MODERN RAPID 3D PRINTER - A DESIGN REVIEW

http://www.iaeme.com/IJMET/index.asp 29 editor@iaeme.com
International Journal of Mechanical Engineering and Technology (IJMET)
Volume 7, Issue 3, May–June 2016, pp.29–37, Article ID: IJMET_07_03_003
Available online at
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ISSN Print: 0976-6340 and ISSN Online: 0976-6359
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MODERN RAPID 3D PRINTER - A DESIGN
REVIEW
T. Prabhu
Assistant Professor, Department of Mechanical Engineering,
Rathinam Technical Campus, Echanari,
Coimbatore–641021
ABSTRACT
3D printing is called as additive manufacturing technology where a three
dimensional object is created by laying down successive layers of material. It
is also known as rapid prototyping, is a mechanized method whereby 3D
objects are quickly made on a reasonably sized machine connected to a
computer containing blueprints for the object. It is working under the
principle of Fused Deposition Modelling (FDM). The 3D printing concept of
custom manufacturing is exciting to nearly everyone. The basic principles
include materials cartridges, flexibility of output, and translation of code into
a visible pattern.3D Printers are the machines that produce physical 3D
models from digital data by printing layer by layer. It can make physical
models of objects either designed with a CAD program or scanned with a 3D
Scanner. Here we are going to propose a model report on design and
fabrication of a 3D printer.
Key words: 3D Printer, Additive Manufacturing, FDM, 3D Scanner.
Cite this Article: T. Prabhu. Modern Rapid 3D Printer - A Design Review.
International Journal of Mechanical Engineering and Technology, 7(3), 2016,
pp. 29–37.
http://www.iaeme.com/currentissue.asp?JType=IJMET&VType=7&IType=3
INTRODUCTION
3D printing or additive manufacturing is a process of making three dimensional solid
objects from a digital file. The creation of a 3D printed object is achieved using
additive processes. In an additive process an object is created by laying down
successive layers of material until the entire object is created. Each of these layers can
be seen as a thinly sliced horizontal cross-section of the eventual object.
It all starts with making a virtual design of the object you want to create. This
virtual design is made in a CAD (Computer Aided Design) file using a 3D
modelling program (for the creation of a totally new object) or with the use of a 3D

T. Prabhu
scanner (to copy an existing object). A 3D scanner makes a 3D digital copy of an
object.
To prepare a digital file for printing, the 3D modeling software “slices” the final
model into hundreds or thousands of horizontal layers. When the sliced file is
uploaded in a 3D printer, the object can be created layer by layer. The 3D printer
reads every slice (or 2D image) and creates the object, blending each layer with
hardly any visible sign of the layers, with as a result the three dimensional object.
OBJECTIVE
1. To implement additive manufacturing
2. To increase the rapid prototyping technology
3. To design and manufacture simple 3D printer
4. To provide low cost 3D printer to the society
5. To make 3D printer as a domestic product
6. To reduce the casting process and time in industries.
ADDITIVE MANUFACTURING
Additive manufacturing is the official industry standard term (ASTM F2792) for all
applications of the technology. It is defined as the process of joining materials to
make objects from 3D model data, usually layer upon layer, as opposed to subtractive
manufacturing methodologies. Synonyms are additive fabrication, additive processes,
additive techniques, additive layer manufacturing, layer manufacturing, and freeform
fabrication.
Figure 1 Additive Manufacturing
The primary applications of additive fabrication are design/modeling, fit and
function prototyping, and direct part production.

Modern Rapid 3D Printer - A Design review
Table 1 Different between Subtractive and Additive manufacturing:
SUBTRACTIVE MANUFACTURING ADDITIVE MANUFACTURING
It is also called as machining process It is also called as 3D printing.
Take a block of material and carve it out Take a block of material and melt it out
Generate 3D model Generate 3D model
Generate CNC program Software slices the 3D model into thin slices
Machine away unwanted material Machine builds it layer by layer
If possible, recycle waste No waste produce
Uncovering a form Creating a form
Less efficient More Efficient
Take more time Take less time
Replacement for manual machining process Replacement for casting process
Example: CNC Machines Example: 3D printers
Fig. Shows about this Fig. Shows about this
Types of Additive Manufacturing
 Extrusion
 Light polymerised
 Powder bed
 Laminated
 Wire
Extrusion:
There are two types of principles used in extrusion type additive
manufacturing. They are
 Fused Deposition Modelling (FDM)
 Robo casting or Direct Ink Writing (DIW)
Fused Deposition Modelling
Fused deposition modelling (FDM) was developed by S. Scott Crump in the
late 1980’s and was commercialized in 1990 by Stratasys. In fused deposition
modelling the model or part is produced by extruding small beads of material which
harden immediately to form layers.

T. Prabhu
Figure 1 Fused deposition Modelling
SPECIFICTION
 Plastic Parts – 26
 Shafts- 14Nos - AISI 430 grade rod
 Shaft type- Threaded and smooth
 Frame- 12mm - plywood
 Printing Size- 200mm x 200mm x 270mm
 Motor- 5 x Nema 17 - stepper motor
 Frame manufacturing- Basic wood tools
 Bill of Materials- 193 Nuts, Screws and Washers
 Bearings- 10 linear and 4 Ball bearing

Rapid Prototype Parts
Part Name Quantity Design
Z-Axis Top 1
Z-Axis Bottom 1
Y- Axis Motor mount 1
Y-Axis Idler 1
Y- Axis Corner 4
Y- Axis Belt holder 1
X- Axis End Motor
Holder
1
X- Axis End Idler 1
X- Axis Carriage 1
Belt Guide 1

T. Prabhu
Stepper Motor
 Nema 17 – 200 steps per revolution, 1.8 degrees
 Coil #1: Red & Yellow wire pair.
 Coil #2 Green & Brown/Gray wire pair.
 Bipolar stepper requires 2 full H-bridges!
 4-wire, 12 inch leads
 42mm/1.65"square body
 31mm/1.22" square mounting holes, 3mm metric screws (M3)
 5mm diameter drive shaft, 24mm long, with a machined flat
 12V rated voltage (you can drive it at a lower voltage, but the torque will drop) at
350mA max current
 28 oz*in, 20 N*cm, 2 Kg*cm holding torque per phase
 35 ohms per winding
Machine Assembly
Individual components and parts of this model are designed and each of them
is assembled according to the axis.
X Axis Assembly
Y-Axis Assembly

Z- Axis assembly
Final Design 3D view
All components and axis are assembled together. Finally the model is designed
with required dimension.
Left Side View Right Side View
Front View Back View
WORKING
Fused deposition modeling (FDM) is an additive manufacturing technology
commonly used for modeling, prototyping, and production applications. It is one of
the techniques used for 3D printing.
FDM works on an "additive" principle by laying down material in layers; a plastic
filament or metal wire is unwound from a coil and supplies material to produce a part.
PROCESS
FDM begins with a software process which processes an STL file (stereo
lithography file format), mathematically slicing and orienting the model for the build
process. If required, support structures may be generated. The machine may dispense
multiple materials to achieve different goals: For example, one may use one material
to build up the model and use another as a soluble support structure, or one could use
multiple colors of the same type of thermoplastic on the same model.
The model or part is produced by extruding small flattened strings of molten
material to form layers as the material hardens immediately after extrusion from the
nozzle

T. Prabhu
A plastic filament or metal wire is unwound from a coil and supplies material to
an extrusion nozzle which can turn the flow on and off. There is typically a worm-
drive that pushes the filament into the nozzle at a controlled rate.
The nozzle is heated to melt the material. The thermoplastics are heated past
their glass transition temperature and are then deposited by an extrusion head.
The nozzle can be moved in both horizontal and vertical directions by a
numerically controlled mechanism. The nozzle follows a tool-path controlled by
a computer-aided manufacturing (CAM) software package, and the part is built from
the bottom up, one layer at a time. Stepper motors or servo motors are typically
employed to move the extrusion head. The mechanism used is often an X-Y-Z
rectilinear design, although other mechanical designs such as deltabot have been
employed.
Although as a printing technology FDM is very flexible, and it is capable of
dealing with small overhangs by the support from lower layers, FDM generally has
some restrictions on the slope of the overhang, and cannot produce
unsupported stalactites.
Myriad materials are available, such as Acrylonitrile Butadiene Styrene ABS,
Polylactic acid PLA, Polycarbonate PC, Polyamide PA, Polystyrene PS, lignin,
rubber, among many others, with different trade-offs between strength and
temperature properties. Recently a German company demonstrated for the first time
the technical possibility of processing granular PEEK into filament form and 3D
printing parts from the filament material using FDM-technology.
CONCLUSION
It is generally accepted that 3D printing will be a revolutionary force in
manufacturing, whether positive or negative. Despite concerns over counterfeiting,
many companies are already using the technology to repeatably produce intricate
components, for example in automotive and aerospace manufacturing.
As 3D printers become more affordable, they will inevitably be used for local,
small scale manufacturing, largely eliminating supply chains for many types of
product. Consumer units for home use will even become feasible, allowing end users
to simply download a design for the product they require and print it out.
There will be major challenges for the conventional manufacturing industry to
adapt to these changes. The opportunities for technology and engineering are clearly
huge, however, and the creative possibilities in product design and printing material
formulation are nearly endless.
REFERENCE
[1] http://www.instructables.com/id/3D-Printing
[2] http://individual.troweprice.com/staticFiles/Retail/Shared/PDFs/3D_Printing_Inf
ographic_FINAL.pdf
[3] http://www.industryweek.com/emergingtechnologies/history-3-d-printing-
slideshow
[4] http://www.3ders.org/3d-printing-basics.html
[5] http://www.wipo.int/wipo_magazine/en/2013/02/article_0004.html
[6] http://www.imaginarium.co.in/tech-3d.html
[7] http://www.arctron.de/uploads/media/3DPrinting-Info.pdf

[8] http://iysn.org/2011/09/17/pushing-boundaries-3-d-printing/
[9] www.journalistsresource.org/wpcontent/uploads/2013/03/3d-printing.pdf
[10] Chua C.K. et al., “ Rapid Prototyping: principles and applications” Wiley,2003
[11] Jacobs P.F., Stereolithography and other Rapid Prototyping & Manufacturing
Technologies, McGrawHill ,New york,1996
[12] Maha M. Lashin, Design and Execution of A 3D Printer Using A Pla Filament as
A New Application of Arduino. International Journal of Mechanical Engineering
and Technology, 5(7), 2014, pp. 171–183.
[13] Ravi Terkar, Dr. Hari Vasudevan and Dr. Vilas Kalamkar, Remanufacturing For
Profitability and Green Growth Sustainability: A Case Study of Printer Cartridge
Sector in India. International Journal of Production Technology and
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