants.3-D printing allows quicker manufacturing of steel
components without extra tools the use of the 3-d CAD model. Maximum financial savings
during the improvement of a brand-new product, in producing prototypes or smaller series
can be obtained the use of 3-D printing. This generation is irreplaceable within the shape of
complex internal structures along with parallel cooling stations and lattice structures. The
cost-effectiveness of additive production is disputed. The machines themselves have the
equal fees as modern-day CNC machines, but the charge is still high in comparison to
inventory. Additive production offers many opportunities for custom product production but
will now not completely replace the vintage production technology soon. Designers and
engineers need to be delivered to additive manufacturing and well-knowledgeable, with a
view to recognize all the advantages and downsides of new technologies. additive
manufacturing offers amazing freedom with partial posture, but residual stress, porosities,
facial stiffness, partial length, to be had substances, and further publish operations, are some
of the principal barriers that want to be taken into consideration.

2.3 Concluding remarks

Various researchers conducted experiments based on different 3D printing techniques. They
studied various processes such as FDM, SLS, SLA, and LOM. More emphasis is on fused
deposition modeling & SLS which are mainly based on plastic and resin polymers.

Government College of Engineering, Karad Page 8

 CHAPTER 2

2.4 Identified gaps in the literature

From the previous studies, it is observed that most of the work has been done on processes
such as FDM, SLS, SLA, and LOM. The literature review also shows that there is no much
of work undertaken with sheet based technique such as SDL.
• Researchers have done work on different plastic materials used in FDM.
• Most of the researchers considered FDM 3D printing process for study.
• A few researchers considered types and usage of different programming tools.

Government College of Engineering, Karad Page 9

 CHAPTER 3

DESIGN AND EXPERIMENTATION

3.1. Experiment and methodology
Our mission was to design and build an additive manufacturing system for 3D components
with wastepaper. In the previous chapter, we examined history, various printing methods
and a summary of the past study. This chapter covers the design and manufacture of the
same. First, we ordered the entire toolkit, along with all parts and components needed to
create a 3D printer. It took a while to get the whole set. In the meantime, a 3D printer CAD
model was developed with CATIA. First, we designed all the components needed for the
assembly and the measurements were taken specifically in light of different operating
parameters. Both parts are then assembled in the 3d printer assembly in the CATIA. Here
are the pictures of real life, the nature of individual components and their working
mechanism.

3.1 3D Printer Design 3.2 Paper Feeding Mechanism

3.2 Flow chart

The following flow diagram demonstrates the technique for constructing a 3D printer. The
first step is to pick among several processes mentioned in Chapter 2 one of the additive
manufacturing processes. The required mechanism is then chosen for motions of the X, Y
and Z axes, taking account of different factors such as cost of manufacturing, simplicity of
design, synchronization, precision etc. The next step, when the mechanism is chosen, is
the integration

Government College of Engineering, Karad Page 10

 CHAPTER 3

of electronics and software. The final step is to synchronize the mechanical, electrical and
software components of the system.

Figure 3.3 Flowchart of design, development, and calibration of open source

Government College of Engineering, Karad Page 11

 CHAPTER 3

3.3 Selection of process

The key difference among SDL and the traditional LOM technique, as mentioned above, is
how the glue is distributed, not only with a knife but also a laser. Instead of a sturdy even
adhesive coating around the whole structure, SDL uses just a small amount of glue in the
waste material. The real models are solidly glued, while the waste material can be easily
broken by the small glue that holds them together. SDL is a layer-by-layer process, like in
most 3D printing methods, that reflects a number of steps.
The first sheet of paper is added manually to the building board with a masking tape, which
forms a secure base on which the model is constructed. The mechanism repeats the
following from there:
1. Apply a small amount of glue selectively on the top layer.
2. Take the new sheet of paper and placed it on top of the build.
3. Start raising and pressing the build to tie the sheets against the heat plate.
4. Cut the model outline and the grid pattern of the waste parts in the new top layer.
5. Check if the construction is complete, and if not, go back to step 1.
3.4 Characteristics of Paper
Papers of all kinds are processed by extracting cellulose fibers of wood, cotton or other
organic materials mechanically or chemically and therefore by blending them with water
into pulp. The pulp is first guided via, vacuum dryer and then through a variety of rollers,
which progressively suck, press, and heat the water out of the blend to finally produce a flat
sheet of paper. Regular paper forms have three characteristics:

1. Porous structure, meaning low density and weight.

2. Low bending stiffness and high flexibility.
3. High in-plane tensile stiffness and strength.

The type of fibers and their length, direction and indoctrination primarily determine these
characteristics. Longer and more entangled fibers create paper that is stronger and stiffer.
Chemical pulping, which is a rougher operation, creates longer fibers than mechanical ones.
It is also possible to beat chemical pulp, a grinding process that "roughs" the fibers, making
them more easily entangled. The continuous method of production aligns the fibers with the
direction
Government College of Engineering, Karad Page 12
 CHAPTER 3

of working, or the direction of the machine (MD), giving the paper anisotropic properties.
By changing the speed and feed rate of the pulp, the degree of anisotropy can be varied to a
certain degree, but strength and rigidity are normally often lower in the cross-direction (CD)
of the paper [26, 27]. SDL uses standard bond paper of 0.1 mm and 80 gsm (grammes per
square meter) thicknesses, more commonly referred to as office, copy or writing paper. You
can also use 0.19 mm thick 160 gsm colored paper to make solid color versions. Bond paper
is made of more than 90% chemical pulp and is durable, relatively rigid (but flexible
enough, for example, for copier machines) and usually white, with a rough, permeable
writing and printing surface. For all prints, Multi Copy Original 80gsm copier paper was
used during this research. The table lists some characteristic values for this type of
document. The resulting block of paper is removed from the construction plate when the
construction is completed, and the models are manually "dug out" from it. By gridding the
waste material and the selective application of adhesive, the de-cubing process or weeding is
made simpler. A pair of pliers and tweezers is still useful, but compared to previous LOM-
based solutions, SDL provides a major enhancement in user friendliness.

Property Value Unit

Density 80 g/m2
Thickness 0.1 mm
Tensile index 50/25 Nm/g
(MD/CD)
Tensile strength 4.0/2.0 kN/m
(MD/CD)
Breaking strain 1.8/4.7 %
(MD/CD)'
Permeability 750 ml/min
Table 3.1 A4 size Paper properties
3.5 Selection of Mechanism
Mechanisms such as SCARA, Cartesian, Polar, Delta etc. are currently used for the
production of FDM 3D Printers. Our Cartesian construction configuration is selected where
bed travels in the Y direction i.e., the pivot bearing, and the extruders' spout moves
horizontally i.e. both in the X and Y core courses. Z hub creation on such a 3D printer is
highly accurate and needs a low speed but the bed must be lightweight to ensure accuracy

Government College of Engineering, Karad Page 13

 CHAPTER 3

and therefore make it more difficult to have a fully programmed bed levelling system. It is
mechanically smooth and usually easy to manage a straight-forward Cartesian system like
this from the product perspective, which is what most today's 3D printers use this kind of
strategy. For a long time, cartesian arrangement systems have been used with instruments
such as plotters, CNC machines and 2D printers.

Figure 3.4 Cartesian Type Mechanisms

3.6 Electronics selection

3.6.1 Controller
The controller is our 3D Printer's brains. Nearly all 3D Printer controllers are based on the
microcontroller Arduino. Though there are many variants. They can be traded and
eventually all do the same. Now and then the controller remains solitary and filled with
chips, in some cases an Arduino Super controller has an additional board (referred to as a
"Shield"). But in our case, we used the controller board called MKS GEN V1.4, which also
operates with minimal space considerations on the Arduino & Ramps board. To solve the
complex interfaces and broken problem of ramps1.4 mix, we combine 2560 and ramps1.4 in
a board. Replaceable driver, 4988 driver and 8825 driver support. High-quality 4-layer
circuit board and particularly for thermal optimization; ramps is a 2-layer board. Use high
quality MOSFET tube with higher dissipation of heat. The power chip is used to help the
12V-24V input to solve the problem of converted Ramps voltage to chip heating. To accept
24V input, the heating current of the MOS tube hot bed can be reduced to 1/4 at the

same power, efficiently solving the heating problem. Firmware will use the Marlin open-

Government College of Engineering, Karad Page 14

 CHAPTER 3

source firmware, which can replace Ramps1.4 directly in the same configuration as
ramps1.4. Can link directly to Ramps1.4, the 2004LCD and 12864LCD control boards. Put
aside the engine pulse and direction output port for easy connection of external high current
(e.g., 2A, 5A) motor drive circuit. Reserve the Servos, AUX-1, AUX-2 interfaces on
Ramps1.4, providing three 5V output, three 12V output interfaces. This board is an upgrade
part of the MKS Gen V1.2 board, improving the performance of power protection and USB
communication stability.

Figure 3.5 MKS GEN V1.4 Motherboard

3.6.2 Stepper Motors
A stepper motor is a brushless DC driven motor that divides a complete pivot into a
numerical advance of the equivalent. The location of the motor could then be guided to shift
and keep one of these devices without a vital sensor as long as the motor was intentionally
calculated for use. For every beat of vitality, the stepper motor pushes a known break. A
stepper driver gives this beat of vitality and is suggested as a point. As each movement
moves the engine to a known partition, it makes it useful for repeatable arrangement. We'll
use a stepper motor to shift the bed carry and various meetings in each X-Axis, Y-Axis, Z-
Axis individually.

Government College of Engineering, Karad Page 15

 CHAPTER 3

Figure 3.6 NEMA -17 stepper Motor Figure 3.7 NEMA-17 3D view

Stepper Motor Applications

Stepper motors are commonly used in a range of applications in which exact position
control is required and feedback control device costs or complexity is unjustified. Here are
several applications that also find stepper motors:
i. Printers ii. CNC machines
iii. 3D printer/prototyping machines iv. Laser cutters
v. Pick and place machine vi. Linear actuators
vii. Hard drives

Types of Stepper Motor

1.NEMA 11:
This hybrid bipolar stepping motor has a 1.8-degree step angle of 200 Steps / revolution.
Each stage draws a 670mA at 3.5V, which makes a 600 gcm holding torque. These engines
consist of four colored coded wires which are connected to one bow in black and green; blue
and red are connected to the other. A pair of suitable H bridges can also be managed.

2.NEMA 14:
The 1.8-degree step angle of this hybrid bipolar stepping motor is 200 steps / revolutions.
Each stage draws between 500mA and 10V and makes a holding torque of 1 kg-cm. These
motors are four color-coded wires which are attached to one coil with bare paths black and
green; red and blue with each other. It can be operated by a suitable H-bridge pair.

Government College of Engineering, Karad Page 16

 CHAPTER 3

3.NEMA 17
A NEMA 17 stepper motor is a standard 1.7x1.7-inch faceplate motor. The NEMA 14 is
bigger and often extremely heavier than alternating motors, such as the NEMA 14, but it
also has more room for putting a higher torque. Its size is not a power sign. This bipolar 4
wire stepper has a
1.8 degree for smooth movement and a good holding torque for each step. The engine has
been designed to have a maximum current of 350mA, so that Adafruit motor shield for
Arduino and the divider connector or corrosive lead battery can be worked effectively.

4.NEMA 23
This high torque hybrid stepping motor has a 1.8-degree phase angle. Each step draws 1A at
5.7V, allowing torque of 4 kg-cm to be sustained. The engine has a six-colored coded wire
with naked leads which can be powered by the stepper motors of the unipolar and bipolar
steppers. All six leads are used when using a unipolar stepper motor. The middle tap yellow
and the white cables can be left disconnected with a bipolar stepper motor driver.

3.6.3. End stops

Mechanical switches are less difficult to implement and more economical than optical end
stops since there is no need for a circuit board and only 2 wires are used to connect the
switch. Pull up and down resistors can be mounted near the main board. Read switches are
termed contact-less magnetic switches. They are closing (or switching) proximity switches
if a magnet comes near enough (normally 1 mm or less) and open when the magnet moves
away. Reed switches are used to classify open windows and doors as sensors in home-
caution frames.

Figure 3.8 End stops Figure 3.9 End stops 3d view

Government College of Engineering, Karad Page 17

 CHAPTER 3

3.6.4 Stepper Drives

A phase driver is an engine that serves as an intermediary between a stepper engine and the
controller. It simplifies the signs that must be sent to the phase motor with a view to
encourage it to travel. Here and there the stepper drivers were linked to the controller using
links on autonomous circuit sheets. The stepper drivers are now and then on small circuit
boards that attach easily to the controller. The controller will have room for no less than 4 of
these small circuit boards (one for each stage motor). Ultimately, the stepper drivers are
often soldered to the controller itself.

Figure 3.10 A4988 stepper driver Figure 3.11 A4988with Arduino interfacing

3.6.5 Display board

Your printer's firmware decides how items are seen, what choices you have and how the
navigation works. However, you will find the temperature of your entire nozzle and bed, the
percentage of power your fan must work, your print speed multiplier, time since printing
began, often the percentage or progress bar. To improve print efficiency, SMPS delivers
power to this display & MKS GEN V1.4 provides the details required to display or to
monitor it. This total graphic smart controller includes an SD card with an encoder and an
LCD display of the 128x64 dot matrix. IT can be attached without much stretch to the
slopes of the 3d printer using the keen connector included. When connected to ramps, PC is
no longer needed as the smart controller provides your SD card with a power. Enable all
tasks such as calibration; axis movements with this Smart controller can conveniently be
performed.

Government College of Engineering, Karad Page 18

 CHAPTER 3

Figure 3.12 Display board

3.6.6 Thermistor
A thermistor is used to discover the heat plate temperature. Thermistors are the
resistors that fluctuate in temperature protection. Enormous attributes of the thermistor are a
well-known safety appreciation in its operating measure at each temperature. The descent or
increase depends at the shape of thermistor kelvin, that's known as its coefficient. High-
quality warm coefficient % will growth as negative coefficients ntc will lower in
temperature protection. The recipe is not straight, however every so often a particular desk
of calculations is leading to the direct equation. Those projections can typically be
discovered within the thermistor information sheet.

Figure 3.13 Thermistor

NTC Temperature Sensor thermistor is one in which the thermistor chip is welded by
composite patching and then incompletely operated by glass attachment. They consist of
those semiconductors that are predominantly silicon and germanium, and this safety can be
differentiated by numerous requests for extent of their temperature range. A 100k NTC
thermistor has a room temperature safety estimate of 100k ohm and decreases to 100 ohms
at 300 ohm.
Government College of Engineering, Karad Page 19
 CHAPTER 3

3.6.4 Power supply

The engine plus single hot end takes 5A or so, usually the heated bed takes 5A-15A. See a
total of 18-30A for regular installation with heated bed, roughly 220-360W at 12V. For
some configuration, less power can be used. The power supplies in Switch mode have
relatively complex circuits to convert the AC power supply into the DC voltage needed by
the Steppers and the Electronics circuits. The key benefit is that the power supply of a
switch mode is extremely energy efficient.

Figure 3.14 Power Supply

3.7 Software
3.7.1 CAD Tools
For designing 3D parts for printing, the Computers Aided Design is used. Computer Aided
Design (CAD) is where we use the computer system to assist in the study of change
development or design optimization. Computer-aided design software is used to extend the
designer's performance, enhance the interface process, improve interchanges through
documentation, and create a production database.
In perhaps the most profound sense, computer-aided design files are meant to allow you to
effectively modify and manage parts with specifications in mind. Once in a while and
alluding to CAD files as parametric documents. The sections that are depicted as a tree of
Boolean operations, they are carried out on basic forms like cubes, circles, cylinders,
pyramids.
1.SOLIDWORKS
It was published by the Dassault device. The solid works are often used for solid computer
modelling (CAD). The 3D printed parts have been built with solid construction to assemble
a full

Government College of Engineering, Karad Page 20

 CHAPTER 3

design, solid work, 3D printer that can directly be printed in the 3D printer, just like you
print a document on your standard printer. It operates for operating systems such as
Windows 7 or 8 etc. Also, different output types can be supported including STL, IGES,
VRML and JPEG. We most likely use the STL file because it is 3D printing format, and the
printed model has many formats. There are no post-processing criteria for data description
such as orientation, colour; solid materials etc. are supported by any slice method to produce
a G-code for printing 3D models, therefore in this software we preferred a solid 2015 model
design.

2.CATIA

It was also released by DASSAULT Device. CATIA is the computer assisted integrated
three- dimensional application. It can be used to build 3D CAD models but could not be
used for the input of a 3D printer directly. The 3D printer is a layer-by - layer operation and
thus no slicing programme is assisted. This method cannot be carried out by CATIA, while
there is no STL file to convert any G-code. This is the problem with the CATIA 3D model
design.

Figure 3.15 Design in CATIA

Government College of Engineering, Karad Page 21

 CHAPTER 3

3.7.2 CAM TOOLS

CAM-based tools manage the intermediate step of transforming Cad drawings into such a
computer-friendly template which is used for certain 3D printer hardware. Here we use the
program that integrates the slicing artifacts, G codes and M-codes creation, model
positioning and other printer settings. CAM software generally involves an STL file to
transform a 3D component into a computer format. The user-friendly print format is called
the G-code.

1. CURA:
It is the world's most advanced 3D printer application. Cura seems to be the environmentally
friendly for slicing; however, most consumers wouldn't recognize what to do. Simply
upload the cad model to the software; the quality can be printed by clicking on the printer
option. It is as straightforward as 2D printing norm. Essentially, all Cura print apps carry a
digital file into the 3D printer in any format from any device. Thus, 3D printing will snatch
its own printing. Cura could be downloaded online for you, but its open source as well. It is
the worldwide software of the daily 3D slicer. When comparing Cura with other 3D slicing
applications, Cura is easy to slice, and you have many features available in comparison with
other apps with fewer choices and modifications. But if you need it, Cura has more complex
settings; it's designed only smoothly and easily. Cura is designed by Ultimaker, a 3D printer
developer and they are perfectionists as everybody is aware of their hardware. In most other
trimming applications, almost all the settings and options are found in Cura applications.
We can adjust the setting by adjusting some quality and pace choices, and then in Cura, all
is carefully planned and ready to go. We only suppose you turned to the printer and filled
the filament. It will help to direct activity in the way of Cura 3D and start 3D printing from
that point on. Cura can be built seamlessly into the best 3D printing experience across
hardware, software and materials supporting various file formats like STL, 3MF and OBJ.
We use STL file format in our 3D printer because the model is entirely built out of solid
works and the file format is in STL.

Government College of Engineering, Karad Page 22

 CHAPTER 3

Figure 3.16 Cura slicing

Any model we create to print must be interpreted into commands that your end user
recognizes. The very first aspect you need now is a 3D model, so cura recognizes it, that the
exporting file is STL. Cura cuts the printable models in a few periods. By configuring the
printer, you can make any changes necessary for a 3D printer.

2. FIRMWARE

Marlin is the open-source firmware for replicating rapid prototypes for the RepRap
community, usually called 3D printers. These were built on Sprinter and grbl and on the
12th of August 2011 with the GitHub launch has been an autonomous open-source platform.
Marlin is GPLv3-licensed and can register for all applications. Early on, Marlin has created
a simple, effective, and versatile printer that can be "functional only" for RepRap
adventurers. Marlin is often used by well-known 3d printing technology as evidence of its
efficiency. Just some of the Marlin delivery companies include Ultimaker, Printout,
Artifacts (Lulzbot) and Prusa Research. Marlin is indeed able to operate laser engravers and
CNC's. The strength of Marlin is that it operates with low-cost 8-bit Atmel AVR controls-
with Marlin 2.x adding 32-bit support to the panel. These processors are in the center of the
famous Arduino. Arduino Mega2560 with RAMPS 1/4 including Re-Arm with Ramp-1.4
are the Marlin aiming systems. Marlin strives as a public good to respond with as many
boards and processing

Government College of Engineering, Karad Page 23

 CHAPTER 3

methods as feasible. For enthusiasts and retail companies, it is accessible, flexible, versatile,
and economical. Firmware has been the permanent software in solid - state storage read-
only storage (ROM) in a programme that allows hardware control of a computer. It can
provide systems with a basic operational environment, with much more complicated
software that lets hardware to operate on the OS, to execute different devices to fulfil all
surveillance as well as other manipulation functions. 3D printer electronics are operated by
the CPU including the Intel Processor and Arduino Microcontroller used throughout the 3D
printing. is used for various purposes such as consumer products, computer peripherals, and
others. The processors are used for running the rudimentary programme in the machine. The
whole software's firmware allows the 3d printing work, so that the firmware component is
the nearest to the current programming. But the word "cross-compiling" is what you're
doing with a firmware.

3. MARLIN Firmware
Marlin is an open-source firmware that replicates any RepRap family in rapid prototyping
and is also known as a 3D printer. It was obtained by Grbl and Sprinter and became an open
source for all 3D printers. A number of suppliers have been using Marlin only to supply a
version of marlin for useful 3D printers like Ultimate, Prusa and Printrbot. Marlin operates
8-bit chip microcontrollers in the heart of the open sourcing platform Arduino Mega2560
Marlin with RAMPS 1.4. Marlin is a firmware that can be used in any single processor
electronics, for example Arduino2570 is based on the Ultimaker, ramps and some other 3D
printers. It can be printed with folders via USB or SD cards and is planned for the future.
Marlin is licensed under GNU GPL v3 or later. It is based on the GPL v2 GPL approved
sprinter firmware. Marlin Firmware runs via a 3D printer's main board for managing any
system operations in real time. Heaters, buttons, sensors, measures, LCDs, lights are
organized, and all will be used for 3D printing. Marlin refers to an additive approach called
fused deposition modelling. This allows the motor to push the thermoplastic filament into a
heat pin that melts and extrudes the content, while the pin is forced under machine control.
It starts to map a physical entity layer by layer after several minutes.

Government College of Engineering, Karad Page 24

 CHAPTER 3

Since each printer is distinct, while we won't ever find G-code files downloaded, we've got
to slice it. As Marlin receives all instructions, they can be executed in the order obtained in a
motion queue. The steps stop the queue processes and begin to transform linear motions into
accurate electronic pulse engines. Marlin must also produce thousands of phase pulses at
moderate speeds per second. The CPU is literally overloaded to read sensors for security in
the Marlin firmware.

1.Steps to install firmware

Step 1: Download the Arduino IDE from the Arduino website and configure the Arduino
IDE according to the normal operating procedure. In Linux, Windows and Unix, Marlin can
be compiled.
Step 2: Download Marlin’s website firmware source code, pick the correct website code-
based edition.
Step 3: See Marlin configuration for an overview of configuration file format and a
description of most of the file choices to decide which hardware is in use.
Step 4: Check / Compile the Arduino IDE firmware
Step 5: Attach your controller to your PC via USB cable. Step 6: Upload the CPU controller
firmware software.

Figure 3.17 Program of Arduino

Government College of Engineering, Karad Page 25

 CHAPTER 3

3.8 CONCEPTUAL DESIGN

The model design must be performed in software, in which the current model is built with
the necessary dimensions in order to print the model. To build and produce the model there
are several processes and parameters that primarily require model design. The design
process began by retaining the print volume as the basic parameter of the design. The
project aims to create a cost-effective and sizable 3D printer, which has a print volume of
320 x 320 x 320 mm3. The three-dimensional movements are accomplished by
synchronizing the X, Y and Z directions of the movements. Therefore, X-Y directions for
drag knife cutting tool and Z directions for bed movement are included as mechanisms for
our 3D printer. This process uses 4 step-engines, one for moving of the Y-axis (to and for),
one for moving of the X-axis, and two for moving of the Z-axis (vertical movement). This
system uses two motors to power the lead screws whereby the printed bed is attached in a Z-
direction movement. The lead screws are powered by the motor which drives the bed
vertically. At first the conceptual design was visualized in CATIA software.

Figure 3.18 Conceptual view

Government College of Engineering, Karad Page 26

 CHAPTER 3

3.9. Working of machine

➢ Solid physical model is developed by Design Software (CATIA V5 R19 etc.). Each
outline of the cross-section form of the CAD model is divided into layers.
➢ The paper sheet is taken from a paper roll or a paper feeder (Take up a roll).
➢ The paper sheet is typically supplied as rolls spooled among two reels with an adhesive
backing.
➢ Drag knife paper cutter cuts the paper as per the computer programme instructions.
➢ After cutting, the excess material in the layer remains in place to protect the component
throughout the construction of the artifact.
➢ This process is repeated until the last or the top layer of the object has been built.

3.9.1 Process flow chart of machine

1. 3D data (STL files) is loaded

2. Model is oriented within system

3. System slices STL data.

4. New paper layer is placed on block

5. Block and new layer are pressed against hot plate

6. Layer is cut to shape by computerized knife.

7. Processes are repeated rapidly and accurately

8. Unnecessary parts are removed

Government College of Engineering, Karad Page 27

 CHAPTER 3

3.10. Detail design

3.10.1 Z-axis Movement

The following figures demonstrate the CAD model of the vertical movement process. It
consists of plume screws, shaft connector, flange nozzle and print bed as shown in the
image. The spinning motion of the motor is transmitted via the rotation of the lead screws
attached to the upper and lower extrusion profiles using the necessary connectors as shown
in Figure 4.11. The torque produced by the motor is transmitted through the shaft coupler
and flange nozzle to the lead screws. When the engine rotates, say clockwise, the coupler
rotates the lead screws in the same direction, say clockwise. 2 stepper motors power the Z-
axis. It increases the accuracy with 2 phase motors on the z-axis. We have mounted 2 lead
screws and 4 sliding rods for better precision.

Figure 3.19 Mechanism for Z – axis movement (vertical direction)

Figure 3.20 Bed support

Government College of Engineering, Karad Page 28

 CHAPTER 3

In order to develop this vertical movement process, we must first determine the 3D printer
volume printing. The height of the lead screw and the area of the bed are measured
depending on the volume. The bottom of the structural stability support plate, as shown in
Figure 3.24, is given for the bed. The support mechanism has two slots at the end to position
the LM8UU bearings that guide the sliding rods.

Figure 3.21 Bed Support

3.11. BEARINGS
Bearings are a revolving oscillating or sliding shaft, pivot or wheel assisted and driven.
Anywhere a pole turns; it needs a heading for smooth and efficient action. A heading should
be:
• Friction reduction
• Load support component
• Moving parts guide –shaft, pivots, wheel,

3.11.1 Ball bearings

A ball bearing is a kind of moving part bearing that can be used to preserve the gap between
the bearing races.

Figure 3.22 Ball Bearing

Government College of Engineering, Karad Page 29
 CHAPTER 3

The ball bearing trigger reduces the rotational tension and the radial and axial loads
are assisted. This can be achieved by using at least two breeds to transport the balls and pass
through to the balls. In certain implementations, one race is constant; the other is related to
the rotating assembly (e.g., center point or shaft). When one of the races is spinning, the
balls are still spinning. The balls are spinning because they have a much lower grid
coefficient than in the other two phases.

Figure 3.26 Flanged bushing ball bearing

Brand Machine fit
Model F623ZZ
Material 3x10x4mm
Outer Diameter 10mm
Inner Diameter 3mm
Thickness 4mm
Table 3.2 Specification of ball bearing

3.12 Paper feeding and gluing mechanism

The figure shows 3d model of paper feeding mechanism. It consists of one take up
roller at middle position, which pushes paper forward for further proceedings. Two set of
rollers then pushes paper forward over the plane surface bed of 3d printer. Upper roller is in
dry state whereas bottom roller is in wet state.

Fig 3.23 Paper feeding mechanism

Government College of Engineering, Karad Page 30

 CHAPTER 3

3.13 Paper gluing mechanism

The figure shows 3d model of paper gluing mechanism. Paper feeding holder
placed on X-Y axis mechanism as shown in fig 3.28, X-Y axis mechanism consist of paper
cutting mechanism and paper gluing mechanism, paper gluing glue stick is mounted on
gluing mechanism.

Fig 3.24 Paper gluing mechanism with X-Y axis

Fig 3.25 Actual Paper gluing mechanism with X-Y axis

Government College of Engineering, Karad Page 31

 CHAPTER 3

Government College of Engineering, Karad Page 32

 CHAPTER 4

RESULTS AND DISCUSSION

4.1 Introduction
A static structural analysis is the analysis displacements, stresses, strains and forces
on structure or a component due to load application. The structures response and loads are
assumed to vary slowly with respect to time. There are various types of loading that can be
applied in this analysis which are externally applied forces and pressures, and temperatures.
Table 3.19 shows properties of various materials. These Three materials are used for
manufacturing 3D printed component, so these are considered for analysis.

4.2 Static Structural Analysis

Table 4.1 Mechanical properties of materials

Bulk Shear
Materials Density Young’s Poisson’s Modulus Modulus
ratio (Pa) (Pa)
(kg/m3) Modulus
(Pa)

Acrylonitrile 1040 2.39E+09 0.399 3.9439E+09 8.5418E+08

Butadiene
Styrene
(ABS)

Polyethylene 1280 2.01E+09 0.4 3.35E+09 7.1786E+09

Terephthalate
Glycol Sheet
(PETG)

Polylactic 1250 3.45E+09 0.39 5.2273+09 1.241E+09

Acid
(PLA)

Government College of Engineering, Karad Page 33

 CHAPTER 4

4.2.1 Meshing

ANSYS Meshing is a general-purpose, intelligent, automated high-performance

product. It produces the most appropriate mesh for accurate, efficient Multiphysics
solutions. A mesh well suited for a specific analysis can be generated with a single mouse
click for all parts in a model. Full controls over the options used to generate the mesh are
available for the expert user who wants to fine-tune it. The power of parallel processing is
automatically used to reduce the time you must wait for mesh generation. Creating the most
appropriate mesh is the foundation of engineering simulations.
ANSYS Meshing is automatically integrated with each solver within the ANSYS
Workbench environment. For a quick analysis or for the new and infrequent user, a usable
mesh can be created with one click of the mouse. ANSYS Meshing chooses the most
appropriate options based on the analysis type and the geometry of the model. Especially
convenient is the ability of ANSYS Meshing to automatically take advantage of the
available cores in the computer to use parallel processing and thus significantly reduce the
time to create a mesh. Parallel meshing is available without any additional cost or license
requirements. Fig 4.19 shows meshed model and Fig 4.20 shows Fixed support of 3D
printed Z axis bed support.

Fig.4.1 Meshing of component

Government College of Engineering, Karad Page 34

 CHAPTER 4

Fig. 4.2 Fixed Support

4.2.2 Static Structural Analysis Results

The total deformation is an important factor in static structural analysis, we can find total
deformation, equivalent stress distributions and equivalent strain distributions by using
ANSYS tool. Total deformation is the vectors sum all directional displacements of the
systems.
In the experimentation, we applied 100 N force on three 3D printed Z axis bed support
of three different materials including Polylactic Acid (PLA), Polyethylene Terephthalate
Glycol Sheet (PETG) and Acrylonitrile Butadiene Styrene (ABS)

Fig.4.3 Total deformation of Polylactic Acid (PLA)

Government College of Engineering, Karad Page 35

 CHAPTER 4

For the applied force total deformation range for Polylactic Acid (PLA) plastic is 0 to
0.1266 mm. The value for maximum deformation for the PLA bed support is 0.1266 mm
and observed at the portion of extreme end part of bed support.

Fig 4.4 Total deformation of Polyethylene

Terephthalate Glycol Sheet (PETG)

For the applied force total deformation range for Polyethylene Terephthalate Glycol
Sheet (PETG) plastic is 0 to 0.22156 mm. The value for maximum deformation for the
PETG bed support is 0.22156 mm and observed at the portion of extreme end part of bed
support.

Fig 4.5 Total deformation of Acrylonitrile Butadiene Styrene (ABS)

Government College of Engineering, Karad Page 36

 CHAPTER 4

For the applied force total deformation range for Acrylonitrile Butadiene Styrene
(ABS) plastic is 0 to 0.18634 mm. The value for maximum deformation for the ABS bed
support is 0.18634 mm and observed at the portion of extreme end part of bed support.

Graph 4.1 Total Deformation Distributions

The graphical representation above shows the total deformation distribution for
given materials. The material Polyethylene Terephthalate Glycol Sheet (PETG) plastic
shows higher total deformation distribution and Polylactic Acid (PLA) plastic shows lower
total deformation distribution.

Fig 4.6 Equivalent (Von-Mises) Stress of Polylactic Acid (PLA)

Government College of Engineering, Karad Page 37

 CHAPTER 4

For the applied force equivalent stress range for Polylactic Acid (PLA) plastic is
0.00002265 to 1.308 MPa. The value of maximum stress for the PLA bed support is 1.308
MPa and observed at the portion of extreme upper part of bed support.

Fig 4.7 Equivalent (Von-Mises) stress of Polyethylene

Terephthalate Glycol Sheet (PETG)

For the applied force equivalent stress range for Polyethylene Terephthalate Glycol
Sheet (PETG) plastic is 0.000018018 to 1.3225 MPa. The value of maximum stress for the
PETG bed support is 1.3225 MPa and observed at the portion of extreme upper part of bed
support.

Fig 4.8 Equivalent (Von-Mises) Stress of Acrylonitrile Butadiene Styrene (ABS)

Government College of Engineering, Karad Page 38

 CHAPTER 4

For the applied force equivalent stress range for Acrylonitrile Butadiene Styrene
(ABS) plastic is 0.000018048 to 1.3226 MPa. The value for maximum stress for the ABS
bed support is 1.3226 MPa and observed at the portion of extreme upper part of bed support.

Graph 4.2 Equivalent stress Distributions

The graphical representation above shows the equivalent stress distribution for given
materials. The material Polyethylene Terephthalate Glycol Sheet (PETG) plastic and
Acrylonitrile Butadiene Styrene (ABS) shows higher total deformation distribution and
Polylactic Acid (PLA) plastic shows lower equivalent stress distribution.

Fig 4.9 Equivalent Elastic Strain of Polylactic Acid (PLA)

Government College of Engineering, Karad Page 39

 CHAPTER 4

For the applied force equivalent elastic strain range for Polylactic Acid (PLA) plastic is
6.4825e-6 to 0.38241 mm/mm. The value of maximum stress for the PLA bed support is
0.3824 mm/mm and observed at the portion of extreme upper part of bed support.

Fig 4.10 Equivalent Elastic Strain of PETG plastic

For the applied force equivalent elastic strain range for Polyethylene Terephthalate
Glycol Sheet (PETG) plastic is 1.1107e-5 to 0.7085. The value of maximum stress for the
PETG bed support is 0.7085 and observed at the portion of extreme upper part of bed
support.

Fig 4.11 Equivalent Elastic Strain of Acrylonitrile Butadiene Styrene (ABS)

Government College of Engineering, Karad Page 40

 CHAPTER 4

For the applied force equivalent strain range for Acrylonitrile Butadiene Styrene
(ABS) plastic is 9.3219e-6 to 0.59594. The value for maximum stress for the ABS bed
support is 0.59594 and observed at the portion of extreme upper part of bed support.

Graph 4.3 Equivalent Elastic Strain Distributions

The graphical representation above shows the equivalent elastic strain distribution
for given materials. The material Polyethylene Terephthalate Glycol Sheet (PETG) plastic
shows higher strain distribution and the material Polylactic acid (PLA) shows lower
equivalent strain distribution.

The static structural analysis for applied 100N force shows that total deformation
range of PLA material is between 0 to 0.1266 mm, for PETG material is 0 to 0.22156 mm
and for ABS material is 0 to 0.18634 mm. The equivalent (Von-Mises) stress range of PLA
material is between 0.00002265 to 1.308 MPa, for PETG material is 0.000018018 to
1.3225 MPa and for ABS material is 0.000018048 to 1.3226 MPa and the equivalent strain
range of PLA material is between 6.4825e-6 to 0.38241 mm/mm, for PETG material is
between 1.1107e-5 to 0.7085 and for ABS plastic is between 9.3219e-6 to 0.59594.

Government College of Engineering, Karad Page 41

 CHAPTER 4

4.3 OPTIMIZATION OF PAPER ADHESIVE

Table no 4.2 shows compressive strength and adhesive strength of deferent stick
adhesives

The general stick-type adhesive use PVP, polyurethane, polyvinyl acetate, urea, or water-
soluble epoxy, among which PVP is known to be the most popular and exhibits excellent
properties. Above graph 4.4 and 4.5 represents adhesive strength and compressive strength
of different adhesives

Graph 4.4. Adhesive strength comparison of different adhesives

Government College of Engineering, Karad Page 42

 CHAPTER 4

Graph 4.5. Compressive strength comparison of different adhesives

From graph no 4.4 and 4.5 we show that, stick adhesive has much better adhesive
strength (2.11 MPa) and compressive strength (30.11 N) amongst adhesive and stick
adhesive has no geometrical and accuracy related side effects on paper 3D object.

4.4 SPECIFICATIONS OF THE FINAL PRODUCT

Table 4.3 Specifications of additive layer manufacturing systems

Government College of Engineering, Karad Page 43

 CHAPTER 4

4.5. RESULTS
4.5.1. Results of additive layer manufacturing system
• The cost and weight factors are reduced to considerable rate by using 3d printed
parts.
• The paper feeding mechanism accuracy is very good.
• The glue used in paper gluing mechanism gives dimensional accuracy and strength
to paper 3D object.
• The desired build volume is achieved by a perfectly aligned and calculated linear
motion system.
4.5. CONCLUDING REMARKS

The static structural analysis of bed support of z-axis evaluates results for total
deformation, equivalent (Von-Mises) Stress and equivalent elastic strain. Above results
shows that Polylactic Acid (PLA) shows lower total deformation distribution, lower
equivalent (Von-Mises) stress distribution and lower equivalent strain distribution and
Polyethylene Terephthalate Glycol Sheet (PETG) shows higher total deformation
distribution, lower equivalent (Von-Mises) stress distribution and lower equivalent strain
distributions.

Government College of Engineering, Karad Page 44

 CHAPTER 5

CONCLUSION

The concluding observations from the present research work is given below.
1. Development of low cost 3d component manufacturing system using wastepaper as
an input raw material has been successfully completed. Instead of using readymade
filaments, the model produced at the level that the wastepaper become a printable
material, which is environmentally friendly and contributes to a major reduction in
environmental degradation.
2. The ANSYS static structural analysis is carried out for 3D printer bed support PLA,
PETG and Acrylonitrile Butadiene Styrene (ABS). The polylactic acid (PLA)
shows lower total deformation distribution (range 0 to 0.1266 mm), lower
equivalent (Von-Mises) stress distribution (range 0.00002265 to 1.308 MPa) and
lower equivalent strain distribution (range 6.4825e-6 to 0.38241 mm/mm) amongst
three materials. So, PLA is safe for making 3D printed Z-axis bed support.
3. The adhesive strength of the stick-type adhesive is 2.11 MPa, and its compressive
strength was 30.11 N. There is no change in its dimensional properties of A4 size
papers after applying stick-type adhesive. There is not any geometrical effect of
stick adhesive on A4 size paper after applying stick adhesive also bond between
two papers after applying stick adhesive is much stronger.
4. The cost and weight factors are reduced to considerable rate by 10% to 15% using
3d printed parts. The parts are initially rendered in 3d design software and started
fabrication as per the dimensions made. Thus, able to design and develop, a low
cost 3d component manufacturing system by using wastepaper as a raw material
according to its virtual design proposed at reduced cost.
5. A consumer-based product was developed in accordance with the product design
and prototyping process. The product being additive manufacturing system, which
is helpful in small level applications like educational, household, research purposes
and this work will helps to understand integration of electronic and mechanical
system.

Government College of Engineering, Karad Page 45

 CHAPTER 5

REFERENCES
1.Jing Zhan a, Takayuki Tamura, “Metal-plastic hybrid 3D printing using catalyst-loaded
filament and electroless plating”, ELSEVIER 2020.
2. Anton Wiberg, Johan Persson and Johan Olvander, “Design for additive manufacturing –
a review of available design methods and software” Rapid Prototyping Journal 25/6 (2019)
1080–1094 Emerald Publishing Limited [ISSN 1355-2546]
3.Thomas Duda, “3D printing Technology”, ELSEVIER 2020.
4. Nico Helpesrieder “Method for generating manufacturable, topology-optimized parts for
Laminated Layer Manufacturing”, ELSEVIER 2020.
5. Meisam Askari, David A. Hutchins, Peter J. Thomas, Lorenzo Astolfi, Richard L.
Watson, Meisam Abdi, Marco Ricci, Stefano Lauretta, Lushan Nia, Steven Freer, Ricky
Wildman, Christopher Tuck, Matt Clarke, Emma Woods, Adam T. Clare, “Additive
manufacturing of metamaterials: A review”, ELSEVIER 2020.
6. Naira Dias Pinheiro, Rafael Teixeira Freire, Josiele Aparecida M. Conrado, “Paper-based
optoelectronic nose for identification of indoor air pollution caused by 3D printing
thermoplastic filaments”, ELSEVIER 2020.
7.Fabio Giudice, Raffaele Barbagall, Giovanna Fargione, “A Design for Additive
Manufacturing approach based on process energy efficiency: Electron beam melted
components”, ELSEVIER 2020.
8. Christoph Klahna, Bastian Laurencekirk, Mirko Meboldtb, “Design Strategies for the
Process of Additive Manufacturing”, ELSEVIER 2015
9. Lim Chin Hwa, Srithar Rajoo, “Recent advances in 3D printing of porous ceramics: A
review”, ELSEVIER 2020.
10. A. Vranić, N. Bogojević, S, Ćirić Kostić, D. Croccolo, G. Olmi, “Advantages and
Drawbacks of Additive Manufacturing”, ResearchGate 2017

Government College of Engineering, Karad Page 46