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Design and Development of low cost 3D Printer Prepared by: Apurva V. Tolia Sharanya S. Deshpande Sagar V. Tamaliya

Report on design and development of low cost 3d printer

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Design and Development of low cost 3D Printer

Prepared by:

Apurva V. Tolia

Sharanya S. Deshpande

Sagar V. Tamaliya

Design and Development of low Cost 3-D Printer

A PROJECT REPORT

Submitted

by

Apurva V. Tolia (110970111004)

Sharanya S. Deshpande (120970111028)

Sagar V. Tamaliya (110970111054)

In fulfilment for the award of the degree

Of

Bachelor of Engineering

In

Electronics and Communication Engineering

Faculty of Technology

Marwadi Education Foundations’ Group of Institutions,

Rajkot

Gujarat Technological University

Ahmedabad

May 2016

i

Faculty of Technology

Marwadi Education Foundation’s Group of Institutions

Department of Electronics and Communication Engineering

DECLARATION

We, hereby declare that the project report, for the project entitled “Design and

Development of low cost 3-D Printer” submitted in fulfilment for the degree of

Bachelor of Engineering in Electronics and Communication of Gujarat

Technological University, Ahmedabad, is a bonafide record of the project work

carried out at Marwadi Education Foundation’s Group of Institutions under the

supervision of Prof. Ravi Butani and that no part of any of this report has been

directly copied from any student’s reports or taken from any other sources, without

providing due references.

Date:

Place:

Apurva V. Tolia (110970111004)

Sharanya S. Deshpande (120970111028)

Sagar V. Tamaliya (110970111054)

SIGNATURE

ii

Faculty of Technology

Marwadi Education Foundation’s Group of Institutions

Department of Electronics and Communications

Engineering

2016

CERTIFICATE

Date:

This is to certify that the project entitled “Design and Development of low cost 3-D

Printer” has been carried out by Apurva V. Tolia (110970111004), Sharanya S.

Deshpande (120970111028) and Sagar V. Tamaliya (110970111054) under my

guidance in fulfilment for the degree of Bachelor of Engineering in Electronics

and Communication for 8th Semester of Gujarat Technological University,

Ahmedabad during the academic year 2015-2016. These students have successfully

completed all the required activities under my guidance.

Guide Head of Department

Prof. Ravi Butani Prof. Rajendrakumar Patel

GUJARAT TECHNOLOGICAL UNIVERSITYCERTIFICATE FOR COMPLETION OF ALL ACTIVITIES AT ONLINE PROJECT PORTAL

B.E. SEMESTER VIII, ACADEMIC YEAR 2015-2016

Date of certificate generation : 12 April 2016 (21:26:53)

This is to certify that, Tolia Apurva Vijaykumar ( Enrolment Number -

110970111004 ) working on project entitled with Design And Development Of

Low Cost 3-D Printer. from Electronics & Communication Engineering

department of Marwadi Education Foundation's Group Of Institutions-Faculty

Of Technology, Rajkot had submitted following details at online project portal.

Periodic Progress Reports (PPR) Completed

Business Model Canvas (Image) Completed

Business Model Canvas (Report) Completed

Patent Drafting Exercise (PDE) Completed

Final Plagiarism Report Completed

Final Project Report Completed

Name of Student : Tolia Apurva Vijaykumar Name of Guide : Miss. Jigisha Sureja Sureja

Signature of Student : _____________ *Signature of Guide : ________________

Disclaimer :

This is a computer generated copy and does not indicate that your data has been evaluated. This is the receipt that GTU

has received a copy of the data that you have uploaded and submitted as your project work.

*Guide has to sign the certificate, Only if all above activities has been Completed.

GUJARAT TECHNOLOGICAL UNIVERSITYCERTIFICATE FOR COMPLETION OF ALL ACTIVITIES AT ONLINE PROJECT PORTAL

B.E. SEMESTER VIII, ACADEMIC YEAR 2015-2016

Date of certificate generation : 13 April 2016 (19:48:04)

This is to certify that, Deshpande Sharanya Suresh ( Enrolment Number -

120970111028 ) working on project entitled with Design And Development Of

Low Cost 3-D Printer. from Electronics & Communication Engineering

department of Marwadi Education Foundation's Group Of Institutions-Faculty

Of Technology, Rajkot had submitted following details at online project portal.

Periodic Progress Reports (PPR) Completed

Business Model Canvas (Image) Completed

Business Model Canvas (Report) Completed

Patent Drafting Exercise (PDE) Completed

Final Plagiarism Report Completed

Final Project Report Completed

Name of Student : D e s h p a n d e S h a r a n y aSuresh

Name of Guide : Miss. Jigisha Sureja Sureja

Signature of Student : _____________ *Signature of Guide : ________________

Disclaimer :

This is a computer generated copy and does not indicate that your data has been evaluated. This is the receipt that GTU

has received a copy of the data that you have uploaded and submitted as your project work.

*Guide has to sign the certificate, Only if all above activities has been Completed.

GUJARAT TECHNOLOGICAL UNIVERSITYCERTIFICATE FOR COMPLETION OF ALL ACTIVITIES AT ONLINE PROJECT PORTAL

B.E. SEMESTER VIII, ACADEMIC YEAR 2015-2016

Date of certificate generation : 12 April 2016 (21:28:21)

This is to certify that, Tamaliya Sagar Vashrambhai ( Enrolment Number -

110970111054 ) working on project entitled with Design And Development Of

Low Cost 3-D Printer. from Electronics & Communication Engineering

department of Marwadi Education Foundation's Group Of Institutions-Faculty

Of Technology, Rajkot had submitted following details at online project portal.

Periodic Progress Reports (PPR) Completed

Business Model Canvas (Image) Completed

Business Model Canvas (Report) Completed

Patent Drafting Exercise (PDE) Completed

Final Plagiarism Report Completed

Final Project Report Completed

Name of Student : T a m a l i y a S a g a rVashrambhai

Name of Guide : Miss. Jigisha Sureja Sureja

Signature of Student : _____________ *Signature of Guide : ________________

Disclaimer :

This is a computer generated copy and does not indicate that your data has been evaluated. This is the receipt that GTU

has received a copy of the data that you have uploaded and submitted as your project work.

*Guide has to sign the certificate, Only if all above activities has been Completed.

Acknowledgement

Any accomplishment requires the effort of many folks and this work is not different and it

is our prime duty to acknowledge the person who directly or indirectly helped us during

completion of this report. So we take opportunity to heartily thank our project guide

respected Ass. Prof. Ravi Butani for his valuable guidance and touch of inspiration and

motivation throughout the project work without whose help the work would not have been

in the shape what it has to be.

This project is not just the electronics but an integration of electronics, electrical and

mechanical interaction. We also heartily thank our friends who greatly helped us in our

project work without them we would never have gain the actual problem set solutions that

we faced.

Last but not the least, we heartily thank our respected H.O.D. Prof Rajendra Patel who kept

on pushing our limits and taught us to be positive in every way.

We also show our gratitude to all other relevant staff of various departments for their

cooperation, help and guidance from providing us all the required equipment’s to the full

internet access.

viii

Abstract

Nowadays 3D printing has become a big boom. This technology is not only

used in industries but also used at those places where the prototyping is an

important constraint.

This project aims to develop a 3D printer that not only counts for a cost

effective output but a product that can be used by each and every one. After

this project gets a final touch it will benefit the common people where the

cost effectiveness is very crucial. Many 3D printing technologies are

available to build a 3D object but this project aims to use that 3D

manufacturing process that gives a cost effectiveness solution at a low

wastage of printing material.

3D printers capable of outputting in color and multiple materials already

exist and will continue to improve to a point where functional products will

be able to be output.

Printing rather than “3D printing” has bought a radical change in the world

we live.

Now a days 3D-Printing has gone from developing a factory need object to

a medical need artificial bones and making it a “low cost” is the new area of

development. Gone are those days where the 3D objects were brought from

the market, who would have thought that this 3D printer would do the same

work with a low cost!!!

“Once u have this fascinating 3D printer, do not forget the fact this is a low

cost one!!”

ix

List of Tables

Table No. Table Description Page No

Table 3.1 Changing value of MS1, MS2 and MS3 13

x

List of Figures

Figure No. Figure Description Page No

Fig. 2 (a) Prusa Model 6

Fig. 2 (b) Kossel Model 6

Fig. 2 (c) Block Diagram of the Entire System 6

Fig. 2 (d) STL file from CAD 7

Fig. 3 (a) Frame structure (1) 10

Fig. 3 (b) Frame structure (2) 10

Fig. 3 (c) Extruder 10

Fig. 3 (d) Stepper motor Nema 17 11

Fig. 3 (e) A4988 Driver 12

Fig. 3 (f) Simplified connection of Driver and controller 12

Fig. 3 (g) ABS Plastic 13

Fig. 3 (h) PLA Plastic 13

Fig. 3 (i) SMPS (12 V) 14

Fig. 3 (j) A4988 Driver 15

Fig. 3 (k) A4988 Driver 15

Fig. 3 (l) Arduino Atmega 2560 15

Fig. 3 (m) Ramp 1.4d 16

Fig. 3 (n) Connection of Arduino 2560 and Ramp 1.4D (1) 16

Fig. 3 (o) Connection of Arduino 2560 and Ramp 1.4D (2) 16

Fig. 3 (p) Connection of Arduino 2560 and Ramp 1.4D 17

Fig. 3 (q) Running motors through electronics 17

Fig. 3 (r) Kossel frame work 18

xi

Fig. 4 (a) Stereography method 20

Fig. 4 (b) Fused Deposition Method 21

Fig. 4 (c) Selective Laser Melting 22

Fig. 1 Observation Matrix 101

Fig. 2 Product Development Canvas 101

Fig. 3 AEIOU 102

Fig. 4 Ideation Canvas 102

Fig. 5 Business Model Canvas 104

xii

List of Symbols, Abbreviations and Nomenclature

Symbol Abbreviations

WWW World Wide Web

3D Three Dimentional

xiii

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 1

Tables of Contents

LIST OF TABLES

LIST OF SYMBOLS,ABBREVIATIONS AND NOMENCLATURE

TABLE OF CONTENTS

1 INTRODUCTION ................................................................................................................................................... 3

2 PROJECT AT A GLANCE .................................................................................................................................... 5

2.1 DEFINITION ....................................................................................................................................................... 5

2.2 DESIGN ............................................................................................................................................................. 5

2.3 PROBLEM STATEMENT ...................................................................................................................................... 5

2.4 POSSIBLE SOLUTION .......................................................................................................................................... 5

2.5 SIMPLIFIED BLOCK DIAGRAM ............................................................................................................................ 6

2.6 WORKING WITH FILES ........................................................................................................................................ 7

2.7 HOW 3D PRINTER WORKS .................................................................................................................................. 8

3 COMPONENT DESCRIPTION .......................................................................................................................... 10

3.1 FRAME ............................................................................................................................................................ 10

3.2 EXTRUDER ...................................................................................................................................................... 10

3.3 STEPPER MOTOR ............................................................................................................................................. 11

3.4 DRIVER A4988 ................................................................................................................................................ 12

3.5 PLASTICS ........................................................................................................................................................ 13

3.3.1 ACRYLONITRILE BUTADIENE STYRENE (ABS) PLASTICS ......................................................................... 13

3.3.2 POLYLACTIC ACID OR POLYACTIDE (PLA) PLASTICS .............................................................................. 13

3.6 SOFTWARE THAT NEED TO BE INSTALLED IN THE COMPUTER TO RUN THE MODEL ........................................... 14

3.7 TO DO LIST: BASIC ELECTRONICS CONNECTION ............................................................................................... 14

3.8 FRAMEWORK .................................................................................................................................................. 17

4 PRESENT 3D PRINTING TECHNOLOGIES .................................................................................................. 19

4.1 STEREO LITHOGRAPHY (SLA) .......................................................................................................................... 19

4.2 FUSE DEPOSITION MODELLING (FDM) .............................................................................................................. 20

4.3 SELECTIVE LASER SINTERING (SLS) ................................................................................................................. 21

4.4 SELECTIVE LASER MELTING ............................................................................................................................ 21

5 CONCLUSION ..................................................................................................................................................... 33

APPENDIX 1 – PPR ....................................................................................................................................................... 24

APPENDIX 2 - PSAR ..................................................................................................................................................... 53

viiiAKNOWLEDGEMENT ................................................................................................................................................

......................................................................xiii

LIST OF FIGURES .........................................................................................................................................................xi

.x

ABSTRACT .....................................................................................................................................................................ix

..........................................................................................................................................................

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 2

APPENDIX 3 - CANVAS ............................................................................................................................................... 99

APPENDIX 4- PATENT DRAFTING EXERCISE ................................................................................................... 106

APPENDIX 5 - PLAGIARISM REPORT .................................................................................................................. 114

REFERENCES.............................................................................................................................................................. 119

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 3

1 Introduction

History of printing starts from the duplication of images by means of stamps followed by the

flat bed printing process in 18th century. In mid of the 19th centuries color printing called as

Chromolithography became very popular. A revolution occurred when the print workings,

specifically a 2D printer was used as a peripheral device, which made a persistent human

readable representation of the graphics a text in paper. After some years the concept of 3D

printer starts evolving, a new way to look at the past printing technologies.

Our report emphasizes on the design and development of a low cost 3D printer. 3D printer

basically is concept to make or print the objects layer by layer and thus making it so called

“Three dimensional”.

Nowadays 3D printer available is of higher costs that is due to the printing technology used

and the material used in 3D printer, so this projects sparks upon making the 3D printer low cost

by using the scrap materials and designing a frame for the 3D printer.

The main aim of this project is to make the 3D printer available to a common man making this

equipment easy to operate and automate working once the command and specific design is

given to this device. So operating time will automatically decrease as it can handle the task

without any human intervention .This also makes this device reasonable and approachable to

everyone this project. This project deals or in other words targets the people who has cost as a

main constrain and thus making a 3D printer useful in school laboratories, making imitation

jewellery for women, automobile industries, making a prototype material in industries etc.

This project aims to produce a plastic 3D output and make it accurate as close as possible

compared to the present 3D printer requirements. This technology is a newly expanding find

in terms of increasing the efficiency, increase in accuracy of product, reducing the cost of the

printer. 3D printing technology is all about developing the self-replicating machine and brings

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 4

versatility due to which medical implants are possible through these printers’ end products. This

technology has a drastic impact and can bring a radical change in our world as more and more

people are getting accesses to these amazing machines.

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 5

2 Project At A Glance

This chapter deals with the introduction, design and goal and the basic working principle of how

the project works with a simplified block diagram and its brief explanation. Thus with this

chapter the main motive of the project would be clear with the basic understanding of the

project.

2.1 Definition

3D Printing technology is an additive manufacturing technology where a three dimensional object is

created. This technology is a rapid prototyping technology.

2.2 Design

The design structure that this project aims is a PRUSA OR KOSSEL Model.

2.3 Problem Statement

The present 3D printing technology is very time consuming with a high manufacturing cost.

This project aims not only to reduce the cost of the 3D Printer but also working upon

its accuracy and time constraints.

2.4 Possible Solution

The possible solution is designing a frame and using only the most important materials and

using the printing technology that minimizes the wastage of plastic to give maximum efficiency to

the product output.

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 6

2.5 Simplified Block Diagram

Figure 2 (c) Block Diagram of the Entire System

This above block diagram describes the basic working of the product. As shown in above block

diagram:

Firstly a 3D object is designed using a CAD Tool and then is converted in such a file

format specifically a G-Code using software’s like Cura or Repetier that is

understandable by the electronics that mainly includes the Microcontroller.

Figure 2 (a) Prusa Model Figure 2 (b) Kossel Model

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 7

Input is given to the electronics that give commands to the motors according to the

design in the CAD Tool.

The mechanical components including motors, extruder works accordingly and thus a

layer by layer object is printed (in layman language plastic is glued) on the print plate or

glass plate. After the 3D object gets cooled to a certain temperature the final end product

can be taken out.

In this way the simple process works to build a 3D object. Thus a prototyping of the project also

becomes easier as the specified or the required designed on an initial stage is formatted on a CAD

Tool and your printer starts to print! To get a change in the final product structure the design in

the CAD Tool only needs the change, rest all the working remains unchanged.

2.6 Working with Files

Figure 2 (d) STL file from CAD

There are several different file types used in 3D Printing file extensions that includes .stl, .fff,

.gcode, .factory. STL and OBJ files are the output from the CAD Software’s. After the STL and

OBJ files are imported the next work is to add the process. This process adds all the information

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 8

that how the object is sliced and printed on the print plate including the settings of the extruder,

infill, temperature, supports etc. After this process is saved and exported a FFF file is created. If

we want to again change the process settings for example changing the printing speed, infill

percentage etc. There comes option of “Edit Process Settings”. After making such modification

the OK option is clicked to save the changes.

GCode / X3G files gives the instructions for the printer .Gcode tells the machines how much to

move, where to move ,how fast to move .Such types of settings are also called as 3D Printing

Tool Path. Gcode uses plain text format while the X3G uses binary language which is used by

the machine with the maker boat type firm wares. When the option Prepare to Print is clicked the

3D model will automatically get converted into 3D Tool paths for the machine.

Factory files is a combined file to retain the simplify 3D Project. It offers a unique way to save all

the data about the project into a comprehensive file called as “Factory File”. This file includes copy

of 3D models been imported, their positions on bed, process settings etc. 3D Printers typically uses

software that “slices” a 3D model into layers and then the software generates a GCode that extrudes

the plastic to fill each layer. Mostly slicer software works, CAD program is compatible of producing

STL’s.

2.7 How 3D Printer Works?

The basic working principle of 3D printer is to print the object layer by layer fill the targeted

object design and to finish the printer has a frame structure and three axis x y and z axis that

moves left to right front to back and up and down .

The component called extruder which is responsible for feeding the plastic to print and melt the

plastic. To print the plastic layer the movement of the extruder and stepper motor need to be

controlled for that PWM generated by the Arduino is used, the g-code generated is used to drive

the axis accordingly with help of CAD tools targeted objects are designed and converted into g

codes with the help of software like Cura and being given to electronics that includes motor

which is placed on the frame according to the frame design. According to the commands given to

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 9

the electronics motor works and through the help of extruder which is also running through the

motor melts the plastic accordingly on the print plate.

The plastic material used in this project is bio degradable plastic materials. After the object is

finished the final object is taken out. In this way the process started with the designing object

specifically a 3D object and ended with the generating the same 3D object same object in front

our eyes!

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 10

3 Component Description

This chapter includes the description of various different components used in the development of the

system project. It is really very necessary to describe the features of the components that are used in

the designing of the system. This chapter includes the brief description of the components along

with their pin configuration and different features.

3.1 Frame

Selection of frame is an essential part for system designing. This frame gives the support to the

printer. All the axes of the motor added to this frame. The threaded rods are mounted on this frame

and rubber strips controlled by motor action.

Figure 3 (a) Frame structure (1) Figure 3 (b) Frame structures (2)

3.2 Extruder

Figure 3 (c) Extruder

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 11

Extruder consists of two parts, a cold top part that feeds the plastic filament, hot part at bottom that

melts and extrudes the plastic. The speed of the extruder head may also be controlled, to stop and

start deposition and form and interrupted plane without stringing or dribbing between sections.

3.3 Stepper Motor

The stepper motor is an electromagnetic device that converts digital pulses into mechanical shaft

rotation. Many advantages are achieved using this kind of motors, such as higher Simplicity,

since no brushes or contacts are present, low cost, high reliability, high torque at low speeds, and

high accuracy of motion.

This project involves the usage of at least five motors specifically five stepper motors .one motor

to control the Y-axis, the other to control the X-axis, two to control Z-axis and one to control the

extruder. The configuration of all the five motors is same and the driver is used to drive the motor.

Figure 3 (d) Stepper motor Nema 17

The two types of stepper motors that are the bipolar motor and unipolar motor. The bipolar and

unipolar motors are similar, except that the Unipolar has a center tap on each winding.

Don’t forget to name the motors when completing the electronics part so that the wiring

won’t get very confusing and untidy.

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 12

3.4 Driver A4988

Figure 3 (e) A4988 Driver

The driver features adjustable current limiting, over current protection, and five different micro step

resolutions. It operates from 8 – 35 V and can deliver up to 2 A per coil. Five drivers are used for

running 5 motors. Heat bed is pasted on the ramp so that IC should not be burned out.

Things to remember:

To place the driver on Ramp 1.4 in a way that the pins of the driver should not bent.

To look whether the Ramp IC is burning.

Heat bed to be attached on each driver.

Figure 3 (f) Simplified connection of Driver and controller

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 13

Below shows the variation of output after changing the value of MS1 MS2 and

MS3.

MS1 MS2 MS3 Resolution

Low Low Low Full step

High Low Low Half step

Low High Low Quarter step

High High Low Eighth step

Table 3.1 Changing value of MS1, MS2 and MS3

3.5 Plastics

Plastics are one of the most important materials that are required because it is the material of

which the end product is made. This project uses two types of plastics.

3.5.1 Acrylonitrile Butadiene Styrene (ABS) Plastics

It is a common thermoplastic polymer and is amorphous in nature .The most important prospect of

this material is its resistance power subjective to force and toughness.

3.5.2 Polylactic Acid or Polyactide (PLA) Plastics

It is a biodegradable plastic material which is made from renewable resources such as corn

starch and sugarcane. The main difference between the two plastics is that the ABS plastic type

is known for its toughness whereas the other is known for its soft type of material. Thus for

different purpose different plastic materials are used.

Figure 3 (g) ABS Plastic Figure 3 (h) PLA Plastic

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 14

3.6 The Software That Needs to Be Installed On the Computer to Run the

Model:

Arduino Software:

This application allows installing the printer firmware on the ATMEGA 2560 microprocessor. To

update the firmware each time this installation is required.

Skien Software:

The application to slice STL files into the G-Code is called as Skein Software. Each time the part

that needs to be printed needs this type of software.

Host Software:

Before the print job this application is responsible for the communication with the electronics. In

simple words it makes the printing output to be ready before the actual printing job.

3.7 TO DO LIST: Basic electronics connection:

Step 1: Look for an appropriate power source that will give the circuit 12V. For safety we

should SMPS.

Figure 3 (i) SMPS (12 V)

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 15

Step 2: Paste heat sink on the drivers as shown below so that the IC would not get damaged.

Figure 3 (k) A4988 Driver

Step 3: Take Arduino 2560 and Ramp 1.4 male and connect it as shown.

Figure 3 (l) Arduino Atmega 2560

Figure 3 (j) A4988 Driver

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 16

Figure 3 (m) Ramp 1.4D

Figure 3 (n) Connection of Arduino 2560 and Ramp 1.4D (1)

Step 4: Attach all the 5 drivers on the Ramp 1.4 as shown below and connect all the stepper

Motor’s to the drivers.

Figure 3 (o) Connection of Arduino 2560 and Ramp 1.4D (2)

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 17

Figure 3 (p) Connection of Arduino 2560 and Ramp 1.4D

Figure 3 (q) Running motors through electronics

3.8 Framework

After assembling the whole electronics part now it is the time for the mechanical structure to be

decided and to fit our electronics in it.

Decide the frame structure.

Assemble the structure using rods or waveguide structure and integrate electronics in it.

For our project Kossel model is selected.

Shown below is the basic structure of the Kossel model. It can be varied according to the need.

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 18

Figure 3 (r) Kossel frame work

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 19

4 Present 3D Printing Technologies

The aim of all the 3D printing technologies is to develop an additive manufacturing process that

creates an object layer by layer. Some common features for all the additive manufacturing

processes is the usage of computer with special 3D modeling software. The first part of this process

is to create a CAD diagram. The AM device reads the output from the CAD file and builds a

structure layer by layer with the printing material which can be plastic, powder filaments or may be

a sheet of paper. This chapter deals with all the famous 3D Printing Technologies that are used

commonly.

4.1 Stereo lithography (SLA)

This method is the oldest method and is still been used nowadays. This method was patented in

year 1986. This process involves a stereo lithography apparatus (SLA) which converts liquid

plastic into solid 3D objects. In this method the CAD file generated creates an output in such a

way that can be understood by the electronics. The Standard Tessellation Language (STL) is

commonly used for this process. This process first produces STL file such that the printing

machine should have the information of each layer. The SLA machine uses laser to cut the layer

when a required dimension is completed and this process is repeated again and again till the whole

structure is printed on the printed plate.

After plastic hardens a platform of the printer drops down in the tank a fraction of a millimeter and

laser forms the next layer until printing is completed. Once all layers are printed the object needs

to be rinsed with a solvent and then placed in an ultraviolet oven to finish processing.

Stereo lithography is widely used in prototyping as it does not require too much time to produce

an object and cost is relatively cheap comparing to other means of prototyping.

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 20

Figure 4 (a) Stereography method

4.2 Fused Deposition Modelling (FDM)

Fused Deposition Modeling (FDM) technology was developed and implemented in 1980’s. By

using this method not only functional prototypes can be printed but also concept models and

final end-use product is implemented. What is good about this technology is that all parts printed

with FDM can go high-performance which is highly beneficial for mechanic engineers and

manufactures. FDM is the only 3D printing technology that builds parts with production grade

thermoplastics, so things printed are of excellent mechanical, thermal and chemical qualities.

This method does not waste plastics so this method is widely uses more over this method does

not uses lasers.

3D printing machines that use FDM Technology build objects layer by layer from the very

bottom up by heating and extruding thermoplastic filament. The whole process is bit similar to

stereo lithography .Firstly a special software “cuts” CAD model into layers and calculates the

way printer’s extruder would build each layer then the printer heats thermoplastic till its melting

point and extrudes it throughout nozzle onto base, that can also be called a build platform or a

table along the calculates path.

Once the layer is finished, the base is lowered to start building of next layer .compared to the

previous process this method is bit slower. When printing is completed support materials can

easily be removed either by placing an object into water and a detergent solution or snapping the

Project Report for DESIGN & DEVELOPMENT OF LOW COST 3D PRINTER Page 21

support material off by hand.

Figure 4 (b) Fused Deposition Method

4.3 Selective Laser Sintering (SLS)

Selective laser sintering is a technique that uses laser as power source to form solid 3D objects. This

technique was also developed in 1980’s .the main difference between the SLS and SLA is that it uses

powdered material in the vat instead of liquid resin as stereo lithography does. Unlike some other

additive manufacturing processes such SLA and FDM, SLS doesn’t need to use any support

structures as the object being printed is constantly surrounded by unfiltered powder. Like all other

methods listed above the process starts with creation of computer aided design (CAD) file, which

then needs to be converted to .stl format by special software the material to print with might be

anything from nylon ceramics and glass. To some metals like aluminum, steel or silver. Due to wide

variety of material that can be used with this type of 3D printer this technology is very popular for

3D printing customized product.

4.4 Selective Laser Melting (SLM)

Selective laser melting (SLM) is a technique that also used 3D CAD data as a source and forms a

3D object by means so a high-power laser beam that fuses and melts metallic powders together.

This method fully melts the metal material into solid 3D- dimensional part unlike selective laser

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sintering. The fine metal powder is evenly distributed onto a plate, and then each slice of 2D

layer image is intensively fused by applying high laser energy that is directed to the powdered

plate. The energy of laser is so intense that the metal powder melts fully and forms a solid object.

After the layer is completed the process starts over again for the next layer. Metals that can be

used for SLM include stainless steel, titanium, cobalt chrome and aluminum.

Figure 4 (c) Selective Laser Melting

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5 Conclusion And Future Work

This report is the hard work of all out teammates .this report would not have been possible without

the help of our teachers, friends. Not only we learned technical prospect but also working in team,

listening to each and every group member perspective of thinking. This project is a blend of

integrated work and individual hard work too. We also learned that everyone is not perfect in every

case but if that perfectness of each group member in some parts can be bought together than a great

work can be achieved. Hence this project will benefit too many.

Once this project target is achieved that is to “Design and Develop a Low Cost 3D Printer” our

future plan is to further work on the accuracy of the printer sooner or later we would also work

upon reducing the timing of printing the end output.

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Appendix 1 – PPR

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Appendix 2 - PSAR

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Appendix 3 – Canvas

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Appendix 4– Patent Drafting Exercise

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Appendix 5 Plagiarism report

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Appendix 6 References

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2007. http://www.economist.com/node/10105016?story_id=10105016 (accessed 4Th Jan 2012.

Berg, S. Dalton, T. (1975), ‘Sectoral Employment and Shifts in the Aggregate Phillips Curve’.

Southern Economic Journal, Vol 41, No.4, Apr 1975, p593-601

BMWTv. ‘Rapid Prototyping from BMW: high speed with high

technology.’ http://www.youtube.com/watch?v=kdiFkH5Ugwk, (accessed 4th Jan 2012)

Bowyer, A. (2010), ‘2020 – Shaping Ideas Project: 3D Printing and the Future of

Manufacturing’. http://econfuture.wordpress.com/2010/03/25/2020-shaping-ideas-project-3d-

printing-and-the-future-of-manufacturing/. 25th March 2010 (accessed 11th Jan 2012)

Castells, M (1996). The Rise of the Network Society, The Information Age: Economy, Society

and Culture Vol. I. Cambridge, MA; Oxford, UK: Blackwell.

Chua, K. Leong, K. Lim, C. (2003). ‘Rapid Prototyping: Principles and Applications’ (2nd

edition). World Scientific Publishing Company Singapore, 2003, P124

Corney, J. (2005), ‘The Next and Last Industrial Revolution?’. Assembly Automation Vol.25,

No.4, p.257

Flahety, N. (2007), ‘Moral Dimension to Prototyping System’. Electronics Weekly No.2299

(Aug 1, 2007), p.3

Gershenfeld, N. (2005), ‘The Coming Revolution on Your Desktop: From Personal Computers

to Personal Fabricators’, Basic Books, New York, NY, April.