A

PROJECT REPORT ON
DESIGN & MODELLING OF RAPID PROTOTYPING (RPT)
3D – PRINTING

SUBMITTED BY

NAME:
Roll Number:

MECHANICAL ENGINEERING
Under the Esteemed guidance of
NAME OF THE GUIDE,
Asst. Professor,
Dept. of MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

VISAKHA INSTITUTE OF ENGINEERING AND TECHNOLOGY
(Affiliated to JNTUGV, VIZIANAGARAM and Approved by AICTE (NEW DELHI))
88th DIVISION, NARAVA, VISAKHAPATNAM - 530 027

i
VISAKHA INSTITUTE OF ENGINEERING AND TECHNOLOGY
(Affiliated to JNTUGV, VIZIANAGARAM and Approved by AICTE (NEW DELHI))
88th DIVISION, NARAVA, VISAKHAPATNAM - 530 027

CERTIFICATE
This is to Certify that this INTERNSHIP report on “DESIGN & MODELLING OF
RAPID PROTOTYPING (RPT) 3D – PRINTING” is the bonafide work of the team
those who carried out the project work done under mysupervision.

PROJECT GUIDE Head of the Department

Mr. M.Tech Mrs. Siva Karuna M.Tech(Ph.D)

Assistant Professor Assistant Professor

ii
 ACRONYMS

CAD-Computer Added Graphics

AM-Additive manufacturing

DARPA- Defence Advanced Research Projects Agency

SLS- Selective Laser Sintering

ABS-Acrylonitrilebutadienestyrene

PLA- Polylactic Acid

FDM-FuseddepositionModelling

SHS-Selective Heat Sintering

SLM- SelectiveLaser Melting

EBM-ElectronBeam Melting

SLA-Stereo Lithography Apparatus

DLP- DigitalLight Processing

LOM-LaminatedObject Manufacturing

RAMPS- Reprap Arduino Mega PoluloShield

SMPS- Switched Mode Power Supply

iii
INTRODUCTION:

The beginning of 3D printing is related to studies of photography, sculpting, and Landscape

design, which took place in America. Much of the technology was not being developed until
the mid-1980s. During this period, 3D printing was known as “RAPIDPROTOTYPING”.
Chuck Hull, of 3D Systems Corporation, manufactured the first usable 3D printer. Later in
the 80’s, Selective Laser Sintering (SLS) technology was synthesized by Dr. Deckard at the
University of Texas during the commencement of project being done by Defense Advanced
Research Projects Agency. In the 1990s, the technology was further improvised with the
advancement of a method that uses UV light to solidify photopolymer, a highly viscous liquid
material .In the 20th century, 3D printers were very expensive and were used to print a few
number of products. Most of the printers were owned by scientists and electronics groupies
for research and display. However advancements in the area of 3D printing have allowed for
the design of products to no longer be limited by complex shapes or colors .

PRINTING METHODS:

FUSED DEPOSITION MODELLING:

In this process the thermoplastics; which constitute ABS (Acrylonitrile butadiene styrene),
wax and nylon were utilized. The introductory venture of the FDM procedure were to warmth
up the thermoplastic constituent until it is at an intertwined state .Then, the 3D printer uses
advanced demonstrating information from a CAD record to create the 3D item layer by layer,
The printers join a much weaker bolster composite. The bolster material goes about as
framework to the test item. This is valuable amid the building procedure when parts have
overhangs that could not bolster it. The thermoplastic for the most part has a filamentous
structure which benefits warmth exchange and serves to move with a print head that
navigates in the x and y bearings. After every layer is printed, a cylinder navigates the stage
beneath (z-hub) the separation of thickness of printed layer. There are numerous benefits of
FDM innovation; it is anything but difficult to control, use, and fix. The expense of the
machine and material are generally low.

4
Fig-1: BASIC METHOD OF FDM TECHNOLOGY

Fig-2: Thermoplastic

5
GRANULAR MATERIAL BINDING (USING HEAT/ ENERGY):

The joining of granular materials involves specifically fusing powder, layer by layer.
The elemental constitution of the powder and binding process relies on the machine.

Fig-3: Granular material binding

SELECTIVE LASER SINTERING (SLS):

One of the sorts of binding processes is Selective Laser Sintering, or SLS. It utilizes a high-
powered laser to sinter the powder. Once the first layer is made, the whole granular plate, in
which the powder (and the "print") is found, is cut down. As seen in Figure 6, this procedure
is supplemented by the vertical development of a cylinder. Moreover, cylinders are
additionally utilized as a part of a few printers to send the coupling powder up so that the
moving instrument would continue working adequately and the sintering can proceed. A
mirror is integrated to control the laser bar into the foreordained "cut" of the CAD model.
When the greater part of the layers is appropriately sintered, the item is removed from the
build chamber.

6
 Fig-4: Selective Laser Sintering Citation Process

SELECTIVE HEAT SINTERING:

SHS is indistinguishable to SLS. Selective Heat Sintering utilized a thermal print head. This
new strategy uses concentrated heat to fuse the binding powder.

Fig-5: Illustration of a Blue Printer Citation

7
 Fig-6: A model created by Blue Print Citation

SELECTIVE LASER MELTING (SLM):

SLM is almost as same as SLS. A more powerful laser is generally used. It required more
energy for the metal to be melted.

8
 Fig-7: Illustration of selective laser sintering method

Fig-8: Selective laser sintering in action

Electron Beam Melting (LBM):

Electron Beam Melting is some cases similar to SLM; an electron beam was used to melt the
powder. Unlike models produced by SLM, EBM models are fully accurate, void-less, and
extremely powerful.

9
 Fig-9: Illustration of an EBM process citation

GRANULAR MATERIAL BINDING (USING BINDING AGENT):

This methodology utilized fluid binding material for the binding procedure of the powder
together, instead of a laser. Zcorp, has a copyright of this innovation around the world. 3D
printing is also called fundamental inkjet printing procedures. As opposed to utilizing paper
like as a part of the instance of a 2D printer, a 3D printer moves the print heads over a bed of
powder whereupon it printed information sent from the product. The fluid binding materials
here utilized is much the same as super glue. Composite material or mortar is utilized as
powder here.

10
 Fig-10: Illustration of granular material

Photo Polymerization:

This is an additive manufacturing process. This methodology utilizes UV light for the
hardening of the photograph polymer. There are diverse sorts of photopolymers which are
accessible today. Photograph polymerization is really same as FDM and Granular Material
binding process. The fundamental contrasts are the material sand the system utilized for the
printing systems.

Stereo Lithography:

A stereo lithographic printer is regularly known as a SLA. A perforated platform was put just
beneath the surface of a carriage of fluid polymer.

11
Fig- 11: Illustration of SLA Platform

The UV-treatable fluid solidifies quick, shaping the essential layer of the 3D-printed item.
Next, the stage was brought down, uncovering another surface layer of the fluid substance.
This procedure is rehashed more till the whole question is framed and is completely
submerged in the tank . Regularly, the utilization of the UV stove issued for the ensuing cure
of the photograph polymer.

12
 Fig- 12: Illustration of SLA process

DLP Projecting:

DLP (Digital Light Processing) is one kind of stereo lithographic procedure. It utilizes a
projector to solidify a layer of photopolymer at once, as opposed to utilizing a laser for the
following of distinctive layers. A mirror was most normally used to position and size the
replication precisely onto layer of photopolymer.

Fig- 13: Illustration of DLP Projection

13
Material Jetting:

Material Jetting is much the same as the FDM process, yet it works absolutely in an alternate
manner than the basic plastic extrusion system. Layers were made by emanating fluid
photopolymer into a specific example. These sorts of printers utilize a bolster material
alongside the model material. When every layer is shaped, an UV laser is utilized for the
solidification of the photopolymer. The platform is then moved down, and the model is
printed layer by layer.

Fig- 14: Illustration of material jetting process citation

Laminated Object Manufacturing (LOM):

Covered article assembling can give great results. Other than the laser (carbon dioxide) that is
involved for following the patterns in the material. It is a less prevalent rapid prototyping
process yet looks into are continuing for its future actualizes.

14
 Fig- 15: Depiction of Laminated Object Manufacturing process

In this technique the chose printing material is initially covered with a sticky material. The
material supply roll turns simply enough with the goal that there is another layer of substance
which is prepared to be cut with the assistance of the laser. The warmth and weight from the
roller join so that the following layer is safely stuck to the past layer. The laser is being
customized in a manner that it cuts the material so that the abundance material is effortlessly
expelled from the setup. After the "print" is expelled from the stage, the abundance material
and backings are to be uprooted. In this technique at last, regularly there is requirement for
devices, for example, etches, to pry the additional parts far from the set up.

15
Fig- 16: Example of final LOM printed model citation

2.1. HISTORY OF 3-D PRINTING:

3D printing technologies first became visible in the 1980’s; at that time they were called
Rapid Prototyping (RP) technologies. The very first patent application for RP technology was
filed by a Dr Kodama in 1985. Hull became the co-founder of the 3D corporations which is
one of the largest and most major companies in the field of 3D printing and rapid
prototyping.

The primary business Rapid prototyping framework, the SLA-1, was presented in 1987 The
patent in regards to the FDM innovation was at initially issued to Stratasys in 1992. After a
wasting with the stereo lithography process, EOS' R&D center was chiefly on the laser
sintering (LS) process, which got reinforced step by step. Today, the EOS frameworks are all
around perceived the world over for their gainful and subjective yield for mechanical
prototyping and enthusiastic applications in the 3D printing part. The organization's metal
laser sintering (MLS) procedure came about because of an undertaking with a bureau of
Electrolux Finland, which was later obtained by the organization EOS in the year 1993.
16
EXPERIMENT AND METHODOLOGY:

Our objective was to study, design and fabrication of a 3d printer. We studied the history,
different printing methods and overview of the past research in the previous chapter. This
chapter includes design and fabrication of the same mentioned earlier. First we ordered the
whole tool-kit including all the parts and components those are used to manufacture a 3d
printer. It took a while to procure the whole kit. In the meanwhile a CAD model of a 3d
printer has been created using solid works. First we designed all the parts required for the
assembly and dimensions were strictly taken from internet as we didn’t have the kit or
manual to find out the original dimensions. Then all the parts are assembled in the solid
works workbench to create the 3d printer assembly. Here are the real life pictures, designed
modelof individual parts and their working process.

Assembled 3d printer:

FIG.17 (A) fully assembled working 3D printer FIG.17 (B) CAD model of 3D printer

17
Different parts of a 3d printer:

Various components of 3D printers are: Frame, Y-axis and bushing, Extruder, print plate,
stepper motors, Z-axis and Y- axis, X-carriage, Electronics parts, stepper motor controllers
and end-stops .

Description of a 3d printer parts:

Frame: The frame provides the printer its property regarding stiffness. The three axes of the
printer are added to frame. The frame consists of threaded rods combined together with
printed parts. Aside from the vertex the edge likewise comprises of printed parts to hold and
recreate the Y-axis and Z-axis. On the upper left and upper right we observe the printed parts
that hold the stepper motors of the Z-axis.

FIG.18 Empty 3d printer Frame

Y-axis and Bushing:

From picture 19 we can see the print base plate is collected on the Y-axis smooth poles. The
Y-axis has one degree of freedom i.e. it can move between the front and back of the casing.
The Y-axis is controlled by a belt drive appended to a stepper motor with pulley. The print
base plate has four bushings joined to it. Bushings are only plain bearing. They slide over
smooth bars and give right around zero rubbing when going here and there the poles. On the
3d printer, the bushings climb and down the smooth poles taking after a virtual line on the
bars. Linear Bearing has little balls inside and gives free and smooth movement in one course

18
just. Metal bushings are by and large comprised of metal which have low erosion and is self-
greasing up too. 3D printer outline utilizing direct course by and large favor LM8UU metal
orientation. The standard 3D printer utilizes bushings.

Fig-19: 3D printer frame with y-axis installed

Fig-20: Brass Bushing inserted in printed parts

Fig-21: Printed Linear Bearing

19
Z-axis and Y-axis:

From figure 22we can see 3D printer frame with X-, Y- and Z-axis assembled and installed.
The Z-axis and Y-axis follow the identical construction process. The Z-axis moves the X-axis
up and down the frame. The X-axis traverses the extruder left and right within the frame.

The Z-and-X axis development utilizes two printed parts called the X-end idler and X-end
engine as indicated in the figure. The stepper motor will turn the strung pole around its own
particular pivot which thus will permit the X-end idler climb and down. Collected X-end idler
is indicated in figure 23:

The X-end motor is assembled of the comparable two areas and is assembled in a
comparative manner. As we can see from the figures, Z-axis is controlled by 2 stepper
motors. It results out to be less expensive and improvement of precision to have 2 stepper
motors on the Z-axis rather than one motor and a belt, on the grounds that the later one
requests an extremely complex development and an extravagant belt too. The Y- and X-hub
are commonly controlled by one motor and a belt drive.

Fig-22: 3D printer frame with X-axis, Y-axis and Z-axis installed

20
Fig-23: X-end idler part on LHS and X-end motor part on RHS

Fig-24: Assembled X-end idler

EXTRUDER:

Fig-25: Wade’s geared extruder

21
The 3D printer is generally assembled with a Wade’s geared extruder. This extruder contains
two parts: a cold top part which feeds or provides the plastic filament and a hot bottom part
which helps in melting and in turn the plastic gets extruded. These two parts, usually known
as the Wade extruder (the cold part) and the hot-end (the hot part).

The Wade extruder holds of a large gear which is driven by a stepper motor. This large gear
drives a bolt, which extracts the plastic filament and pushes it into the hot-end where the
plastic starts melting.

The hot-end is generally a bolt made up of metal with a gap penetrated down the vertical
pivot. This screw, otherwise called a heater barrel. At the tip of the heated barrel, the way out
opening diminishes down to under 1mm from 3mm.

Two techniques are utilized to warmth the hot-end: utilizing resistor or NiChrome wire. A
NiChrome wire is far too simple .A resistor needs a heater block which will be turned onto
the heater barrel.

Fig-26: shows a heater block with a resistor installed.

Fig-27: Heater barrel wrapped with nichrome wire

22
A hot-end have three basic parts: Thermistor, to discover the temperature, a heat barrier to
keep the hot-end far from the cool end, the chilly end will dissolve without heat barrier and a
spout which permits the dissolved plastic to be flown out of the heater barrel.

A connection has been made in the middle of thermistor and the gadgets board - only like the
resistor or NiChrome wire – and this helps the hardware to quantify and choose the
temperature of the warmer barrel. The radiator barrel meets expectations at a temperature
configurationally, and that temperature could be come to utilizing a thermistor Figure 28
shows a heater barrel with nozzle:

Fig-28: Heater Barrel

X-CARRIAGE: The amassed extruder alongside cold end, heat barrier and hot-end is fitted
on the X-axis carriage. Figure 29 beneath demonstrates an amassed X-axis with two smooth
poles, a X-end idler and a X-end motor parts and the printed X-carriage:

Fig-29: Assembled X-axis with two smooth rods, the X-end idler and X-end motor printed
parts and the printed X-carriage:

The movement of the X-carriage is taken care by one stepper motor and a belt.

23
Fig-30: Assembled Wade’s geared extruder mounted on the X-carriage

PRINT PLATE:

Printed parts are intended to be imprinted on the print plate. The three axes move with respect
to one another so that the nozzle can be set simply over the print plate for the printing reason
in a range given by the particular of the print plate.

The print plate for the most part constitutes two plates: the print base plate which is fitted and
mounted on the X-pivot smooth poles by utilizing a bushing or a direct bearing and the print
top plate which is mounted on the base plate and in this way, shapes the print surface.

Fig-31: Top print plate stack on bottom print plate

Another vital part of a 3D printer is the heated bed. These altogether cutoff the measure of
twisting on the printed parts, particularly on the lower layers. Distorting is brought on

24
because of the uneven and undistributed cooling of both external and inward segments of a
printed part. This will make the cooler material to get twisted or bowed while the hot material
will never. This uneven contracting will twist the straight edges and can bring about
changeless disappointment in parts. Twisting is basically a significant issue for the lower
layers of a part as the print plate will cool those layers at a rate much speedier than higher
layers.

Fig-32: Left hand part clearly shows warping of bottom section

So we have to keep the entire lower section of a part at the same temperature. A heat bed
heats up the top print plate up to 100C.

Fig-33: heat bed mounted on top print plate

ELECTRONICS:

The electronics board known as microcontroller controls the entire printing process. Several
electronics options do available for 3D printers which are all open-source. Presently the most
popular are:

25
  RAMPS, a DIY shield board for Arduino MEGA
 Sanguinololu, a DIY board with microprocessor on board

Functions of a 3d printer electronics board:

 Processes G-code instructions.

 Controls and regulates the four stepper motor controllers where both Z-axis motors
are essentially connected to the same stepper motor controller.
 Monitors the end-stops
 Controls the temperature of the heated bed

The electronics board is connected to the PC using a USB-to-serial converter.

STEPPER MOTOR:

There are five stepper motors used in the 3D printer are One to control the Y-axis, One to
control the X-axis, Two to control the Z-axis, One to control the extruder.

STEPPER MOTOR CONTROLLER:

Controlling a bipolar stepper motor is truly muddled, particularly in the matter of smaller
scale venturing mode. Unipolar stepper motors are much simpler to control however they
give lesser torque given the motor size is same. Exceptionally outlined stepper motor
controllers are being utilized to assume control over the troubles of directing a stepper motor.
With the assistance of such controller stand out small scale step can be made. Consequently
controlling of a stepper motor has been rearranged.

END STOPS:

While printing an object, all three axes need to be altered the initial position to their starting
one. This is known as the zero position of any Cartesian robot. The axes can’t move any
further than zero.

To acquire this, three end stops are to be installed one for each axis. An end stop needs to be
mounted at such a position where the axis shouldn’t go beyond:

26
For the X-axis, this ought to be the position where the nozzle achieves the left-hand side of
the print plate, For the Y-axis this ought to be on the posterior of the pivot such that the print
plate is permitted to move to the back sufficiently far so that the nozzle winds up on the
forward of the print plate, For the Z-axis position ought to be the place the nozzle scarcely
touches the print plate.

In a 3d printer 2 SMPS ,1 voltage converter,1 micro cotroller,5 stepper motors and 2 belt
drives are considered as important components. After all the connection is made, AC power
supply is given to the SMPS. Later this voltage is supplied to the voltage converter which is
basically a step down transformer which reduces the voltage up to a noticeable level. This
reduced voltage is just high enough to propel a 3d printer and this voltage is supplied to the
micro controller. All the motors are connected to the micro controller which sends
appropriate signal to each component for it to work.

Some of the parameters those need to be valued before printing a product using 3d printer
are:

Bed Temperature, Extruder Temperature, Feed Rate, Flow Rate .Bed Temperature shouldn’t
exceed the melting temperature of the filaments used. A number of fans are required for the
cooling purpose of the bed and for all the metallic parts of the printer.

27
DIFFERENT VIEWS OF THE COMPONENTS:

Here are some images representing the Left side view, Right side view, Top view and
Isometric view of some essential components of a 3D printer.

Fig-39: Ball Bearing 624_2z Fig-40: Axial

Fig-41: Ball Bearing608_2z Fig-42: Axle holder

28
Fig-43: X- Carriage Fig-44: Extruder Idler

Fig-45: Head Nozzle Fig-46: Body Extruder Wade

29
Fig-47: X-Idler Fig-48: Bearing LM8UU

Fig-49: X End Motor Fig-50: Struts

30
Fig-51: Bolt M3x12 Fig-52: Nut _M4

Fig-53: X End Idler Fig-54: Wade Big Gear

31
Fig-55: Wade Small Gear Fig-56: Bracket 20x20

Fig-57: Y- Axle holder Fig-58: End Stop Holder

32
SPECIFICATION OF DIFFERENT COMPONENTS:

ELECTRONICS:

 1 x Ramps board (RAMPS +Mega 2560+ A4988 Polulu stepper Drivers quantity 4
nos.)
 3 x End stops including connecting cables
 1 x Heat Bed
 5 x NEMA 17 Stepper motor ( 5.5 Kg-cm)
 1 X Power Supply ( 220 Volt, assured 12 Volt ; 29 Ampere supply)

HARDWARE:

 Smooth and threaded rods

 Linear bearing , ball bearing , coupling , belt , GT pulley , GT 2 belt
 Screw Nut, washers,
 Metal Frame.

PLASTIC PARTS:
Printed Plastic parts to build PRUSA i3.

HOT END:

 Magma Hot end kit (Thermister& resistor included)

 40 mm Fan & its Holder.

SOFTWARE:

 Repetitor (open source)

 V-rep ( Open source)

33
3D printing is a new and promising technology, and as with all developing fields the
Scope for improvement and advancement are definitely infinite.

CONCLUSION:

Not all technical information about 3D printing could be shared in this introduction of the
subject. Documenting the technology, very much a work-in-progress, must also recognize
that not all authors agree on the likelihood of 3D printing gaining wider dissemination into
the homes of individuals. Also, as a still emerging technology, 3D printing is not without its
problems, such as slow printing speeds. Nevertheless, as prices are decreasing, the number of
3D printers sold worldwide has been growing steadily.

34