A

Project Report

on

“CARTESIAN FDM 3-D PRINTER”

Submitted in partial fulfilment for the award of the degree of

Bachelor of Technology

in

Mechanical Engineering

Submitted By:-
Aryan (20001013030)
Avinash (20001013032)
Aviral (20001013033)
Ayush Goyal (20001013034)
Ayush (20001013035)

Project Supervisor:
Dr. Krishan Verma (Assistant Professor)
Department of Mechanical Engineering

J.C. BOSE UNIVERSITY OF SCIENCE & TECHNOLOGY

YMCA, FARIDABAD
August 2022

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 DECLARATION

I hereby declare that the work, being presented in the project report entitled as
“CARTESIAN FDM 3-D PRINTER” in partial fulfilment of the requirement for the
award of the Degree in Bachelor of Technology in Mechanical Engineering and
submitted to the Department of Mechanical Engineering of J.C. Bose University of
Science and Technology, YMCA, Faridabad is an authentic record of my own work
carried out during a period from June 2022 to August 2022 under the supervision of Dr.
Krishan Verma (Assistant Professor), Department of Mechanical Engineering. No part of
the matter embodied in the project has been submitted to any other University / Institute
for the award of any Degree or Diploma.

Signature of Student(s)
Aryan (20001013030)

Avinash (20001013032)

Aviral (20001013033)

Ayush Goyal (20001013034)

Ayush (20001013035)

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 CERTIFICATE

This is to certify that the project entitled, “Cartesian 3D Printer” submitted in partial
fulfillment of the requirements for the degree in Bachelors of Technology in
Mechanical Engineering is an authentic work carried out under my supervision and
guidance.

Dr. Krishan Verma

Assistant Professor
Department of Mechanical Engineering
J.C. Bose University of Science and Technology, Faridabad

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 ACKNOWLEDGEMENT

We take this opportunity to express our deep sense of gratitude and respect towards our
supervisor Dr. Krishan Verma, Assistant Professor, Department of Mechanical
Engineering, J.C. Bose University of Science & Technology, YMCA, Faridabad.
We are very much indebted to him for the generosity, expertise and guidance. Without
his support and timely guidance, the completion of this report would have seemed a
farfetched dream. In this respect we find ourselves lucky to have him as our supervisor.
He has supervised us not only with the subject matter, but also taught us the proper style
and technique of working and presentation. It is a great pleasure for us to express our
gratitude towards those who are involved in the completion of my project report.
We would also like to thank Department of Mechanical Engineering, J.C. Bose University
of Science & Technology, YMCA, Faridabad for providing us various facilities. We are
also grateful to all the faculty members & evaluation committee members for their
constant guidance during this project work.
We express our sincere thanks to all our friends, our well-wishers and classmates for their
support and help during the project.

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 ABSTRACT
3D printing also known as Additive manufacturing technology has been dubbed the
next big thing and be as equally wide spread as cellular telephone industry. 3D printers
print objects from a digital template to a physical 3-dimensional physical object. The
printing is done layer by layer (Additive manufacturing) using plastic, metal, nylon, and
over a hundred other materials. 3D printing has been found to be useful in sectors such
as manufacturing, industrial design, jewellery, footwear, architecture, engineering and
construction, automotive, aerospace, dental and medical industries, education,
geographic information systems, civil engineering, and many others. It has been found
to be a fast and cost-effective solution in whichever field of use. The applications of 3D
printing are ever increasing and its proving to be a very exciting technology to look out
for. In this paper we seek to explore how it works and the current and future
applications of 3D printing.

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 TABLE OF CONTENTS

INTRODUCTION .................................................................................................. 1
3D Priniting ......................................................................................................... 1
Applications ......................................................................................................... 1
LITERATURE REVIEW....................................................................................... 3
Design and Development .................................................................................... 3
Utility and challenges .......................................................................................... 4
OBJECTIVES …..................................................................................................... 5
METHODOLOGY ………..................................................................................... 6
Selection of Process …….................................................................................... 6
Software …………….......................................................................................... 6
Software used for printing……........................................................................... 7
MAJOR COMPONENTS ...................................................................................... 8
WORKING ……….................................................................................................. 12
Principle ……...................................................................................................... 12
Processes ……..................................................................................................... 12
CONCEPTUAL DESIGN........................................................................................ 13
CONCLUSION & FUTURE SCOPE .................................................................... 14
REFERENCES ….................................................................................................... 15

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LIST OF ABBREVIATIONS

CAD Computer Aided Design

FDM Fused Deposition Modeling

3D 3 Dimensional

STL Standard Triangle Language

SLA Stereolithography

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 Chapter 1
INTRODUCTION

3D printing or additive manufacturing is a process of making a three-dimensional solid

object of virtually any shape from a digital model. Successive layers of material are laid
down in different shapes. Traditional machining techniques rely on the removal of
material by methods such as cutting or drilling whereas 3D printing layers are added
successively. Thus, it uses a layering technique where an object is constructed layer by
layer until the complete object is manufactured. In this way 3D printing moves us away
from the mass production line to a one-off customizable production. You can literally
make any object from a house to a bar of chocolate, so to say. The initial 3D printers were
used in the 1980s where a pattern submerged in a liquid polymer would be traced by a
computer. The traced pattern hardened into a layer, thanks to the laser, and that was how
you built an object out of plastic. Since then, tremendous progress has been made in
additive manufacturing such that material extrusion is now used. By this method, an
object is built out of matter that is pushed from a mechanical head like the way an inkjet
printer extrudes ink onto paper. Interestingly, the cost of acquiring 3D printers has been
decreasing with the advancement of technology. Domestic usage of 3D printers has been
on the rise with the average cost ranging from a few hundreds of dollars going up.
However, one major drawback is that it requires expertise to print 3D objects. In fact, it
requires a competent person to make both the digital file and the final printing.
Commercial usage of 3D printers has been on the increase too in sectors such as the
automotive industry and aerospace engineering. Spare parts, for example, are being made
in the automotive and aero-space industry leading to improved economies of scale. 3D
printing is changing how the production line in industries works which made some
analysts to dub the emergence of 3D printers as the second Industrial revolution. 3D
printing has also had a tremendous usage in the field of medicine; from the field of
Bionics, to Prosthetics to Digital Dentistry. Inevitably, this is positively affecting and
changing every aspect of medicine. Most of the work is still in its exploratory phase but
pundits predict medicine of tomorrow is going to be revolutionized by the integration of
3D printing as a tool.

APPLICATIONS OF 3D PRINTING

3D printing technology has been applied in various and varied sectors. Figure 3 shows the
various kinds of usages of 3D printing which include research, artistic items, visual aids,
presentation models, device covers, custom parts, functional models, and patterns as well
as series production.

• Healthcare. 3D printers do not have a great bedside manner they look more like
futuristic bread boxes than nurses.

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• Aeronautics and Space Travel. Usually, mass-producing a complex machine
means manufacturing a million different parts. 3D-printing changes that, though.

• Food. Most 3D printers wont print just anything the inner workings were designed
to print a particular material, like plastic or metal.

• Fashion. Though 3D printers are versatile, they are not omnipotent. Though they
excel at printing plastic-like materials, printing anything that drapes or feel good to touch
remains prohibitively expensive.

• Construction. A hundred years from now, the phrase printing a house might have
replaced building a house in common parlance.

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 Chapter 2
LITERATURE REVIEW

Mechanical properties of FDM and SLA low-cost 3Dprints

[1] Ksawery Szykiedansa et al 2015, A recent development of the 3-D printers, has
made them readily available to the public at low costs. In order to make 3-D printed
parts to be more useful for engineering applications the mechanical properties of printed
parts must be known. This paper quantifies the basic tensile strength and elastic
modulus of printed components produced with application of FDM and SLA printers.

Importance and Utilization of 3D Printing in Various Applications

[2] CH. Venu Madhav et al, 3D printing is one of the most important technological
advancements in Additive manufacturing which has been Implemented and recognized
as a part of modern industry. Development of various components ranging from simple
structures used in everyday life to complicated Components in aerospace applications,
3D printing Provides many advantages few are Simplicity, Reliability and Precision etc
this makes it one of the most widely used for making components which can be used as
concept. Components.3D printing is the most widely used additive manufacturing
processes in the current industry not only limited to Engineering.

Design and Development of FDM Based Portable 3D Printer

[3] Ashish Patil et al, Additive manufacturing process or 3D printing process is now
becoming more popular because of its advantages over conventional processes. A 3d
printer is a machine that create objects out of plastic, nylon like many other materials.3D
printers now days available are not so portable and also, they are very costly. By analysing
this problem, we are trying to make a portable 3D printer which we can take anywhere
easily because of its briefcase like design. The cost of this printer will be very less
compared to other 3D printers. In these 14 printers we are also providing more interfacing
options like we can control it through computer or we can send G-codes directly from SD
card.

HIGHLIGHTS:
FDM, G-Code, STL File. 3D printers use a variety of very different types of additive
manufacturing technologies, but they all share one core thing in common: they create a
three-dimensional object by building it layer by successive layer, until the entire object
is complete. It’s much like printing in two dimensions on a sheet of paper, but with an
added third dimension. In the 3D world, a 3D printer also needs to have instructions for
what to print. It needs a file as well. The file, a Computer Aided Design (CAD) file is
created with the use of a 3D modelling program, either from scratch or beginning with a
3D model created by a 3D scanner. Either way, the program creates a file that is sent to
the 3D printer. Along the way, software slices the design into hundreds, or more likely
thousands, of horizontal layers. These layers will be printed one atop the other until the
3D object is done.
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Utility and challenges of 3D Printing
[4] Aman Sharma et al0, this paper is all about the advanced technology of 3D printing,
their implementation in the respective fields and its significant contribution in the global
world of science and medical. In this paper we will deal with the term Additive
Manufacturing or 3D Printing and a little bit of its history. Its various applications along
with the type of materials used in the 3-D are also described. We shall also throw some
light on the numerous opportunities provided by this emerging technology as well as the
risks and challenges related to it. Its environmental aspects are also shown in the paper.
Lastly the scope and scenario in future potential of 3D printing is also evaluated 15

HIGHLIGHTS:
3D Printing; Additive Printing; Fused Deposition Modeling (FDM); Stereo-lithography;
ABS Plastics. The different types of materials used are FDM Thermoplastics, Polyjet
Photopolymer, WDW materials etc. Recently chocolate has also been used as a material
in 3D printer. Other materials such as carbon compounds and combination of different
element are also being tested. Nowadays 3D printers are also used in the field of
medical science to repair tissue cells and to replicate the body organs. Ears, kidney and
heart vessels have already been made and in near future it may be possible to print a real
3D printed heart working on its own. 3D printers were earlier used by the engineers to
make only the prototypes but with the betterment of the technology, these are now used
to print finished products. Around 28% of the output of 3D printers is now the final
product which is expected to rise to 50% by 2016 and to 80% by the year 2020. 2.5
Metallic 3D Printer- New Era In Printing [5] Orugonda Ravali et al, This paper aimed at
Design and Development of metallic 3D printer. 3D printing machine is designed and
developed with different parts like extruders, nozzle, stepped motors, Teflon tube etc
which are assembled, tested and also printed some objects. The development involves
the preparation of the filament that could print the metallic objects. Trials were made on
different filaments and conclusions are drawn. Betterments are made to improve the
performance of the filament in all the aspects required.

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 Chapter 3

OBJECTIVES OF

PROJECT

The objectives of our present work are as follows:

▪ Additive manufacturing process or 3D printing process is now becoming more

popular because of its advantages over conventional processes. A 3D printer is a
machine that create objects out of plastic, nylon like many other materials.3D
printers now days available are not so portable and also, they are very costly. By
analyzing this problem, we are trying to make a portable 3D printer The cost of
this printer will be very less compared to other 3D printers.
▪ Making low-cost 3D printer with price 15% lower than market
▪ To print complex and intricate parts
▪ To build large printing volumes accurately
▪ To solve the problems of bed leveling

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 Chapter 4
METHODOLOGY

SELECTION OF PROCESS

The rundown of 3D printing innovations and procedures keeps on developing as 3D

printing is continually evolving. The 3D printing industry continues upgrading its
hardware and the materials and strategies to make protest or parts. Contingent upon
numerous factors, for example, spending plan, outline or capacity, picking the fitting 3D
printing process and also the correct material is imperative.

The FDM technology is clean, simple to use and it is environmentally stable. Complex
shapes and intricate parts can be printed. FDM is at the very entry of the market as it
mainly used by individuals.

FDM is an affordable 3D printing process compared to other 3D printing technologies.

FDM starts with a product procedure which forms an STL file (stereolithography file
format), scientifically cutting and situating the model for the building procedure. In the
event that required, support structures might be created. The machine may apportion
numerous materials to accomplish diverse objectives.

SOFTWARE

CAD-

Tools Computer Aided Design are used to design 3D parts for printing. Computer aided
design (CAD) is where we use the computer system to assist in the creation modification
analysis or optimization of a design. Computer aided design software is utilized to expand
the efficiency of the creator, enhance the nature of configuration, enhance interchanges
through documentation, and to make a database for manufacturing.Computer-aided
design files in the most genuine sense are intended to enable you to effectively change
and control parts in view of parameters. Now and then CAD files are alluded to as
parametric records. The parts which are being represented as a tree of Boolean operations
which are performed on primitive shapes such as cubes, spheres, cylinders, pyramids.

CAM-

Tools Computer Aided Manufacturing, or CAM, tools handle the intermediate step of
translating CAD files into a machine-friendly font used for our 3D printer electronics.
Here we will be using a software which will be an integration of object slicing, Generation
of G codes and M codes, Object Placement and other printer settings. Usually to turn a

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3D part into a machine format, CAM software needs a STL file. The machine friendly
format that is used for printing is called G-code.

FIRMWARE-

3D Printer electronics are controlled by an inexpensive CPU such as the Atmel AVR
processor. Atmel processors are what Arduino-based microcontrollers use. These
processors are exceptionally weak contrasted with even the normal laptop you find in the
landfill these days. However, so they do run primitive software. This primitive software
they run is the firmware. The entire software chain that makes the 3D Printer work, the
firmware portion of it is the closest you get to actual programming. In fact, the term for
what you are doing with firmware is called cross compiling.

SOFTWARES USED FOR PRINTING THE 3D MODELS

CURA-

The world’s most advanced 3D printer software. Cura is the Eco-friendly to face the
slicing software so that many users don’t know how to realize what it’s doing. Just load
the cad model into the software, select the quality should be printed by pressing the print
option in the software. It’s as easy as traditional 2D printing. Essentially that’s all Cura
is print software can get a digital file from any computer to the 3D printer in any format.
so that the 3D printing can understand itself for printing. Cura can be available free for
you to download, but it is also open source. It is the standard software of 3D slicers
worldwide. If you compare Cura to other 3D slicing software, it seems very simple in
cura there are many features available for slicing when compare to other software with
limited options and adjustments. But Cura’s has more complex settings are there if you
need them; it’s just been designed very neatly and user-friendly. Cura is developed by 3D
printer manufacturer Ultimaker and, as everyone is known from their hardware, they’re
perfectionists.

PRONTERFACE-

Pronterface is a GUI host for 3D printing: It can manage your printer as well as prepare,
slice, and print your STL files. As such, you can use its graphic environment to easily
configure and control your 3D printer through a USB cable. Running on Python source
code, Pronterface has become very popular since it’s release thanks to the quick setup
and easy-to-use interface. Despite looking simplistic, with the bare minimum in graphics
and UI, it’s still very useful.

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 Chapter 5
MAJOR COMPONENTS

BODY FRAME / CHASSIS

The most basic structure of any machine is its frame structure or chassis. This is the frame
body for FDM 3-D printer. It is square shape steel tubes, having high area moment of
inertia, resisting in bending and is capable to bear the weight of others parts.

FILAMENT

Filament is the most important component. It holds the solid material, which is to be
transmitted to the heat sink, with the help of stepper motor.

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LEAD SCREW

The LEAD screw is 8mm thread with 3mm pitch. This is used for easy movement of the
gantry block, 2 lead screw are used of same pitch, for movement in X and Y axis.

STEPPER MOTOR

Stepper motors move in precisely repeatable steps, hence they are the best choice. The
motors position can be commanded to move or hold at one position with the help to Servo
Motor Drivers.

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BRUSHLESS DC FAN

LEVELLING BED ADJUSTER HANDLE

FOOT ADJUSTER WITH RUBBER PADS AND BOLLTS OF M8

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 Chapter 6

MODELING

SOLIDWORKS

E-DRAWINGS 2020 X-64 EDITION

CAD IMAGE OF 3-D PRINTER MODEL

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 Chapter 7
WORKING
Principle

FDM 3D printing is a technology that works both horizontally and vertically, where an
extrusion nozzle moves over a build platform. The process involves the use of
thermoplastic material that reaches melting point and is then forced out, to create a 3D
object layer by layer. As the design takes shape, it is clear to the see each layer as a
horizontal cross section. Following the completion of one layer, the nozzle of the printer
is lowered in order for the next layer of plastic to be added to the design When the FDM
printer begins printing, the raw material is extruded as a thin filament through the heated
nozzle. It is deposited at the bottom of the printer platform, where it solidifies. The next
layer that is extruded fuses with the layer below, building the object from the bottom-up
layer by layer. Most FDM printers first print the outer edges, the interior edges next and
lastly the interior of the layer as either a solid layer or as a fill in matrix. In some objects
/ models, there are fragile ‘overhangs’ that will droop unless they are given some support.
FDM printers incorporate a mechanism whereby these support structures (called struts)
are printed along with the object. They are later removed once the build is complete.
These struts are usually of the same material as the object. Some printers have a second
extruder to specifically deposit soluble thermoplastic struts when there is a need to
prevent the overhangs from drooping. These struts may be of a different composition than
the thermoplastic used for the 3D model.

Processes

Many different 3D printing processes and technologies have been invented from late
1970. The printers were originally very large and expensive in what they could produce.
A large number of Additive manufacturing processes are now available. Some of the
methods melt or soften material to produce the layers, e.g., selective laser melting
(SLM), selective laser sintering (SLS), fused deposition modelling (FDM), while others
cure liquid materials using different other technologies, e.g., stereolithography (SLA)
and with laminated object manufacturing (LOM).

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 Chapter 8
CONCEPTUAL DESIGN

The design of the model has to be done in software where the actual model with the
required dimensions is developed so that it can be used to print the model. To develop
and fabricate the model there are many processes and parameters involved mainly
design of the model. The design process started by keeping the print volume as a basic
design parameter. As the objective of the project is the construction of economical and
sizable 3D Printer, a print volume of 200 x 180 x 180 mm3 is selected. The 3 –
Dimensional motion is achieved by synchronization of movements in X, Y. The lead
screws are driven by the motor which in turn moves the bed in the vertical direction.
Two motors have been used here because the print volume is large, there will be a
disruption in the movement if only a single motor is used. The conceptual design has
been initially visualized in Sketch-up software.

X – AXIS MOVEMENT

Figure shows the rendered CAD model of the mechanism of Lateral movement. It
consists of the pulleys, timing belt, carriage, cylindrical rods, and extruder nozzle (used
in FDM process) arranged as shown. The rotary motion from the motor in the y-axis is
converted into linear sliding motion and this linear motion is transfer by flange bearing
by timing belt- pulley connection as shown. The extruder nozzle is the main printing
part of the machine. For its movement in a horizontal direction, the carriage is provided.
The extruder nozzle is mounted onto to the carriage on one side, this may result in
imbalance 46 and failure of the machine. To avoid this, the carriage is mounted on two
rods and designed for balance.

Y – AXIS MOVEMENT

The rotary motion of the motor is transfer by rotating the leadscrews connected to the
bed by using flange nut and shaft coupler as shown. The torque produced by the motor
is transmitted to the lead screws by using shaft coupler and flange nut. When the motor
rotates, say in a clockwise direction, shaft coupler rotates lead screws in the same
direction, say in a clockwise direction. The bed is connected to the lead screws using
threaded couplers, this makes the bed move in a vertical direction when the lead screw
rotates.

To design this mechanism for Y – axis movement, first the carriages are designed. The
carriages are designed to mount the motor, pulley and to hold X – axis rods.

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 Chapter 9

CONCLUSION & FUTURE SCOPE

Introduction part is about the brief of 3D printing, in the next section we have depicted
the 3D-printing and the processes used in 3D-printing and the properties of the 3Dprinter
materials. In the third section, we have highlighted the main advantages and limitations
of the 3D printing technology. One can conclude that the 3-D printing technology's
importance and social impact increase gradually day by day and influence the human's
life, the economy, and modern society. 3D Printing technology could revolutionize the
world. Advances in 3D printing technology can significantly change and improve the way
we manufacture products and produce goods worldwide. The drawback in few of the 3D
Printer which uses bed movement in Y axis has distortion of the printed layer at high rates
of printing.

The control synchronization can be achieved using this new 3D printer technique it was
concluded that among various printing techniques available for additive manufacturing
like fused deposition modelling, selective laser sintering, stereo lithography etc., fused
deposition modelling is the most feasible and can be easily implemented without much
complexity. FDM method is economical method to build a low-cost 3D printer.

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 REFERENCES
Wikipedia
[1] Ksawery Szykiedansa,*, Wojciech Credoa “Mechanical properties of FDM
and SLA low-cost 3Dprints” The 20th International Conference: Machine
Modeling and Simulations, MMS 2015.
[2] CH. Venu Madhav 1, R. Sri Nidhi Hrushi Kesav 2, Y. Shivraj Narayan3VNR
Vignana ,Jyothi Institute of Engineering and Technology “Importance and
Utilization of 3D Printing in Various Applications” International Journal Of
Modern Engineering Research (IJMER) , ISSN: 2249-6645
[3] Ashish Patil1 , Bhushan Patil2 , Rahul Potwade3 , Akshay Shinde4 , Prof.
Rakesh Shinde5 ,Saraswati College of Engineering, India “Design and
Development of FDM Based Portable 3D Printer” International Journal of
Scientific & Engineering Research, Volume 8, Issue 3, March-2017 ISSN 2229-
5518
[4] Aman Sharma1 , Harish Garg2 “Utility and challenges of 3 D Printing” IOSR
Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684,
p-ISSN: 2320–334X
[5] Shanling Han,1 Yu Xiao,1 Tao Qi,1 Zhiyong Li,1 and Qingliang Zeng2
“Design and Analysis of Fused Deposition Modeling 3D Printer Nozzle for Color
Mixing” Hindawi Advances in Materials Science and Engineering Volume 2017,
Article ID 2095137

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