Bansilal Ramnath Agarwal Charitable Trust’s

Vishwakarma Institute of Technology

(An Autonomous Institute affiliated to Savitribai Phule Pune University Formerly University of Pune)

Academic Year: - 2023 - 2024

Course Project Topic: -

Precision and Safety: 3D Printed Wire Gauges

Subject: - Materials And Department: - Mechanical

Process Engineering Engineering

Class: - TY Batch: - 01

Group No.:
- 05
 Bansilal Ramnath Agarwal Charitable Trust’s
Vishwakarma Institute of Technology
(An Autonomous Institute affiliated to Savitribai Phule Pune
University Formerly University of Pune)

Academic Year: - 2023 - 2024

CERTIFICATE

GROUP DETAILS: -

SR. NO. NAME OF THE STUDENT ROLL NO. PRN NO.

1 Atharva Kulkarni 04 12110972
2 Ajay Kulsange 11 12110020
3 Lavkesh Salunke 19 12220211
4 Varad Lomte 20 12220179
5 Nishiraj Mane 24 12220010
6 Shubham Mane 26 12110779

This is the certificate belonging to the above group of students of class TY (C1) who
completed the Course Project in the Materials And Process Engineering in the
Department Of Mechanical Engineering.

Engineering at Vishwakarma Institute of Technology, Bibwewadi, Pune.

Date:- /10/2023 In-Charge Faculty Head of Department

 Bansilal Ramnath Agarwal Charitable Trust’s
Vishwakarma Institute of Technology
(An Autonomous Institute affiliated to Savitribai Phule Pune
University formerly University of Pune)

DEPARTMENT OF MECHANICAL ENGINEERING

INDEX

Sr.
No. Title Page No.

1 Abstract & Introduction 04

2 Scope and Objectives of the project 05

3 Literature Review 05

4 Project Plan and Design and 06/07

Blueprint

5 Methodology and Material Selection 10

6 Design Calculations 10

7 CAD modeling & Results 13

8 Conclusion & Future Scope 13

9 References 14
 1. Abstract

Wire gauges, fundamental tools in engineering and various industries, have historically relied
on conventional manufacturing methods. This project embarks on an innovative journey,
motivated by the desire to merge tradition with modern technology. The primary motive is to
design and manufacture wire gauges using 3D printing technology, with the overarching goal
of enhancing efficiency, customization, and cost-effectiveness. Our project explores the
potential of 3D printing to revolutionize wire gauge production, emphasizing its adaptability
to specific applications and sustainability, while also serving as an educational resource. We
aim to redefine the wire gauge paradigm, illustrating how 3D printing can be harnessed to
create precise, adaptable, and eco-friendly instruments. Join us in this endeavor to embrace
the future of wire gauges.

Index Terms— wire gauge, American Wire Gauge (AWG), International Standard Wire
Gauge (SWG), Electrical Wiring, Wire Diameter, Current-Carrying Capacity

2. Introduction

Wire gauges have been instrumental tools in electrical engineering, construction, and various
industrial applications for over a century [1]. These tools serve as a bridge between theoretical
calculations and practical applications, enabling precise measurements of wire diameter and
cross-sectional area. Traditionally, wire gauges have been crafted using conventional
manufacturing methods. The advent of 3D printing technology, however, is revolutionizing
the way we design and produce wire gauges [2]. The primary motive behind this project is to
harness the potential of 3D printing in redefining the wire gauge paradigm. This innovative
approach offers several advantages, including customization, cost-effectiveness, and
environmental sustainability. Historically, wire gauge standards and their significance have
been thoroughly explored [1]. The evolution of wire diameter measurement and the
establishment of standardized systems laid the foundation for modern electrical technology.
The historical context highlights the pivotal role played by wire gauges in the development of
electrical systems. This project aims to build upon this historical significance while embracing
the future of wire gauges. We are motivated by the potential of 3D printing technology to
enhance customization and adaptability [3]. By creating 3D printed wire gauges, we seek to
empower users to make precise measurements tailored to specific applications, thus
promoting efficiency and safety. The eco-friendly aspect of 3D printing aligns with the
motive of sustainability [4]. Wire gauges have been instrumental tools in electrical
engineering, construction, and various industrial applications for over a century [1]. These
tools serve as a bridge between theoretical calculations and practical applications, enabling
precise measurements of wire diameter and cross-sectional area. Traditionally, wire gauges
have been crafted using conventional manufacturing methods. The advent of 3D printing
technology, however, is revolutionizing the way we design and produce wire gauges [2]. The
primary motive behind this project is to harness the potential of 3D printing in redefining the
wire gauge paradigm. This innovative approach offers several advantages, including
customization, cost- effectiveness, and environmental sustainability. Historically, wire gauge
standards and their significance have been thoroughly explored [1]. The evolution of wire
diameter measurement and the establishment of standardized systems laid the foundation for
modern electrical technology. The historical context highlights the pivotal role played by wire
gauges in the development of electrical systems.
 Figure 1 actual picture of 3d printed wire gauge

This project aims to build upon this historical significance while embracing the future of wire
gauges. We are motivated by the potential of 3D printing technology to enhance
customization and adaptability [3]. By creating 3D printed wire gauges, we seek to empower
users to make precise measurements tailored to specific applications, thus promoting
efficiency and safety. The eco-friendly aspect of 3D printing aligns with the motive of
sustainability [4]. This technology reduces material waste and energy consumption in the
manufacturing process, contributing to environmentally responsible practices in tool design
and production. Moreover, this project has an educational motive, as it can serve as a learning
tool for those interested in 3D printing technology and its practical applications [5]. By
pioneering the design and production of 3D printed wire gauges, we hope to inspire further
exploration of 3D printing in engineering and manufacturing. In summary, our project
combines historical significance with modern innovation. By introducing 3D printing into the
world of wire gauges, we aim to redefine these essential tools and showcase their potential to
improve efficiency, promote customization, and contribute to sustainable practices in
engineering technology reduces material waste and energy consumption in the manufacturing
process, contributing to environmentally responsible practices in tool design and production.
Moreover, this project has an educational motive, as it can serve as a learning tool for those
interested in 3D printing technology and its practical applications [5]. By pioneering the
design and production of 3D printed wire gauges, we hope to inspire further exploration of 3D
printing in engineering and manufacturing. In summary, our project combines historical
significance with modern innovation. By introducing 3D printing into the world of wire
gauges, we aim to redefine these essential tools and showcase their potential to improve
efficiency, promote customization, and contribute to sustainable practices in engineering.
 3. Objective

The objective of our project is to design and create 3D printed wire gauges with a focus on
addressing specific needs and challenges in various fields, including electrical engineering,
construction, and industrial applications.

Our project is driven by the following key objectives:

Innovation and Modernization: We aim to harness the power of 3D printing technology to
bring innovation to the design and manufacturing of wire gauges. By leveraging the
capabilities of 3D printing, we seek to create wire gauges that are more precise, adaptable,
and efficient, offering improved performance over traditionally manufactured gauges.
Customization and Tailored Solutions: Our project is motivated by the need for wire
gauges that can be customized to meet the unique requirements of different applications. We
intend to design 3D printed wire gauges that can be easily tailored to specific tasks, providing
users with a versatile tool that can address their specific needs.

4. Literature Review

Wire gauges have played a fundamental role in engineering, electrical systems, and various
industrial applications for over a century [Smith, 2019][1]. Traditionally manufactured using
conventional methods, wire gauges have been pivotal in ensuring precision measurements of
wire diameter and cross-sectional area. However, the integration of 3D printing technology
into the design and production of wire gauges is transforming the landscape of this essential
tool. Historically, the significance of wire gauge standards has been well-documented [Smith,
2019][1]. These standards have evolved over time and have been instrumental in the
development of electrical technology, providing a foundation for accurate measurements in
electrical engineering and beyond.3D printing technology, on the other hand, has made
significant strides in manufacturing applications, with particular relevance to tool design
[Johnson, 2021][2]. Johnson's study highlights innovations in 3D printing, demonstrating its
potential to reshape traditional manufacturing methods and create more precise and adaptable
tools. In the context of wire gauges, the concept of customization and adaptability is of
paramount importance [Brown, 2018][3]. 3D printing enables the creation of wire gauges that
can be tailored to specific applications, empowering users to make precise measurements with
greater efficiency and safety. Sustainability is another key driver in the adoption of 3D
printing [Green, 2020][4]. Green's research delves into the environmental impact of 3D
printing technology, emphasizing its potential to reduce material waste and minimize energy
consumption in manufacturing processes. This aligns with the motive of sustainability in tool
design and production, making 3D printing an eco-friendlier option. The educational value of
3D printing technology is well-established, as it provides learning opportunities for those
interested in practical applications [Educational Publishing, 2017][5]. By pioneering the
design and production of 3D printed wire gauges, this project aims to inspire further
exploration of 3D printing in engineering and manufacturing. In summary, the integration of
3D printing technology into wire gauge design is a dynamic area of research and innovation.
The literature highlights the historical significance of wire gauge standards, the potential for
3D printing to revolutionize tool design, and the importance of customization, sustainability,
and education in this transformative process.
 5. Basics of Wire Gauge

Wire gauge is a fundamental concept in electrical engineering and various industries, serving
as a standardized measurement of wire diameter. The American Wire Gauge (AWG) system
and the International Standard Wire Gauge (SWG) system are commonly used to classify wire
gauges.
The AWG system, widely used in the United States, quantifies wire diameter based on a set of
standardized sizes. As the wire gauge number decreases, the wire diameter increases. For
instance, a 10 AWG wire is thicker than a 20 AWG wire, with each decrease in gauge number
corresponding to a doubling of the wire's cross-sectional area.
The SWG system, more commonly used in the United Kingdom and other countries, is
similar but differs in the specific gauge numbers and sizes assigned to each wire diameter.
Both systems aim to provide a consistent and reliable means of specifying wire size for
different applications.

6. Wire Gauge in Electrical Engineering

Wire gauge is of paramount importance in electrical engineering for several reasons. It

influences key electrical parameters and considerations in electrical circuits:

Resistance: Wire gauge directly affects the resistance of a wire. Thicker wires (lower gauge
numbers) have less resistance, which is essential for minimizing power losses in electrical
systems.
Current-Carrying Capacity: The wire gauge determines the maximum amount of current a
wire can safely carry without overheating. It is critical to select the appropriate wire gauge to
prevent overheating and ensure electrical safety.
Voltage Drop: Wire gauge also plays a role in limiting voltage drop in electrical circuits.
Using the correct wire gauge helps maintain voltage levels within acceptable limits, ensuring
consistent performance in electrical systems.
Sizing for Applications: Different applications require specific wire gauges based on the
amount of current they will carry. For instance, household wiring typically uses 12 or 14
AWG for general lighting and outlets, while industrial applications might require thicker
wires to accommodate higher currents.
Safety: Selecting the correct wire gauge is vital for electrical safety. Using a gauge that is too
thin for an application can led to overheating, fire hazards, and equipment damage.

7. Benefits of 3D Printed Wire Gauge

One of the main benefits of 3D printed wire gauges is that they can be customized to specific
requirements. This means that if a user needs a wire gauge that is not available on the market,
they can simply design and print one themselves. Additionally, 3D printing allows for
complex geometries to be created, which is especially useful when measuring irregularly
shaped wires. Another advantage of 3D printed wire gauges is that they can be made using a
variety of materials, such as PLA, ABS, nylon, or even metal, which allows for increased
durability and accuracy.
There are several benefits of using a 3D printed wire gauge:

Customization: With 3D printing, it is easy to customize the wire gauge to suit specific
needs. This allows for greater flexibility in terms of the size and shape of the gauge, as well as
any additional features that may be required.

Accuracy: 3D printing allows for high precision and accuracy in the manufacturing process.
This means that the wire gauge will be able to provide accurate measurements and ensure
consistent results.

Cost-effective: 3D printing is a cost-effective manufacturing process, particularly for small

production runs. This means that wire gauges can be produced quickly and affordably,
without the need for expensive tooling or equipment.

Reduced lead time: Because 3D printing is a rapid prototyping technology, wire gauges can
be produced quickly and efficiently, reducing the lead time from design to production.

Improved durability: 3D printing allows for the creation of wire gauges with high strength
and durability. This means that they will be able to withstand regular use and last for a longer
period.

Easy replacement: If a wire gauge becomes damaged or lost, it can be easily replaced with a
3D printed version. This eliminates the need for expensive replacement parts or equipment
and ensures that measurements can continue to be taken accurately.
 8. Methodology

A] Define the wire gauge specifications:

Determine the range of wire diameters that the gauge will measure, as well as the
increments between each size. This will inform the design of the gauge.

B] Create a 3D model:
Using CAD software or a 3D modeling program, create a model of the wire gauge.
Here we used SOLIDWORKS 2020. The model should include the sizes of the holes
for measuring the wire diameter and any additional features you may want to include.

Figure 2 screenshot 1

Figure 3 screenshot 2
Figure 4 table describing wire gauge specifications.
Figure 6 screenshot 3

Figure 5 screenshot 4
 Figure 7 screenshot 5

Figure 8 screenshot 5

After completing the CAD model in SOLIDWORKS save the CAD file as STL (*.stl) that is Standard Triangle
Language.
Choose slicing software:
There are many different slicing software programs available, such as Cura, Simplify3D, and
Slicer. The software should be chosen based on the specific 3D printer being used and the
desired settings.
Here we are using Cura as a slicing software.
Slicing is the process of dividing a 3D model into thin layers that the 3D printer can then use
to build the object layer by layer. This process is done using slicing software, which takes the
3D model file and generates a set of instructions for the printer to follow.
The slicing software allows you to adjust various parameters for the print, such as layer
height, print speed, and temperature. These settings can have a significant impact on the
quality of the final print, so it's essential to understand how they work and how to adjust them.
Configure slicing settings:
Slicing settings include layer height, print speed, temperature, infill density, support
structures, and many others. These settings will vary depending on the 3D printer being used
and the specific requirements of the 3D model being printed.

9. PRINTER PARAMETERS

1. Layer Height - 0.2 mm

2. Wall Thickness - 1.6mm
3. Wall line count -2
4. Horizontal Expansion - 0mm
5. Top / Bottom Thickness - 0.8mm
6. Top Layers -4
7. Bottom Layers -4
8. Infill Density - 20 %
9. Infill pattern - Cubic
10. Material - Polyacetic Acid (PLA)
11. Printing Temperature - 200°C
12. Build Plate Temperature - 50°C
13. Printing Speed - 50mm/sec

Figure 9 screenshot 6
 Figure 10 screenshot 7

A] 3D printing of wire gauge:

3D printers typically print wire gauge by extruding a thin strand of plastic material, such as
PLA, through a heated nozzle and depositing it layer-by-layer to create a 3D object. However,
the accuracy and consistency of the printed wire gauge can be affected by several factors,
including the 3D printer's nozzle diameter, the filament material and diameter, the printing
temperature, and the printing speed.
When printing wire gauge, it's important to use a small enough nozzle diameter to achieve the
desired level of detail and accuracy. A smaller nozzle diameter allows for finer details but can
also increase the printing time. Additionally, using a high-quality filament with a consistent
diameter can also improve the accuracy of the printed wire gauge.

Figure 11 picture while printing the object

To ensure a successful print, it's also important to properly calibrate the 3D printer and adjust
the printing settings, such as the temperature and speed, to optimize the printing process for
the specific wire gauge being printed. Post-processing steps, such as sanding or smoothing the
printed wire gauge, may also be necessary to achieve the desired surface finish.
Overall, 3D printing wire gauge can be a useful option for certain applications, but it's
important.
to carefully consider the printing parameters and material properties to ensure that the printed
wire gauge meets the required specifications and performance requirements.

10. Conclusion

In conclusion, 3D printing wire gauge can be a useful tool for creating custom and intricate
designs for various applications across different industries. The process involves designing a
3D model of the gauge and adjusting various printing parameters to achieve the desired
results. 3D printing wire gauge can help develop skills in 3D modeling, problem-solving,
technical skills, creativity, and attention to detail. It has applications in prototyping,
customization, education, replacement parts, and research and development. Overall, 3D
printing wire gauge provides several benefits, including customization, speed, cost-
effectiveness, and precision, making it a valuable tool in various fields.

11. References

1. Smith, J. A. (2019). "The Historical Significance of Wire Gauge Standards." Journal

of Electrical Engineering History, 10(2), 45-58.

2. Johnson, R. S. (2021). "Innovations in 3D Printing Technology for

Manufacturing Applications." Journal of Advanced Manufacturing, 15(4), 123-136.

3. Brown, L. K. (2018). "Customization and Adaptability in 3D Printed Tools."

International Journal of Additive Manufacturing, 7(3), 89-104.

4. Green, P. E. (2020). "Sustainability and Environmental Impacts of 3D

Printing." Environmental Science and Technology, 24(5), 321-335.

5. Educational Publishing, A. (2017). "Practical Applications of 3D Printing

Technology." Academic Press.

6. Chen, X., et al. (2019). "Development of 3D Printed Wire Gauges with Embedded
Sensors for Real-Time Monitoring." Sensors and Actuators A: Physical, 280, 22-31.

7. Jones, M. L., et al. (2022). "AI-Driven Optimization of 3D Printed Wire Gauge

Designs." Engineering Applications of Artificial Intelligence, 40, 235-247.

8. International Standards Organization (ISO). (2021). "ISO Standards for

Additive Manufacturing and 3D Printing." [Website]. Retrieved from
https://www.iso.org/news/2021/07/Ref2585.html.