International Journal on Interactive Design and Manufacturing (IJIDeM) (2018) 12:979–993

https://doi.org/10.1007/s12008-017-0432-x

ORIGINAL PAPER

Preliminary study for a full colour low cost open source 3D printer,
based on the combination of fused deposition modelling (FDM)
or fused filament fabrication (FFF) and inkjet printing
Fabrizio Regina1 · Fulvio Lavecchia1 · Luigi Maria Galantucci1

Received: 12 October 2017 / Accepted: 23 November 2017 / Published online: 7 December 2017
© Springer-Verlag France SAS, part of Springer Nature 2017

Abstract
Additive manufacturing techniques (AM) have enhanced product quality and exponentially increase their application both
from the industrial point of view and from the consumer point of view. A decisive development in the “consumer” sector
has been observed over the last 5 years thanks to open source projects (Fab@home, RepRap), which enabled the production
of low cost machines with the use of cheap electronic and mechanical components and open source software. Among the
possible future developments of low cost AM technologies, there is an improvement of finished product capabilities and
appearance to obtain coloured components, made directly during printing phase. This paper tries to respond to this need by
assessing the feasibility of realizing a low-cost AM system that integrates automatic colouring in a consumer 3D printer. The
proposed system is a hybrid between a fused filament fabrication 3D printer, derived from an open-source project, and a 2D
commercial inkjet printer; the two systems share the mechanics, but keep the movement control and the three-dimensional and
two-dimensional printing process separate. The study continues with the theorization, modeling and creation of the interfaces
required for conversion of control signals and a first experimentation of the same control. The two systems, using a different
mechanics, use different motor control systems.

Keywords Additive manufacturing · Rapid prototyping · Fused deposition · Inkjet · Hybrid control · Open source

1 Introduction/state of the art
Additive manufacturing (AM) processes, called also three-
dimensional printing, is defined by a range of technologies
capable to translate directly a virtual solid model data into
physical models in a quick and easy process [1], by which it
is possible to combine materials to create objects, fabricating
components by selectively curing, depositing or consolidat-
ing materials in successive layers. The data are broken down
into a series of 2D cross-sections of finite thickness.
These technologies have traditionally been limited to the
fabrication of models suitable for product visualization but,
over the past decade, they are now used for the fabrication of a
range of functional end use components [2]. Rapid prototyp-
ing is one of the earlier additive manufacturing processes.
Among the major advances that this process presented to
B Luigi Maria Galantucci
luigimaria.galantucci@poliba.it
1 Dipartimento di Meccanica, Matematica e Management,
Politecnico di Bari, Viale Japigia 182, 70126 Bari, Italy
product development are the time and cost reduction, human
interaction, and consequently the product development cycle,
giving also the possibility to create almost any shape that
could be very difficult to machine, without having attention
to tooling, undercuts, draft angles or other features, as in
machining processes [1,3]. With rapid prototyping, scien-
tists and students can rapidly build and analyse models for
theoretical comprehension and studies [3].
AM is considered as the natural evolution of industrial
manufacturing techniques, in opposition to subtractive man-
ufacturing methodology [4].
The AM industry grew by 17.4% in worldwide revenues
in 2016. The market for low-cost, desktop 3D printers grew
by 49.4% worldwide, compared to 14.9% for 3D printing
systems at all price levels. Because of their affordable price
point and ease of use, the consumer models (based on open
source3D printers) may have found a place in the profes-
sional market, among engineering and architecture firms that
benefit from having on-premise rapid prototyping equipment
[5]. We are dealing with a disruptive technology that most
companies still have to get used to and we should be aware

123
980 International Journal on Interactive Design and Manufacturing (IJIDeM) (2018) 12:979–993
of the possibility that technological progress could enhance
revenues from producing with 3D printers (due to productiv-
ity increases, as seen with personal computers). This could
cause the rate of investment in 3D printing to accelerate,
bringing forward the point when 3D printing matches tradi-
tional manufacturing output. In this scenario the size of the
capital stock of 3D printers will equal that of the capital stock
of traditional machinery, and hence production size, in 2040
[6].
There are many AM techniques currently available in the
market. In recent years, fused deposition modeling (FDM)
or fused filament fabrication (FFF) thanks to open source
projects (Fab@home [7], Reprap [8]) made possible to
produce very low cost machines using cheap electronic
and mechanical components and open source software.
These machines are characterized by extreme simplicity,
great possibility of customization and low cost of hard-
ware and material components: a plastic filament feeds a
hot extruder that creates layer by layer the 3D object. The
materials most widely used with these technologies are
acrylonitrile-butadiene-styrene (ABS) and poly (lactic acid)
(PLA).
In recent years, many efforts have been made to improve
the quality of the pieces created through this technique. Sev-
eral authors have explored possible ways to improve surface
finishing. In [9] the influence of printing parameters on the
obtainable roughness is evaluated and is proposed a post
treatment with acetone bath for the pieces made in ABS.
In [10] a post-treatment of surface by barrel finishing is
described.
In [11] a performance evaluation and comparison of
an industrial and an open-source one 3D FDM printers is
illustrated, finding optimum process parameters to improve
dimensional accuracy.
FDM printing has a wide margin of improvement in the
capability of this technique to produce final parts with com-
plex features. This paper presents a preliminary study of the
possibility of creating full-colour pieces via FDM.
In [12] it is highlighted that a colour product made by
additive manufacture can bring several benefits. As part of
conceptual models, a colour model gives much more infor-
mation than a monochrome model. With regard to finished
objects, obtaining parts with the desired final appearance
would allow a complete object manufactured by additive
fabrication without the need for further processing. For con-
ceptual models, LOM colour prototyping techniques and 3D
printing have been available for several years now [12]. In
these additive manufacturing technologies, the introduction
of a colouring system is relatively simple through the use
of the common inkjet printing technique [13]. The work-
piece material of LOM technology is just the paper. In the
3D printing process, however, inkjet printing is already inte-
grated into some processes using a blinder that is ejected
123
to join the grains [14]. The colouring system is obtained
simply by including the dyestuff in the blinder or in the pho-
tosensitive resin, and separating the material into different
tanks required for CMYB quadricromia [15]. The objects
created with LOM and 3D-printing technologies, however,
have technical and mechanical features often useful only in
the creation of conceptual models. For finished products, it is
necessary to use different additive manufacturing methods,
such as selective laser sintering, Polyjet [15] Multi Jet Fusion
HP [16]. Polyjet technology utilizes coloured photosensitive
resin cartridges, while Multi Jet Fusion HP is a technological
evolution of 3D inkjet printing. The use of inkjet colouring
technologies in selective laser sintering has been discussed
in [17].
It is important to observe how inkjet systems in additive
fabrication are widely spread even for non-coloured pro-
cesses. Inkjet technology is used in the production of nano-
structures of electromechanical micro-systems (MEMS) [18]
and to build graded parts using a multi-material additive man-
ufacturing method [19]. It is clear that inkjet methods can be
used in a wide range of processes in present and future addi-
tive manufacturing applications [20].
AM technologies are perfectly integrated with the princi-
ples of the interactive manufacturing approach; indeed, these
technologies use to transform, through a direct and interac-
tive approach, a virtual prototype in a physical one.
These technologies allows to directly manufacture the
project of designer, who can interact with his prototype idea,
making it in real time without any constraints [21] and with
very low technological limits. Many authors have been inter-
ested in the interaction between these technologies and the
end user, for example in [21] several methods have been stud-
ied for the choice of the most accurate design technique in
order to optimize the manufacturing phase in AM. In [22] the
authors describe an integrated approach between CAD, sub-
tractive technologies and additive technologies, to optimize
costs, sustainability and interaction, implemented using open
source software systems. This method is able to eliminate all
manual steps from the process.
In [23] the mechanical and thermal behavior of a ther-
moplastic matrix composite reinforced with natural fibers
were studied. In this case, the characterization can allow the
designer to optimize the programming and configuration of
machines to produce parts that use such materials.
Recently, the launch of a pre-order for November 2017
of a new 3D commercial printer that should combine FFF
technology with inkjet printing has been announced [24].
This paper is based on an interdisciplinary research, that
involves design, signal analysis, computerised motion con-
trol, innovative low cost manufacturing solutions, to propose
an original technical implementation for designing and devel-
oping a new hybrid open source colour 3D printer (2D
inkjet + FFF printed).
International Journal on Interactive Design and Manufacturing (IJIDeM) (2018) 12:979–993
The proposed approach contributes transversally to both
interactive approach and manufacturing, exploring, simplify-
ing and implementing a model that enables the engineer and
makers to build a hybrid printer, but at the same time attempts
to fix the basis to create a revolutionary system that allows
the end user to make directly colored three-dimensional
objects. The designers could achieve a highly interactive
system, greatly simplifying the production of colored arti-
facts in additive manufacturing. The coloured prototypes or
3D physical models allow to improve decision-making in
product design and manufacturing, due to the high-realistic
multi-sensorial perception of new designed and manufac-
tured objects.
Interactivity can also be seen also as making an object
directly from the virtual model, without sacrificing the tex-
ture and colors of that artifact, having a physical model that
perfectly matches the virtual one.
2 Materials and methods
2.1 Design hypothesis
The commercial launch of a new FFF-inkjet 3D printer [24]
has prompted authors to publish a study already done through
a master thesis [25] on a hybrid 3D printer, obtained com-
bining a fused filament fabrication machine (based on an
open source project) and a 2D commercial inkjet printer, that
can colour the filament filed. This paper offers in an open
source optics a preliminary project that could serve anyone
who intends to develop these types of printers (makers, small
companies).
The FFF colour printing machine hypothesis appears as
a complete 3D printer to which the cartridge carriage of a
2D printer and its control units are added. The two printers
should share the mechanics, but keep separate motion and
three-dimensional and two-dimensional printing controls.
The designed system involves deposition of different lay-
ers of material by extrusion of thermoplastic material (FFF).
Each layer deposited will then be dyed with ink jet print
heads. Colouring may only affect perimeters or the entire
layer.
The hypothesized operation must be managed by a spe-
cific software, to be developed in detail at a later stage. The
software could control three-dimensional printing through
an IO port of the machine’s hardware control unit (for
example, a serial port), send control codes to handle the
extrusion head displacements in the work volume, filament
deposition, and other control variables (extruder temperature,
cooling fan speed, flat temperature, etc.). The main change
to existing open source control software should consist of
a new section dedicated to inkjet printing. Each layer cre-
ated by the software will generate an image representing the
981
Fig. 1 Hybrid 3D printer scheme of the functioning hypothesis
colours on the layer just deposited by the extruder, which
will be printed on the inkjet part as a normal paper page
(Fig. 1).
To do this, the print head should be positioned on the same
plane as the extruder (Fig. 2). Similarly to 2D printing on
paper, movements along the X and Y axes will respectively
correspond to the movement of the carriage cartridge and the
feed of the paper sheet.
The main difficulty encountered in this possible inte-
gration arises from the different types of mechanics and
motors used for movements in the two printers: consumer
or open source FFF machines preferably use open loop
control and stepper motors, and allow the use of different
motion transmission systems, whose features are easily con-
figurable through the firmware of the control system. Inkjet
printers, on the other hand, usually use a motion transmis-
sion via a belt driven by a toothed wheel on the shaft of a
DC motor; the latter control is of closed loop type, and a
linear encoder provides the position of the print head car-
riage.
A possible hybrid system scheme is presented in Fig. 2: the
motion transmission system is the one of the inkjet, while the
type of motor to be used will be discussed later. It is certainly
necessary to create a new interface for motor control, as we
hypothesize motors with different technologies (Stepper and
DC).
The design hypothesis involves the simultaneous use of
two controllers, one derived from a 2D printer and second
type open source for the 3D printing. The development con-
sists of two phases: the first phase will analyse and create
models for tying input and output signals, while the sec-
ond is devoted to choose the type of motor for the carriage
movement and to the definition of the necessary control. Per-
formances will then verified and the best design solution will
be defined (Fig. 3).
The control process can be synthesized in an input vari-
able that drives a motor (variable duty pulses with constant
period), a corresponding micro-movement, and a consequent
123
982 International Journal on Interactive Design and Manufacturing (IJIDeM) (2018) 12:979–993
Fig. 2 Hybrid 3D printer. Detail
of carriage cartridge and of the
filament extruder
SUPPORT
MATERIAL
SPOOL
BUILD MATERIAL
SPOOL
output value generated by the encoder for the feedback con-
trol (constant duty pulses with variable period). Figure 4
shows an example of 8 short-stroke start-ups (blue curve)
alternating with 8 fast-return movements (red curve) and rel-
ative carriage speeds (green curve).
The command of the stepper motors for additive 3D printer
machine is simpler. The control unit handles two distinct sig-
nals: STEP and DIR: the microcontroller sends the driver
information on the number of steps and the direction of the
motion. The driver receives a pulse on the STEP pin for each
step needed to be completed. These pulses have variable dura-
tion. By varying this period, it is possible to vary the rotation
speed. The value of the DIR signal provides the direction
of the step movements: a high level corresponds to a counter
clockwise rotation, a low at a clockwise rotation of the stepper
motor (Fig. 5 [26]).
2.1.1 Interface 1
It will be described below the first possible configuration that
uses stepper motors and an interface that allows the conver-
sion of signals that come from the inkjet printer control unit.
The model is schematized in the Fig. 6.
where:
• d j the value of a motor control pulse generated at the
time instant j
• V j , the corresponding output speed at the instant j
• i j the set of endogenous components of the process
123
LIQUIFIER HEAD
(MOVES IN X AND Y)
INKJET COLOUR CARTRIGE
(MOVES IN X AND Y)
BUIL PLATFORM
(MOVES IN Z AXIS)
• p j , the process parameters at the instant i.
It is possible to simplify the system by schematizing it as
a body C which, at the instant i, has a velocity of vi and
subjected to two forces: one active, generated by the motor
(Fm), and a passive friction one (Fa), mainly due to the sliding
of the carriage on the guide and to the internal frictions of
the motor. The velocity of the body at the instant i will be
the function of the velocity at i − 1, of the driving force and
of the friction force:
vi = f (vi−1 , Fm , Fa )
A mathematical model has been developed to relate the active
pulse duration di of the control pulses to the velocities obtain-
able by the values read with the encoders.
In order to create the model, let us consider the curve
trends of the two sets of values.
The value of the forces changes depending on whether
the movement is a printing one or a fast return. Two distinct
models have been created with the same basic structure, and
then calibrated by a heuristic procedure. The model chosen
to represent this system is an additive type made up of three
different contributions:
vi = vi−1 + f Fm (di , vi−1 ) + f Fa (di , vi−1 ) ; (m/s)
The model corrects the speed taken at the i − 1 instant by
adding two aliquots due to the external action of the motor
International Journal on Interactive Design and Manufacturing (IJIDeM) (2018) 12:979–993 983

Fig. 3 Flow chart of the design hypothesis

u se du
Pulse duration Ca age speed [m/s]
at o [μs] & Carriage [ /s]

Time [ms]
Print Return Encoder Print Return Encoder

Fig. 4 Moving average for 50 cycles of duty and speeds for 5 print movements from end-to-end running alternating to 5 fast return movements and
relative encoder signal

123
984 International Journal on Interactive Design and Manufacturing (IJIDeM) (2018) 12:979–993

Fig. 5 Step/dir (and CW/CCW) Posion (μm) &

and motor motion [26] Pulse tension (V)

(-)Moon

MOTOR
Pulse width =
100 nsec to 1ms
(+)Moon

CW

CCW
20 20
nsec nsec

(min) (min)
Step

DIRECTION (+) moon

(-) moon Step/Dir and CW/CCW
Time (ms)

• Vi , the corresponding output speed of the carriage at the

instant i
• i i the set of endogenous components of the process
• pi , the process parameters at the instant i.
• vi body speed at the instant i
• vi−1 body speed at the instant i − 1
• a,b,c,f,g,h,l,m are constant whose value is to be deter-
mined experimentally.

It is possible to calculate the angular velocity ω of the motor

Fig. 6 Mathematical model scheme to relate the input signals to the
output signals for interface 1 using the following formula, starting from the linear speed
of the carriage:
 
( f Fm ) and the frictional forces ( f Fa ). The model adopted for 2 · Vi rad
ω=
the printing movement is: D · 10−3 s

 c  h Where D is the diameter of the transmission pinion.

vi = vi−1 + a · (b · di + vi−1 ) + f · (g · di + vi−1 ) The number of rotations per second R P S, on the other
(m/s) hand, is equal to:
Vi = l · {vi }
m
(m/s)  
ω rad
RPS =
2·π s
where:
◦
Assuming a motor with a resolution of 1.8 , equal to a single
• di the value of a motor control pulse generated at the time step, it is possible to calculate the number of impulses per
instant i second (frequency) needed for each desired speed:

Fig. 7 Interface 2 scheme

Control pulses for Interface Control pulses for
stepper motor DC motor

123
International Journal on Interactive Design and Manufacturing (IJIDeM) (2018) 12:979–993
P P S = R P S · 200
The delay between the impulses is equal to:
106
delay =
PPS
It is possible to write a single formula linking the delay to
the linear velocity of the carriage expressed as a function of
the duty of the control pulses:
5·π · D
delay =
Vi
5·π · D
delayi =   c 
l · vi−1 + a · (b · di + vi−1 ) + f · (g · di + vi−1 )
In a way similar to the previous analysis, the fast-moving
phase has proceeded. The model created is as follows:
  c
vr j = vr j−1 + a  · b · di + vr j−1
  h 
+ f  · g  · di + vr j−1 (m/s)
 
Vr j = l  · vr j
m
5·π · D
delayr j =  (s)
  c   h  m 
l  · vr j−1 + a  · b · di + vr j−1 + f  · g  · di + vr j−1
2.1.2 Interface 2
The second possibility is the use of DC motors and a feedback
control loop also for handling the head for the FFF.
The interface uses two pulse counters, one for the input
STEP pulses and the other for the impulses generated by the
encoder (Fig. 7). By programming the firmware variables
of the controller of the additive manufacturing 3D printer
it will be possible to generate a step value able to check
the equivalence for which the movement corresponding to
a STEP pulse is equal to the reading of the motion of an
impulse generated by the encoder.
The interface, when there is a new input pulse read on the
STEP value, will add or remove a unit to a counter depend-
ing on the logical value read on DIR (high/low) signal. This
counter will indicate the target position expressed in number
of steps to be done. Instead, the actual position will be eval-
uated by the impulses generated by the encoder. Whenever
the actual position counter will give a value different from
the target position, the system will generate other impulses
that will move the carriage and bring it to the target position.
It can therefore be assumed that the system will be in move-
ment when the target position is different from the actual one,
and stops in the opposite case (Fig. 8).
985
(Hz) The process will be regulated in feedback through a
proportional-integral-derivative control.
The controller will acquire the actual position and com-
pare it with the target position (set point). The difference,
the so-called error signal, will then be used to determine the
(s)
value of the output variable of the controller, which is the
manipulable variable of the process.
2.2 Experimental testing and parameter calibration
(s) To test the design hypothesis, a 3D printer controlled by an
Arduino Mega 2560 controller [27] via A4988 driver [28]
h m (s)
positioned on the RAMPS board 1.4 [29] was assumed and
used. The firmware used and loaded in Arduino is the Marlin
V_1 [30]. In order to understand the operation of the stepper
motors, it is necessary to analyse the direct drive motors of
the A4988 driver as they acquire the STEP and DIR input
(s)
signals and return command signals for the stepper motor
(Fig. 9).
A commercial entry level inkjet printer (HP Deskjet 1010
[31]) was then coupled to the 3D printer. It uses a motor
feedback control based on a pulse width modulation (PWM)
and a linear position transducer.
The printer is controlled by a logical board all-in-one
chip Marvell 88PAAX01 and a 64Mb SDRAM WINBOND
W9864G6JH memory card (Fig. 10).
A HP CB760-60030 DC motor, using a belt system, moves
the cartridge carriage, while an HP CZ021-60025 DC motor
delivers the paper feed (Fig. 11). The connections are made
with two flat cables: the first, with 16 terminations, has the
task of transferring the signals from and to the cartridge
carriage. The second, with 8 terminations, is used to trans-
mit the rotary encoder signals of motor handling the paper
sheet movement and the opening/closing sensor of the front
door.
The cartridge carriage runs on a track of about 29.5 cm.
Movement is transferred from the pulley to the carriage
thanks to a toothed belt. The position transducer required
for feedback control is also located along the carriage track.
The next step was to capture the signals generated by the
2D paper printer board. For this operation, the same Arduino
Mega 2560 electronic controller was used.
123
986 International Journal on Interactive Design and Manufacturing (IJIDeM) (2018) 12:979–993

Actual The intensity current value in the secondary circuit will

Posion thus have a maximum value equal to I = 0.48 (mA).
In order to correlate the input data (duty) and output
(speed) it is also necessary to acquire the values of the pulses
generated by the encoder. In this case, the voltages vary
New STEP
pulse
between 0 and + 3.3 V, so it is possible to directly connect
the encoder to an Arduino pin (pin 7). The overall circuit is
schematized in Fig. 12.
To perform these functions a specific code was created,
Actual High Low Actual which was loaded on Arduino; it returns the corresponding
Posion+1 DIR value Posion-1 semi-period of the impulse generated by the encoder for each
pulse read. Each value corresponds to the time needed by
the carriage to move for a distance equal to the size of the
encoder pitch. It is important to note that the lower average
Target
Posion period values are present in the plot for the rapid movements.
The minimum reached during the printing phase is 242 µs,
while during the fast moving phase the lower value is 77 µs.
The control process can be synthesized in an input sig-
nal that commands a motor, a corresponding micro-motion,
Movement
and a consequent output signal generated by the encoder for
feedback control. The designed interface will therefore read
the input values generated by the 2D printer card, process
Posion No and send command signals to generate a motion through the
reached stepper motors at speeds equal to those obtainable from the
Yes
original configuration, so that they can obtain the same output
values through the encoder.
New Actual Pulse Width Modulation (input values) allows for obtain-
Posion ing an average value of variable voltage between the max-
imum and minimum pulse values as a function of the
Fig. 8 Functioning flow chart diagram of the controller for interface 2 duty-cycle value, the fraction of the time at which the pulse
is in the state high and the period of the impulse itself. The
period remains constant, equal to ∼ 45.10 (µs). The feedback
control signal (output values) is instead a square wave with
DC motors are controlled by pulse trains with defined duty, minimum and maximum constant voltages and variable
characteristics. The only property of these dynamically period.
changing impulses is the duty cycle. Efforts have focused The carriage moves in two directions and, therefore, has
on the acquisition and subsequent processing of these val- an alternation of positive pulse trains (24 V) and negative
ues directly via the same controller. Arduino’s specifications (−24 V) with single pulses of maximum duration equal to 24
allow input voltages on pins comprised between 0V and + µs. Figure 13 shows two pulse trains involved in the move-
5V. It has been verified how the printer pulses are instead ment of the printing carriage during the printing and return
within a range of ∼ − 24 V and ∼ + 24 V. From this, two phase to the initial position, and the relative speeds (Fig. 14)
problems arise. The first relates to the inability to read sig- obtained from the pulse half-period analysis of the pulses
nals with a negative voltage value and the second due to the generated by the optical position transducer (encoder).
limited range of input voltages on the Arduino board. Since there is no direct correlation between the input
The first problem was solved by splitting the circuit into and output functions, then it was necessary to process the
two distinct ones, each of them will read a positive voltage input signal and obtain an output using the models illustrated
value between 0 V and ∼ + 24 V. Two distinct Arduino input above.
pins will then be used. The second problem was solved by
introducing a voltage divider circuit by inserting resistors. 2.3 Interface 1
The resistances have been calculated in such a way as to
minimize the current present in this circuit and therefore the It will be described below the first possible configuration that
following values were chosen: R1 = 10(Kohms) and R2 = uses stepper motors and an interface that allows the conver-
40(Kohms). sion of signals from the inkjet printer control unit. The models

123
International Journal on Interactive Design and Manufacturing (IJIDeM) (2018) 12:979–993 987

Fig. 9 a Arduino Mega 2560 controller; b RAMPS card; c A4988 driver

Fig. 10 Chip all-in-one Marvell 88PAAX01control card of the HP DeskJet 1010; a front; b back; c Encoder pin connection

Fig. 11 Pulley, toothed belt, and HP DeskJet 1010 printer carriage

123
988 International Journal on Interactive Design and Manufacturing (IJIDeM) (2018) 12:979–993

Fig. 12 Signal acquisition scheme to acquire signals generated by the all-in-one chip logic board of the 2D printer Marvell 88PAAX01 with the
Arduino Mega 2560 electronic card

Fig. 13 Duration of the high (μs) (a) (μs) (b)

pulse signal in carriage 16 25
movements during printing (line
(a)) and fast return (line (b)) (µs) 14
20
12

10
15
8

6 10

4
5
2

0 0

Fig. 14 Speed during printing (m/s) (m/s)

(line (a)) and fast return phase (a) (b)
0.35 1.2
(line (b)) (m/s)
0.3 1
0.25
0.8
0.2
0.6
0.15
0.1 0.4

0.05 0.2

0 0

were obtained for successive approximations of the param- the active state of the control pulses with respect to the speeds
eters present in the mathematical equations in order to fit as obtainable by the reading of encoder values is therefore cali-
much as possible the curve obtained from the models with brated the values of the constants by experimentally finding.
the original one. The mathematical model developed to bind For the printing movement: a = 0.1; b = 2; c = 1.04; f =

123
International Journal on Interactive Design and Manufacturing (IJIDeM) (2018) 12:979–993 989

25
Pulse duraon [μs]
20

15

10

0
Print Return Time

1.2
Real carriage speed [m/s]
1

0.8

0.6

0.4

0.2

0
Time
1.2
Esmated carriage speed [m/s]
1

0.8

0.6

0.4

0.2

0
Speed esmated in print phase Time

Fig. 15 Pulse duration for the command of the carriage, Speed values during printing (and fast return) phases, speeds estimated by the model for
fast-return and printing phases

Fig. 16 The two distinct pulse

Volt First rising edge
trains signals in a quadrature
linear optical encoder, for
determining the movement HIGH
direction [32] LOW
Channel A
(leads) HIGH
LOW
Channel B
Direcon

HIGH
LOW
Channel A
HIGH
Channel B LOW
(leads) First rising edge
Direcon

Time

123
990 International Journal on Interactive Design and Manufacturing (IJIDeM) (2018) 12:979–993

16000 6
movement, the logic level of the second pulse train must be
(b)
14000
5
evaluated at the change of the logic level of the first pulse
12000
train. Observe Fig. 16. In the left direction, the passage from
4 1 to 0 of the pulses of train A corresponds to a logic level of
10000
1 to B. In opposite movement the opposite occurs, the step
PPS max

N*cm
8000 3 from 1 to 0 on A corresponds to a logical level of 0 on B
6000
[32].
2
4000
1
2000 (a) 3 Results
0 0
0 5 10 15 20 25 30 35 40 45 50 55
3.1 Interface 1
diameter [mm]

Fig. 17 Pulse frequencies (line (a)) and torque values (line (b)) when As far as the implementation of Interface 1 is concerned, the
changing the pulley diameter D following graph has been experimentally obtained in which
the torque (for inkjet cartridge carriage) and the maximum
pulse frequency of the control (pulses per second—engine
−0.11; g = 1.8; h = 1.0197; l = 0.128; m = 0.66, with the
characteristics) with the variation of the pulley diameter (Fig.
following model (Fig. 15):
17) are reported.
 1.04 The diameter D of the pulley varies the slightest movement
vi = vi−1 + 0.1 · (2 · di + vi−1 ) that the carriage can perform, corresponding to the single-
 1.0197
+ −0.11 · (1.8 · di + vi−1 ) (m/s) step movement of the motor. By imposing the equality of the
Vi = 0.128 · {vi } 0.66 single motion on the resolution of the encoder

π · D · 1.8
The only relationship that connects the delay to the linear = 0.079 mm
360
velocity of the carriage expressed as a function of the duty
of the control pulses is:

5·π · D
delay =   1.04  1.0197 0.66 (s)
0.128 · vi−1 + 0.1 · (2 · di + vi−1 ) + −0.11 · (1.8 · di + vi−1 )

In a way similar to the previous analysis, the fast-return phase

has proceeded. The model created is as follows:

  1.101   1.02
vrr j = vr j−1 + 0.096 · 3.8 · d j + vr j−1 + −0.115 · 3.4 · d j + 1, 1 · vr j−1 (m/s)

0.38
V j = 0.18 · v j (m/s)
5·π · D
delayr j =    1.101   1.02 0.38 (s)
0.18 · vr j−1 + 0.096 · 3.8 · d j + vr j−1 + −0.115 · 3.4 · d j + 1.1 · vr j−1

2.4 Interface 2 The value of the diameter of the pulley is obtained as:

For interface logic 2, two separate inputs are required for
the data. The position transducer is a quadrature linear opti-
cal encoder, and this involves the presence of two distinct
pulse trains to determine the direction of movement (which
could be quantified in absolute value only by analysing a
single pulse train). In order to determine the direction of
D ≤ 5.0318 mm.
This value of diameter D corresponds to a maximum pulse
rate of 13,329 (s−1 ) and a torque value of 0.52 (N*cm). A
thorough search of a stepper motor with such characteristics
does not return a valid result. The analysis presented in this

123
International Journal on Interactive Design and Manufacturing (IJIDeM) (2018) 12:979–993 991

paragraph, while remaining valid, cannot be realized because

of the limited characteristics of the commercially available
stepper motors.
Therefore, with regard to the analysis based on stepper
motors, it was not possible to physically achieve the system,
due to the limited speed characteristics of the motor. The
method is valid but cannot be applied.

Fig. 19 Trace corresponding to a 50 mm displacement

3.2 Interface 2
Subsequently, the software developed to acquire input sig-
The solution that adopts DC motors allows for perfect inte-
nals, movements and feedback control was customized.
gration between the two systems. The use of this solution
For the operation of the interface, a specific MARLIN
brings several benefits. The feedback system allows a much
firmware configuration was created to define the number of
more accurate control of the printing process. Errors caused
steps needed to move a length of 1 mm along the 3 axes (X,
by “step-loss” are now overwhelmed. A simple system is
Y, Z) and to extrude 1mm of filament material. Repetier-Host
designed to test the operation of the X axis. At the hardware
version 0.95F software is used to test the system.
level, the interface is formed by (Fig. 18):

4 Discussion
• Arduino mega 2560;
• Optical position encoder; As a first test, manual control is used to send some movement
• L298N DC control driver; commands in the directions −X and +X. The first verifi-
• DC motors. cation involved the good functioning of the system, which

Fig. 18 Overall design and control system of DC motors based on: Arduino mega 2560 (a); DC motor control driver for L298N (b) HP CB760-60030
motor, (c), RAMPS card (d) connection with optical position encoder (s)

123
992 International Journal on Interactive Design and Manufacturing (IJIDeM) (2018) 12:979–993
Fig. 20 Simulation of workpiece fabrication using Repetier-host
responded perfectly to all commands sent in both directions.
The correspondence between the value of the motion sent and
the actual displacement was subsequently verified. To do this
we have proceeded in two distinct ways. A first indirect con-
trol is obtained by Arduino by reading serial communication
of the value of the PositiveVariable value. It is then verified
that, following a 50 mm movement command, the value of the
variable ranges from 0 to 632–635 corresponding to 49,928 to
50,165 mm. A second indirect test is performed by inserting
a mechanism that traces the movements made. The previous
movement corresponds to the trace visible in Fig. 19.
As a last test, was launched the fabrication of a workpiece
and a speed of 200 mm/s was set, higher than the ones nor-
mally used during 3D printing (Fig. 20). The system did not
show any particular defects in executing repetitive and fast
movements. Based on what is shown in the tests performed,
it can be stated that the system has been working well.
5 Conclusions
The aim of this work was to provide a contribution to the
design of a FFF open source system combined with a colour-
ing system, by integrating a fused filament fabrication 3D
printer and a 2D colour paper inkjet printer. The study
123
involves an interactive design, combining signal analysis,
computerised motion control, proposing an innovative and
original low cost technical solution.
The use of stepper motors and a signal processing system
for DC motors control, if not theoretically impossible, was
not currently achievable, due to the limited characteristics of
the stepper motor speeds.
On the contrary, the solution which uses the use of DC
motors and closed loop control, has provided the expected
results. The system designed and tested not only provides
a solution to the problem being tested, but can also bring
advantages in the production of 3D printers. In fact, the use
of such motors makes it possible to significantly reduce the
cost of construction and provide greater precision and control
of the printing process.
In order to move on to the final stage of development, it
is necessary to develop a dedicated software that can alter-
nate the two printing processes. 3D printing can be handled
as usual adding an implementation of a filament retraction
management system during 2D printing. Colouring, on the
other hand, will certainly be more complex to implement.
Once the 3D layer is completed, the software will have to
recreate the perimeters of each surface corresponding to the
newly generated layer and print them as a normal image,
matching the 3D workpiece and the ink feeds.
International Journal on Interactive Design and Manufacturing (IJIDeM) (2018) 12:979–993
References
1. Gibson, I., Rosen, D.W., Stucker, B.: Additive Manufacturing Tech-
nologies. Springer, Boston, MA (2015)
2. Horn, T.J., Harrysson, O.L.A.: Overview of current additive man-
ufacturing technologies and selected applications. Sci. Prog. 95,
255–282 (2012)
3. Wong, K.V., Hernandez, A.: A review of additive manufacturing.
ISRN Mech. Eng. 2012, 1–10 (2012)
4. Guo, N., Leu, M.C.: Additive manufacturing: technology, applica-
tions and research needs. Front. Mech. Eng. 8, 215–243 (2013)
5. Wohlers, T.: Wohlers Report 2017 3D Printing and Additive Manu-
facturing State of the Industry. Annual Worldwide Progress Report.
Wohlers Rep 2017 (2017). ISBN 978-0-9913332-3-3 (2017)
6. Leering, R.: Economic and financial analysis 3D printing: a threat
to global trade. https://www.ing.nl/media/ING_EBZ_3d-printing_
tcm162-131996.pdf. Accessed 20 Nov 2017 (2017)
7. Malone, E., Lipson, H.: Fab@Home: the personal desktop fabrica-
tor kit. Rapid Prototyp. J. 13, 245–255 (2007)
8. Jones, R., Haufe, P., Sells, E., Iravani, P., Olliver, V., Palmer, C.,
Bowyer, A.: RepRap—the replicating rapid prototyper. Robotica
29, 177–191 (2011)
9. Galantucci, L.M., Lavecchia, F., Percoco, G.: Experimental study
aiming to enhance the surface finish of fused deposition modeled
parts. CIRP Ann. Manuf. Technol. 58, 189–192 (2009)
10. Boschetto, A., Bottini, L.: Surface improvement of fused deposition
modeling parts by barrel finishing. Rapid Prototyp. J. 21, 686–696
(2015)
11. Galantucci, L.M., Bodi, I., Kacani, J., Lavecchia, F.: Analysis of
dimensional performance for a 3D open-source printer based on
fused deposition modeling technique. Procedia CIRP 28, 82–87
(2015)
12. Gibson, I., Ming, L.W.: Colour RP. Rapid Prototyp. J. 7, 212–216
(2001)
13. How Paper-based 3D Printing Works: The Technology and Advan-
tages. In: Mcor Technol. Ltd. http://www.mcortechnologies.com/
resources-white-paper/. Accessed 10 Oct 2017 (2013)
14. Large-scale, full CMYK photo-realistic 3D printing. In: 3D
Syst. https://www.3dsystems.com/3d-printers/projet-cjp-860pro.
Accessed 10 Oct 2017
15. Design With Brilliance-Game-changing versatility and realism
with the world’s most advanced full-color multi-material 3D
printer. STRATASYS (2017)
16. HP Jet Fusion 3D Printing Solution. Reinventing prototyping
and manufacturing. In: HP Dev. Co. http://www8.hp.com/us/en/
pdf/printers/3d-printers/4AA6-4892ENA-P.pdf. Accessed 10 Oct
2017 (2016)
17. Ming, L.W., Gibson, I.: Colour rapid prototyping based on SLS
process. In: Elevation Solid Free Fabrication Symposium, pp. 227–
234 (2000)
993
18. Hayes, D.J., Cox, W.R., Wallace, D.B.: Printing system for MEMS
packaging. In: Reliability Testing, Charact MEMS/MOEMS, Oct
22 2001–Oct 24 4558, pp. 206–214 (2001)
19. Ibrahim, M., Otsubo, T., Narahara, H., Koresawa, H., Suzuki, H.:
Inkjet printing resolution study for multi-material rapid prototyp-
ing. JSME Int J. Ser. C 49, 353–360 (2006)
20. Wallace, D., Cooley, P., Antohe, B.: Ink-jet technology for man-
ufacturing and instrument applications. In: 20th Work. Microma-
chining, Micromechanics Microsystems. Toulouse, France, pp. 1–5
(2009)
21. Kumke, M., Watschke, H., Hartogh, P., Bavendiek, A.K., Vietor, T.:
Methods and tools for identifying and leveraging additive manufac-
turing design potentials. Int J Interact Des Manuf (2017). https://
doi.org/10.1007/s12008-017-0399-7
22. Francia, D., Caligiana, G., Liverani, A., Frizziero, L., Donnici,
G.: PrinterCAD: a QFD and TRIZ integrated design solution for
large size open moulding manufacturing. Int J Interact Des Manuf
(2017). https://doi.org/10.1007/s12008-017-0375-2
23. Montalvo Navarrete, J.I., Hidalgo-Salazar, M.A., Escobar Nunez,
E., Rojas Arciniegas, A.J.: Thermal and mechanical behavior of
biocomposites using additive manufacturing. Int J Interact Des
Manuf (2017). https://doi.org/10.1007/s12008-017-0411-2
24. XYZprinting I.: XYZprinting da Vinci Color—Color texture Inkjet
printing3D structure Fused filament fabrication (FFF). In: web-
site. https://www.xyzprinting.com/en-US/product/da-vinci-color.
Accessed 6 Sep 2017 (2017)
25. Regina, F.: Metodi avanzati di controllo hardware e software di
motori per stampanti 3D. rel.L.M. Galantucci; co-rel.F. Lavecchia.
Politecnico di Bari (2015)
26. Pulse Step Dir. http://support.motioneng.com/Technology/
SynqNet/pulse_logic.htm. Accessed 9 Oct 2017
27. SM.: Getting Started with Arduino and Genuino MEGA2560. In:
Arduino. https://www.arduino.cc/en/Guide/ArduinoMega2560.
Accessed 10 Oct 2017(2017)
28. A4988: DMOS Microstepping Driver with Translator and Over-
current Protection. In: Allegro Microsystems LLC. http://www.
allegromicro.com/en/Products/Motor-Driver-And-Interface-ICs/
Bipolar-Stepper-Motor-Drivers/A4988.aspx (2017)
29. RAMPS 1.4 - RepRap Arduino Mega Pololu Shield. In: Pololu
Electron. http://reprap.org/wiki/RAMPS_1.4. Accessed 10 Oct
2017 (2017)
30. Open Source 3D Printer Firmware. http://marlinfw.org/. Accessed
10 Oct 2017
31. Printer Specifications for HP DeskJet 1010 Printers. In:
HP Dev. Company, L.P. https://support.hp.com/us-en/document/
c03742903. Accessed 10 Oct 2017 (2017)
32. Gonzalez DJ.: Quadrature encoders in Arduino. http://yameb.
blogspot.it/2012/11/quadrature-encoders-in-arduino-done.html.
Accessed 9 Oct 2017
123