DEVELOPMENT OF TABLE TOP

LOW COST 3D PRINTER

A PROJECT REPORT

Submitted By

DEEPAK KUMAR MISHRA (13UEME0086)

BOYANAGUNTA SRIKANTH (13UEME0075)

BHARGAV PRASAD REDDY MAKALA (13UEME0071)

In Partial Fulfilment for the Award of the Degree

Of

BACHELOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING

JUNE-2017

i
 BONAFIDE CERTIFICATE
Certified that this project report titled “DEVELOPMENT OF TABLE TOP LOW
COST 3D PRINTER” is the bonafide work of DEEPAK KUMAR MISHRA
(13UEME0086), BOYANAGUNTA SRIKANTH (13UEMEOO75), and BHARGAV
PRASAD REDDY MAKALA (13UEME0071) who carried out the project under
my supervision. Certified further, that to the best of my knowledge the work
reported does not form part of any other project report or dissertation on the
basis of which a degree or award was conferred on an earlier occasion on this
or any other candidate.

SIGNATURE SIGNATURE
Dr. A.T.RAVICHANDRAN, ME, Ph.D., Dr. E BALASUBRAMANIAN
HEAD OF THE DEPARTMENT ASSOCIATE PROFESSOR
MECHANICAL ENGINEERING, MECHANICAL ENGINEERING,
VELTECH DR.RR & DR.SR UNIVERSITY VELTECH DR.RR & DR.SR UNIVERSITY
AVADI, CHENNAI-600062 AVADI, CHENNAI-600062

CERTIFICATE OF EVALUATION

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 University Name : Veltech Dr. RR & Dr. SR University
Branch : Mechanical Engineering
Year : IV
Semester : VIII
Title of project : DEVELOPMENT OF TABLE TOP LOW COST 3D PRINTER
Name of the Student Pursuing Title of the project Name of the Internal Guide
Project

Deepak Kumar Mishra DEVELOPMENT OF Dr. E Balasubramanian

TABLE TOP LOW COST Associate Professor
Boyanagunta Srikanth 3D PRINTER Department of Mechanical
Engineering
Bhargav Prasad Reddy Makala

The report of the project work submitted by the above students in partial
fulfilment for the award of DEGREE of BACHELOR OF TECHNOLOGY
in MECHANICAL ENGINEERING of VEL TECH DR. RR & DR. SR
UNIVERSITY was evaluated and conformed to be the report of the work done
by the above students.
This project report was submitted for VIVA VOICE held on
………..................... at Vel Tech Dr. RR &Dr. SR University.

Internal Examiner External Examiner

ACKNOWLEDGEMENT
We are grateful to our Founder President, Col. Prof.Dr. R. RANGARAJAN B.E
(Elec), B.E (Mech), M.S (Auto), D.Sc. and our FOUNDER - VICE CHAIRMAN Dr.
SAGUNTHALA RANGARAJAN M.B.B.S, for providing us ambient learning
experience at our institution.

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We are greatly thankful to our CHAIRPERSON and MANAGING TRUSTEE Dr.
RANGARAJAN MAKALAKSHMI B.E (I.E), MBA (UK), Ph.D., and VICE
PRESIDENT K.V.D KISHORE KUMAR B.E, MBA, for their encouragement and
valuable academic support in all aspects.

We are greatly thankful to our Vice Chancellor, Dr. BEELA SATYANARAYANA,

M.E. (MD), M.E. (IE), and M.Tech. (CSE), Ph.D. (IIT, Delhi) for their patronage
towards our project.

We also submit our special thanks to our Dr. A .T RAVICHANDRAN, Ph.D., Dean,
school of Mechanical and construction Engineering and Dr. A .T RAVICHANDRAN,
Ph.D., Head of the Department Engineering for having extended all the department
facilities without any hesitation.

We heartfelt thanks to the head of the professor , Southern Taiwan University of Science
and Technology (STUST) ,Prof. Dr. NAI-SHANG LIOU , the senior research
associate, for such a guidance , valuables advice and knowledgeable lectures and for
proffering me this immense opportunity to explore my non-theoretical skills through this
project.
We would like to acknowledge and express our sincere thanks to our internal guide Dr.
E. Balasubramanian Department of Mechanical engineering, for his inspiring guidance,
constructive criticism and valuable suggestions through-out our project work which has
helped us in bringing out is proficient thesis.

ABSTRACT

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3D printing is moving in several directions at this time and all indications are
that it will continue to expand in many areas in the future. Some of the most
promising areas include medical applications, custom parts replacement, and
customized consumer products. As materials improve and costs go down, other
applications we can barely imagine today will become possible. Mechanics will
keep specs for every part of every car ever sold in a database and print out
whatever they need immediately with no difficulty.

In our project we designed a new model with the help of available spare parts in
the market stores. This 3D printer is an extrusion based model in which PLA
filament is used for printing the 3D models. As PLA is environmental friendly
and also has higher surface hardness so it is used as an extrusion segment. The
integration of electronic elements, actuators, sensors and stepper motors into an
arduino controller is carried out. Assembled 3D printer is tested to generate the
desired parts generated from a solid modelling package. The fabricated
components are achieved desired size and shape with sufficient strength
characteristics.

TABLE OF CONTENTS

Chapter Title Page

No. No.

5
 Abstract
List Of Figures
List Of Tables
List Of Abbreviations

1 15
Introduction
15
1.1 Typical 3D Printer
15
1.2 Current 3D Printing Technologies
15
1.2.1 Stereo lithography
16
1.2.2 Selective laser sintering (SLS)
16
1.2.3 Multi-jet modelling (MJM)
16
1.2.4 Inkjet 3D printing
16
1.2.5 Fused Deposition Modelling(FDM)
17
1.2.6 Powder Deposition Printing (PDP)
17
1.2.7 Digital Light Processing (DLP)
18
1.2.8 Selective Laser Sintering (SLS)
19
1.3 Components of 3D Printer
19
1.3.1 The Frame
20
1.3.2 Low 3D Filament sensor
20
1.3.3 Ramps 1.4
21
1.3.4 Filament
21
1.4 Types of Filament Used
21
1.4.1 ABS
22
1.4.2 PLA
22
1.5 Direct Drive VS Bowden Extruders
23
1.5.1 Hobbed Gear
23
1.5.2 Idler Gear
23

6
 1.5.3 Hot End - Heat Sink / Hot End Fan 24
1.5.4 Heater Cartridge 25
1.5.5 Thermistor/Thermocouple/RTD 26
1.5.6 Nozzle 27
1.5.7 Layer Cooling Fan 28
1.5.8 Threaded Rods / Lead screws 29
1.6 Belts 30
1.7 Stepper motors 30
1.8 Enclosure
2 31

Electrical Components 31

2.1 Power Supply 31

2.2 Mother Board 32

2.3 Stepper Drivers 33

2.4 User Interface 34

2.5 SD Card Slot 34

2.6 End Stops 34

2.7 Bed levelling 34

2.7.1 PCB Heat Bed 35

2.8 Materials Used 36

2.9 Storage 36

2.10 Smell 36

2.11 Part Accuracy 38

2.12 General Material Properties 38

2.13 Configuration Settings 38

2.13.1Quality Settings 39

2.13.2 In fill settings 39

2.13.3 Speed and Temperature 40

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 2.13.4 Support Settings 41
3 2.13.5 Cool
42
Assembly Instruction 42
3.1 Types of Assembly 42
3.1.1 Chassis Assembly 43
3.2 Stepper motor assembly 44
3.3 Power supply wiring on chassis 44
3.4 Extruder assembly on the chassis 45
3.5. 12v 20W Heat bed wiring 46
3.5.1. Electronic Wiring 47
3.6. Schematic for 12V proximity sensor 48
3.7 Advantage of the system over other system 48
3.8 Difference between PLA and ABS 49
3.9 Mechanical and physical properties 49
3.9.1 PLA 49
3.9.2 ABS 50
4 3.10 Applications
51
Fabrication 51
4.1 Table top 3D printer 53
4.2 Cost Estimation
5

55
Conclusion 56
References

8
 LIST OF FIGURES

Figure No Name Page No.

1.1 Digital light processing (DLP) 18

1.2 Selective Laser Sintering (SLS) 19
1.3 Frame 19

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1.4 Filament sensor 20
1.5 Ramps 21
1.6 Filament 21
1.7 Extruder 22
1.8 Hobbed Gear 22
1.9 Idler Gear 23
1.10 Hot End Fan 24
1.11 Heater Cartridge 25
1.12 Thermocouple 26
1.13 Nozzle 27
1.14 Layer cooling Fan 27
1.15 Motion control 28
1.16 Threaded Rods 29
1.17 Belts 29
1.18 Stepper motor 30
2.1 Mother Board 32
2.2 Stepper Drives 33
2.3 User Interface 33
2.4 PCB Heat bed 34
3.1 Chassis Assembly 42
3.2 Power supply wiring on chassis 43
3.3 Extruder assembly on the chassis 44
3.4 Heat bed wiring 45
3.5 Electronic wiring 46
3.6 Schematic Diagram 47
4.1 Top view of 3D Printer 51
4.2 Horizontal rod with motor 51
4.3 Complete 3D printer 52

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 LIST OF TABLES

Table Name Page

No. No.

1 Difference Between PLA And ABS 48

2 Cost Estimation 53

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LIST OF ABBREVIATIONS

3D 3- Dimensional
PLA PolyLactic Acid
ABS Acrylonitrile –Butadiene Styrene
SLS Selective Laser Sintering
MJM Multi-jet Modelling
FDM Fused Deposition Modelling
PDP Powder Deposition Printing

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 DLP Digital Light Processing

CHAPTER 1
INTRODUCTION

3D printing is a form of additive manufacturing technology where a three

dimensional object is created by laying down successive layers of material.
The 3D printing concept of custom manufacturing is exciting to nearly
everyone. This revolutionary method for creating 3D models with the use of
inkjet technology saves time and cost by eliminating the need to design;
print and glue together separate model parts. Now, you can create a

13
complete model in a single process using 3D printing. The basic principles
include materials cartridges, flexibility of output, and translation of code
into a visible pattern. 3D printers are a new generation of machines that can
make everyday things. They’re remarkable because they can produce
different kinds of objects, in different materials, all from the same machine.

They replace traditional factory production lines with a single machine.

It is a type of additive manufacturing technology where a three dimensional
object is made by laying down successive layers of material which forms the
final object. This is also considered distinct from traditional machining
techniques, which mostly rely on the removal of material by methods such as
cutting or drilling. 3D printing is an enabling technology that encourages and
drives innovation with unprecedented design freedom while being a tool-less
process that reduces prohibitive costs and lead times. In contrast, 3D printing is
a process for creating objects directly, by adding material layer by layer in a
variety of ways, depending on the technology used.

1.1 Typical 3D Printers: -

3D Printers are 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. It is used in a variety of
industries including jewellery, footwear, industrial design, architecture,
engineering and construction, automotive, aerospace, dental and medical
industries, education and consumer products. The technology for printing
physical 3D objects from digital data was first developed by Charles Hull in
1984. He named the technique as Stereo lithography and obtained a patent for
the technique in 1986. While Stereo lithography systems had become popular

14
by the end of 1980s, other similar technologies such as Fused Deposition
Modelling (FDM) and Selective Laser Sintering (SLS) were introduced. In
1993, Massachusetts Institute of Technology (MIT) patented another
technology, named "3 Dimensional Printing techniques", which is similar to the
inkjet technology used in 2D Printers. In 1996, three major products, "Genisys”
from Stratasys, "Actua 2100" from 3D Systems and "Z402" from Z Corporation
were introduced. In 2005, Z Corp. Launched a breakthrough product, named
Spectrum Z510, which was the first high definition color 3D Printer in the
market. Another breakthrough in 3D Printing occurred in 2006 with the
initiation of an open source project, named Reprap, which was aimed at
developing a self-replicating 3D printer.

1.2 CURRENT 3D PRINTING TECHNOLOGIES

1.2.1 Stereo Lithography: -

Stereo lithographic 3D printers (known as SLAs or stereo lithography

apparatus) position a perforated platform just below the surface of a vat of
liquid photo curable polymer. A UV laser beam then traces the first slice of
an object on the surface of this liquid, causing a very thin layer of
photopolymer to harden. The perforated platform is then lowered very
slightly and another slice is traced out and hardened by the laser. Another
slice is then created, and then another, until a complete object has been
printed and can be removed from the vat of photopolymer, drained of excess
liquid, and cured. Fused modelling - Here a hot thermoplastic is extruded
from a temperature-controlled print head to produce fairly robust objects to a
high degree of accuracy Deposition.

1.2.2 Selective Laser Sintering (SLS):-

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This builds objects by using a laser to selectively fuse together successive
layers of a cocktail of powdered wax, ceramic, metal, nylon or one of a
range of other materials.

1.2.3 Multi-Jet Modelling (MJM):-

This again builds up objects from successive layers of powder, with an

inkjet-like print head used to spray on a binder solution that glues only the
required granules together. The V-Flash printer, manufactured by Canon, is
low-cost 3D printer. It’s known to build layers with a light-curable film.
Unlike other printers, the V-Flash builds its parts from the top down.

1.2.4 Inkjet 3D Printing: -

It creates the model one layer at a time by spreading a layer of powder

(plaster, or resins) and inkjet printing binder in the cross-section of the part.
It is the most widely used 3-D Printing technology these days and the
reasons beyond that are stated below.

1.2.5 Fused Deposition Modelling (FDM):-

It is the most commonly used that is when plastic or some sort of substrate is

Heated and extruded into a thin line and moved layer by layer to create 3D
object.

1.2.6 Powder Deposition Printing (PDP):-

It is the process in which a powder or some other substrate that which looks
like a flour is used. It is a bin and a print head comes over and it is very
much like an inkjet printer but instead of ink it prints a binding agent or it
could be a binding agent with color to create a 3D print. The 3D print is
done layer by layer until a solid object is created basically glued together in

16
the powder and it is pulled out. This technology is the only one that Allows
for the printing of full color prototypes. Unlike stereo lithography, inkjet 3D
printing is optimized for speed, low cost, and ease-of-use. Minimal post
printing finish work is needed; one needs only to use the printer itself to
blow off surrounding powder after the printing process. Allows overhangs
and excess powder can be easily removed with an air blower.

1.2.7 Digital Light Processing (DLP):-

Digital Light Processing is another 3D Printing process very similar to

stereolithography. The DLP technology was created in 1987 by Larry
Hornbeck of Texas Instruments and became very popular in Projectors
production. It uses digital micro mirrors laid out on a semiconductor chip.
The technology is applicable for movie projectors, cell phones and 3D
printing. For 3D printing DLP as well as SLA works with photopolymers.
But what makes SLA and DLP processes unalike is a different source of
light. For DLP 3D amateurs generally use more conventional sources of
lights such as arc lamps. The other important piece of process is a liquid
crystal display panel, which is being applied to the whole surface of building
material during single run of DLP process. The material to be used for
printing is liquid plastic resin that is placed in the transparent resin
container. The resin hardens quickly when affected by large amount of light.
The printing speed is pretty impressive. The layer of hardened material can
be created with such printer in few seconds. When the layer is finished, it’s
moved up and the next layer is started to work on.

17
 Fig.1.1 Digital light processing (DLP)

1.2.8 Selective Laser Sintering (SLS)-

Selective Laser Sintering (SLS) is a technique that uses laser as power

source to form solid 3D objects. This technique was developed by Carl
Deckard, a student of Texas University, and his professor Joe Beaman in
1980s. Later on they took part in foundation of Desk Top Manufacturing
(DTM) Corp., that was sold to its big competitor 3D Systems in 2001. As
was stated previously, 3D systems Inc. developed stereolithography,
which in some way is very similar to Selective Laser Sintering. The main
difference between SLS and SLA is that it uses powdered material in the
vat instead of liquid resin as stereolithography does.

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 Fig.1.2. Selective laser sintering (SLS)

1.3 COMPONENTS OF 3D PRINTER

1.3.1 The Frame:-

The frames primary purpose and most important design is it must be solid.
As the head moves to and fro, the machine will shake, and if the frame is
wobbly, then accuracy suffers and eventually breaks.

Fig.1.3. Frame.

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1.3.2 Low 3D Filament Sensor:-

This is a low filament detector for 3d printer. When filament runs low it will
sound the alarm giving you time to pause or reload your filament. This item is
very simple but also very reliable, when your half way through a five hours
print and your printer runs out of filament, this will save the day. It will also
save you money by letting you use that last little bit of filament left on each roll.
It now comes with 3M VHB tape on the back so you can mount it anywhere. It
will work with 1.75 or 3mm filament, by changing a part that is included.

Fig.1.4. Filament sensor.

1.3.3 Ramps 1.4:-

Ramps can only work when connected to its mother board Mega 2560 and
4988/DRV8825. Great compatibility with most 3Dprinter (all Reprap- Mega
2560 and 4988/DRV8825). The combination of
Ramps1.4+MEGA2560+A4988/DRV8825 is becoming a mainstream of DIY
3D Printer control board.

20
 Fig.1.5. Ramps.

1.3.4 Filaments:-

This is the plastic that's consumed by the printer. It comes on a spool. Printers
use two different sizes of filament, 1.75 mm and 3 mm. There are a variety of
different materials.

Fig.1.6. Filaments.

1.4 TYPES OF FILAMENTS USED

1.4.1 ABS: -

The filament is usually stronger. It is used mostly in any sort of consumer

product like video game controller or housing our computer monitor. It can be
bend, if we try to cover or cut with the knife it will carve off in long pieces

21
rather than chip. We can counteract that by putting some hairspray on our
surface, keeping the bottom layer of abs stuck down.

1.4.2 PLA: -

It is organic. This type of filament is good for environment. Being organic it

cans biodegrade and that is also not as strong as ABS. It is more dimensionally
stable, crunchy. It can be broken easily. When we are printing something larger
on our heated bed it is much likely to contract upon itself causing edges to lift
up.

1.4.3 Extruder:-

The extruder is the core of the printer. It is where the plastic gets drawn in,
melted, and pushed out. It is essentially a fancy hot glue gun. It is small, but it is
where most of the printer’s technology is located. The extruder consists of two
parts; the hot end and the cold end. The cold end has a motor that draws the
filament in and pushes it through. The hot end is where the filament gets melted
and squirted out.

Fig.1.7. Extruder.

1.5 DIRECT DRIVE vs BOWDEN EXTRUDERS: -

On direct drive printers, the hot end and cold end are connected together, one
on top of the other. The filament goes straight down through the cold end and

22
into the hot end. With a Bowden setup, the hot end and cold end are separated.
The cold end will be stationary and bolted somewhere onto the printer’s frame.
The filament is pushed through a long tube (called a Bowden tube) to the hot
end.

1.5.1 Hobbed Gear:-

This gear bites the filament and pushes it down through the hot end.

Fig.1.8. Hobbed gear.

1.5.2 Idler Gear:-

The idler is a spring loaded wheel that pushes the filament up against the
Hobbed gear. Most printers have a way to adjust the tension on the idler, so that
it neither squeezes the filament too hard or too little.

23
 Fig.1.9. Idler gear.

1.5.3 Hot End - Heat Sink / Hot End Fan:-

This ensures that heat does not travel up the plastic and melt it prematurely
before it reaches the nozzle. This phenomenon is called heat creep and it causes
jams, especially with PLA. This fan should be running whenever the hot end is
warm.

24
 Fig.1.10. Hot sink.

1.5.4 Heater Cartridge:-

The heater cartridge is pretty self-explanatory. It heats the plastic. It is simply a
high power resistor. Almost all modern printers use cartridge heaters, but many
older printers used coils of nichrome wire (like the kind in a toaster).

Fig.1.11. Heater cartridge.

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1.5.5 Thermistor/Thermocouple/RTD:-
These are all various types of sensors for determining the temperature of the hot
end. They are essentially electronic thermometers. Thermistors are the most
common type of sensor, but some printers will use thermocouples for extremely
high temperature printing.

Fig.1.12. Thermistor.

1.5.6 Nozzle:-
The nozzle is simply a piece with a small hole for the melted filament to come
out of. Nozzles are interchangeable, and come in various sizes; 0.4 mm is
normal, while you might use a smaller nozzle for finer detail or a larger nozzle
to print faster. Nozzles can also sometimes get clogged. This is one of the most
common issues with 3D printers.

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 Fig.1.13. Nozzle.

1.5.7 Layer Cooling Fan:-

This fan cools off the plastic immediately after it is deposited by the nozzle. It
helps the object hold its shape. The slicer will turn this fan on and off under
different circumstances, depending on what material you are printing. It is not to
be confused with the heat sink fan, which cools the hot end itself and not the
printed object.

Fig.1.14. Layer cooling fan.

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1.5.8 Motion Control: - X, Y, and Z Axis:-

Cartesian printers move one or two motors along each of the X, Y, and Z
axes and the name was derived from the Cartesian coordinates system.
They typically have a rectangular build area and the printers themselves
tend to have a cube-like shape.

Fig.1.15.Cartesian.

1.5.8 Threaded Rods / Lead Screws:-

These are usually used on the printer’s Z axis. They rotate, thus forcing
nuts to move up and down. Inexpensive printers will use simple threaded
steel rods, which are essentially extra-long bolts. Higher quality printers
have smooth chrome plated lead screws designed to minimize backlash.

28
 Fig.1.16. Threaded rods

1.6 BELTS:-

Belts move things. The X and Y motors have sprockets that drive the
belts. Most printers also have some way of adjusting the tension on the
belts.

Fig.1.17. Belts.

1.7 STEPPER MOTORS:-

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Unlike regular DC motors, which rotate continuously when given power,
stepper motors rotate in increments. This gives them precise control over their
position. Most printers use NEMA 17 type motors with 200 increments (steps)
per revolution.

Fig.1.18. Stepper motor.

1.8 ENCLOSURE: -

Enclosures for 3D printing are used for safety. There are moving parts and
heating elements that users will want to protect themselves from. If you printer
does not offer an enclosure it is easy to construct your own. Something as
simple as a cardboard box could suffice.

CHAPTER-2

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 ELECTRICAL COMPONENTS

INTRODUCTION

In this chapter we are going to discuss about the electrical components of 3D

printer. The nanomaterial technology can be applied to electrical engineering as
the newest 3D printers can print electrical components for circuits. This
application would allow for the 3D printing of entire circuits and chips which
would forever change the landscape of electrical component production.

2.1 POWER SUPPLY: -

This takes the 120V AC electricity from the wall and converts it to low voltage
DC power for your printer to use. ATX Power Supplies- These are the same
power supplies used in desktop computers. They have been repurposed for
(12V, 5V, 3.3V). Voltage - some machines run 12 volt systems, while others run
24 volt systems. This becomes critical if you are going to replace components -
especially your heater cartridge or hot end. Make sure you order the appropriate
parts.

2.2 MOTHERBOARD:-

The motherboard is the brain of the printer. It takes the commands given to it
by your computer (in the form of G-CODE) and orchestrates their execution.
The motherboard contains a microcontroller (essentially a tiny, self-
contained computer) and all the circuitry needed for running the motors,
reading the sensors, and talking to your computer.

31
 Fig.2.1 Motherboard

2.3 STEPPER DRIVERS:-

These chips are responsible for running the stepper motors. They fire the coils
of the motor in sequence, causing it to move in increments. Many
motherboards have the stepper drivers built in, but some also have them in
modules that can be unplugged. By balancing the power fed to each coil, the
driver is also able to divide steps up into further increments. This is called
micro stepping, and allows more precise control over the motor than is
normally possible. The stepper driver also controls how much electrical current
is fed to the motor. More power makes the motor stronger, but also makes it
run hotter.

32
 Fig.2.2 Stepper drivers

2.4 USER INTERFACE:-

Some printers have an LCD screen so they can be controlled directly without
hooking them up to a computer. These can be basic black and white displays
like the VIKI2 or advanced Wi-Fi enabled touch screens like the matter control
touch.

Fig.2.3 User interface

33
2.5 SD CARD SLOT:-

Some printers also have an SD card slot from which they can load G-Code files.
This allows them to run independently without a computer.

2.6 END STOPS (One for Each Axis):-

The end stops are how the printer knows where it is. They are little switches that
get pushed whenever an axis moves to the end. This is how the printer finds it’s
starting point before printing. Most printers use mechanical switches, but some
are known to use optical sensors.

2.7 BED LEVELLING:-

Many printers have some kind of a system for automatically making sure that
the bed is level with the nozzle. Some do not, though, and must be calibrated
by hand. Matter Control also has the ability to account for unevenness in
software.

2.7.1 PCB Heat Bed:-The MK2A heat bed (200mm x 200mm) is a good
example of a PCB heat bed. This particular heat bed has 2 integrated LEDs
and an integrated resistor which makes it rather ‘plug and play’ when
compared to other solutions.

34
 Fig.2.4 PCB heat bed

2.8 MATERIALS USED:-

There are many materials that are being explored for 3D Printing.
However we are using PLA material for this printer .PLA are known as
thermoplastics and it became soft and mouldable when heated and return
to a solid when cooled. This process can be repeated again and again. The
ability to melt and be processed again is what has made it so prevalent in
society and is why most of the polymers you interact with on a daily basis
are thermoplastics. Its strength and temperature resistance makes it worth
the battle to print accurate and fully fused parts.

35
2.9 STORAGE:-

PLA do best if, before use or when stored long term, it is sealed off from the
atmosphere to prevent the absorption of moisture from the air. This does not
mean your plastic will be ruined by a week of sitting on a bench in the shop, but
long term exposure to a humid environment can have detrimental effects from
to the printing process and to the quality of finished parts. PLA responds
somewhat differently to moisture in addition to bubbles or spurting at the
nozzle. You may see discoloration and a reduction in 3D printed part properties.
As PLA can react with water at high temperatures and undergo de-
polymerization. While PLA can also be dried using something as simple as a
food dehydrator. It is important to note that this can alter the crystallinity ratio
in the PLA and will possibly lead to changes in extrusion temperature and other
extrusion characteristics.

2.10. SMELL: -

The smell of 3D Printer Filament while printing will vary largely from
manufacturer to manufacturer based in large part on how much degradation
occurred during production. PLA on the other hand, being derived from sugar
gives off a smell similar to semi-sweet cooking oil. While it certainly won't
bring back fond memories of home-cooked meals, it is considered by many an
improvement over hot plastic.

2.11 PART ACCURACY: -

PLA are capable of creating dimensionally accurate parts. Compared to ABS,

PLA demonstrates much less part warping. For this reason it is possible to
successfully print without a heated bed and use more commonly available
"Blue" painters tape as a print surface. Ironically, totally removing the heated
bed can still allow the plastic to curl up slightly on large parts, though not
always. PLA undergoes more of a phase-change when heated and becomes

36
much more liquid. If actively cooled, much sharper details can be seen on
printed corners without the risk of cracking or warp. The increased flow can
also lead to stronger binding between layers, improving the Strength of the
printed part

SUMMARY:-

Simplifying the myriad of factors that influence the use of one material over the
other, broad strokes draw this comparison

37
2.12 GENERAL MATERIAL PROPERTIES: -

Created from processing any number of plant products including corn, potatoes
or sugar-beets, PLA is considered a more 'earth friendly' plastic compared to
petroleum based ABS. Used primarily in food packaging and containers, PLA
can be composted at commercial compost facilities. It won't bio-degrade in your
backyard or home compost pile however. It is naturally transparent and can be
cooled to various degrees of translucency and opacity. Also strong, and more
rigid than ABS, it is occasionally more difficult to work with in complicated
interlocking assemblies and pin joints. Printed objects will generally have a
glossier look and feel than ABS. With a little more work, PLA can also be
sanded and machined. The lower melting temperature of PLA makes it
unsuitable for many applications as even parts spending the day in a hot car can
droop and deform.

2.13 CONFIGURATION SETTINGS:

2.13.1 Quality Settings:

The layer height of print is very dependent on the nozzle size of your printer as
well as the quality of the print you would like. A printer with a 0.6mm nozzle
can go up to0.4mm layer heights, and a part with 0.1mm layer heights will take
twice as long as one at 0.2mm, so these factors are important to consider. Our
standard quality print settings are at a 0.25mm layer height. We then hone in the
retraction settings for PLA.

Minimum Travel: 1.5mm

Enable Combing: All

Minimal Extrusion before Retracting: 0.005mm

38
Z Hop When Retracting: .1mm

Combing refers to the printer head following the path of the print rather than
attempting to clear gaps. This will help prevent “hairy” sides of a print. The Z
Hop when retracting is set to a small 0.1mm so that skinny prints are less likely
to be knocked off. When clicking into the advance settings tab us then take a
look at the Retraction and Quality sections of Cora. We set our retraction speed
to 10mm/s and our distance to 1.5mm. Within the quality area of the Advanced
section we do not increase the initial layer thickness but we do increase the
initial line width to 115%.We have found this to help stick to the bed without
impairing the print quality.

2.13.2 Infill Settings:-

In order for a clean PLA print, we always make sure to include a minimum of 4
bottom/top layers (meaning you would multiply layer height by at least 4).This
can increase depending on how flat the object is, how high fill density is set to,
and how thick your layer height is. A long rectangle piece with a .1mm layer
height will require over 10% infill and at least 7 bottom/top layers in order to
not have a pitted look. The print to the right had that exact issue: too small of
infill and too few bottom/top layers – leaving the print unacceptable for a final
version

2.13.3 Speed and Temperature: -

Temperatures and speeds may vary depending on the printer and hot ends you
use. Our nozzle runs at a comfortable (but slightly hotter than average) 205°-
210°C for PLA. We normally run our bed at 60°C, but since we added a thicker

39
“1/4″ glass, we have increased that to 65°C. This thicker glass allows for bed
levelling being easier as well as prevents cracks and chips. We have run PLA on
beds that do not have heating capabilities but we definitely prefer a heated build
plate. Having a glass bed heated to 65° helps prevent warping and to stop parts
from getting knocked off mid print. We run our printers a bit slower in order to
ensure the best surface quality possible. We normally set our average speed to
60mm/s, with slower settings for the outer and top/bottom layers.

In the advanced we have our speed set to:

Travel Speed: 150mm/s

Bottom Layer Speed: 25mm/s
Infill Speed: 60mm/s
Top/Bottom Speed: 40mm/s

2.13.4 Support Settings:-

We have found that support settings are one of the hardest things to dial in. Not
only does each material require a different fill amount percentage and angle,
they each also require unique distances from the print for easy removal. We
have been able to make support removal a minor chore and still have a clean
under surface quality to our prints.

Structure Type: Lines

Overhang Angle for Support: 50°

Fill Amount: 15%

Distance X/Y: 0.8mm

Distance Z: 0.16mm

40
While a brim is not always needed on PLA prints, larger prints can still warp
and skinny parts have difficulty sticking to the bed without being knocked over.
While the outside still requires post-processing to remove the close skirt, this
saves a lot of time removing brim from the inner thin parts of the print.

2.13.5 Cool: -

Finally the last section in the advanced tab is the ability to activate and tweak
the active cooling fan. We always have that checked for PLA and allow for a
20-30 second minimal layer cooling time for skinny prints and thin layers.
When the cooling fan is turned off you can have unpleasant surface quality
results – such as the photo to the right. Please note that the fan speeds depend
heavily on what fan, shroud, and hot end combination you are using.

Fan Full on at Height: .5mm

Fan Speed Min: 35%
Fan Speed Max: 75%
Minimum Speed: 10mm/s
Cool Head Lift: unchecked (unless needed for tiny complex sections)

SUMMARY: - While we have had success with these settings, there are
times when particular models and prints require minor changes to this
formula. Specific angles on print may require your support settings to be
slightly closer in the Z or X/Y direction.

41
 CHAPTER 3
ASSEMBLY INSTRUCTION

3.1 STEPS YOU NEED TO PERFORM

3.1.1 Chassis Assembly:-

For this step, take the longer extrusion profile (50cm) that should be remaining
and place it on top of the side mounts. Use a pair of square holders to fix it.
This should look like on the picture.

List of Parts:-

2 x square holders

8 x M6x12mm screws

8 x T-Nuts

1 x 50cm extrusion profile

[Provided] 1 Allen key

Fig.3.1 Chassis assembly.

42
3.2 STEPPER MOTOR ASSEMBLY:-

Start by preparing the 2 stepper motors. You will have 2 symmetrical motor
holders. One is for the right side, and the other one is the left side. Prepare
M6x12 screws and their T-Nuts. Place them inside the 2 holes near the rounded
corner of the part. Take 4 M3x8mm screws and fix the motor and the support
together. The motor support on the picture below is the Right motor support.
The stepper motor with 1.2meter lead wire is to be screwed on this support.

List of parts:-

2 motors.
4 M6 x 12mm screws.
4 M6 T-Nuts.
8 M3 x 8mm screw.
1 Right plastic motor support.
1 Left plastic motor support.
1 Allen key.
1 cruciform screw driver.

Fig.3.2 Stepper motor assembly

43
3.3 POWER SUPPLY ON THE CHASSIS:-
Power supply unit 220V – 12V 360W 30A previously assembled. Take the
Power supply support that will maintain the PSU in place.
List of parts:-
1 long clip (plastic part).
1 short clip (plastic part).
1 spool holder X 10 (plastic part).
2 M6 X 12mm screws.
2 M6 T-Nuts.
1 power supply cable.
1 screw driver.
1 Allen key.

Fig.3.3 Power supply wiring on chassis

3.4 EXTRUDER ASSEMBLY ON THE CHASSIS:-

The goal here is to place it right next to the power supply unit on the top
aluminium extrusion. If you look at the printer from the front, the power
supply should get to your right. Place the extruder so that the screws start to
get inside the slots located below the aluminium extrusion. The picture
shows you an example.

44
 List of parts:-
1 Extruder already assembled.

2 M6x12mm screws.

2 T-nuts.

1 Allen key.

Fig.3.4. Extruder assembly.

3.5 12V 220W HEAT BED WIRING:-

The assembly is very similar. We will use terminal strip to connect with the
available wires. A static relay is an electronic relay able to switch Power.
You can find different types for different voltages and different powers. In
our case 12V 220W heat bed, you will need to use a DC-DC static relay,
driven by 12V input voltage, and able to drive DC output power voltage.
This type of relay has MOSFET power transistor able to drive DC output
voltage. These have power triacs able to drive 220V alternative output
voltages.

45
 Fig.3.5.Heat bed wiring.

3.5.1 Electronic wiring: -

Electronic Wiring on Ramps 1.4 boards. 12V probe has 1 DuPont 2 pins
connector and 1 red wire left over.

Red wire left over: +12V.

Black wire: 0V- Ground.

Red wire in connector: Signal.

Fig.3.6. Wiring.

46
3.6 SCHEMATIC FOR 12V PROXIMITY SENSOR:-
On this 2nd schematic, you will find a schematic closer to what is provided
within the kit. With the induction probe, the hot end fan and the auxiliary
blower fan. On the induction probe, it is provided with 3 wires. 2 (red and
black) are connected to a DuPont 2 pin connector, and 1 (red) left alone with a
node here, is the power supply of the probe.

Fig.3.7 Schematic diagram for 12v proximity sensor

47
3.7 ADVANTAGES OF THIS SYSTEM OVER OTHER SYSTEM:-

For this system we are using PLA (Polylactic Acid) is one of the most
commonly used desktop 3D printing filaments (with the other being ABS
filament). It is the "default" recommended material for many desktop 3D
printers and with good reason - PLA is useful in a broad range of printing
applications. It has the virtue of being both odourless and low-warp, and does
not require a heated bed. PLA filament is also one of the more eco-friendly 3D
printer materials available. It is made from annually renewable resources (corn-
starch) and requires less energy to process compared to traditional (petroleum-
based) plastics. PLA has low melting point compared to ABS. Outside of 3D
printing, PLA plastic is often used in food containers. Such as candy wrappers,
and biodegradable medical implants. LA filament for 3D Printing is available in
a wide range of colours in both 1.75mm and 3mm.Print prototypes in hours,
obtain feedback, refine designs and repeat the cycle until designs are perfect.
Resources can be finding easily in markets. Cut traditional prototyping and
tooling costs. Identify design errors earlier. Reduce travel to production
facilities. Reduce Development Costs. Easy to handle and compatible in size
and shape.

3.8 DIFFERENCE BETWEEN PLA AND ABS

PLA ABS

PLA (PolyLactic Acid) is a ABS (Acrylonitrile-Butadiene Styrene)

biopolymer i.e. a biodegradable is an oil-based plastic. It is a tough
plastic. It is made from renewable raw material that can be used to create
materials such as corn-starch or robust plastic objects for everyday use.
sugarcane. For example in cars, electrical

48
 equipment or even in the popular Lego
bricks.
PLA is better suited for 3D printing ABS is more susceptible to typical 3D
beginners. printing problems such as warping.

PLA is more prone to clogging or ABS is printed at higher temperatures

jamming the printer nozzle. than PLA, which greatly reduces the
danger of clogging or jamming the
nozzle.

PLA smells somewhat sweet, like When ABS is heated it gives off a bad
waffles or candy when heated. plastic smell.

3.9 MECHANICAL AND PHYSICAL PROPERTIES:

3.9.1 PLA
It is more brittle and has a higher surface hardness. It is more prone to break
when bent. Objects made from this material can be cut, filed, sanded, painted,
and bonded using adhesives. Treating them with acetone (for improving surface
smoothness) is not possible. PLA is biodegradable – after all it is made from
plant material.
3.9.2 ABS

It exhibits a superior layer bond. Objects made from this way will be stronger
and more impact resistant. Therefore, it is better suited for mechanical parts and
for objects that need to be weather-proof. ABS parts are more flexible than PLA
parts and tend to bend rather than break when under pressure. ABS is better
malleable, post processing is easier. The printed object can be cut, filed, sanded,
painted, and bonded and they can be treated with acetone to get a smooth and

49
shiny surface or to weld two objects together. ABS is not biodegradable but can
be easily recycled.

3.10 APPLICATIONS

PLA is widely used in 3D printing, e.g. for household items, gadgets, and toys.
It is better suited when flexibility is not your major requirement as it is more
prone than ABS to break under pressure. On the other hand, it is biocompatible
with the human body and can be used for objects that are worn on the skin. Due
to its relatively low glass point, PLA is unsuitable for objects that are subject to
heat. When exposed to 60ºC or more for some time, it loses its shape. PLA is
stable in general atmospheric conditions and will biodegrade within 50 days in
industrial composters and 48 months in water. PLA is regularly used for the
production of food related items; however confirmation by the filament
manufacturer that it is safe to do so is recommended. PLA is ideal for 3D prints
where aesthetics are important. Due to its lower printing temperature is easier to
print with and therefore better suited for parts with fine details.

SUMMARY: -

In this chapter we studied about the assembly of the 3D printer and some
applications of the PLA filament. How it is more effective over ABS filament
and we mention some difference between PLA and ABS filament. So you can
easily identify why we choose PLA filament for this 3D printer.

50
 CHAPTER-4
FABRICATION OF 3D PRINTER

Fig.4.1 Top view of the 3D printer

Fig.4.2 Horizontal rod with motor.

51
4.1 TABLE TOP LOW COST 3D PRINTER

Fig.4.3.Developed 3D printer.

52
4.2 COST ESTIMATION

List of Components Price (Rs.)

Control board combo set 2000.00

Arduino mega 2560 800.00
Pcb heat bed (MK2A) 800.00
Power supply 12v dc 1500.00
100K Thermistors 70.00
Chrome plated smooth rod(8mm) 1500.00
Threaded rod set M8(300mm) 200.00
Nozzle(0.4mm) 100.00
Solid cube extruder 2000.00
Ramps1.4 700.00
Lcd controller 900.00
Quick connect pneumatic fitting 100.00
Limit switch 50.00
GT2 timing belt(6mm) 120.00

Ceramic heating catridge12v 130.00

PTFE tube (1.75mm) 150.00

MK8 direct drive gear 150.00

4 pin flat connector 60.00

Power cable 100.00

2 pin flat connector 40.00

USB cable 100.00

Mini fan 12v(25*25mm) 170.00

Heat sink 30.00

Stepper motor 28Ncm 1000.00

53
Raspberry pi camera board 1300.00
Arduino CNC shield V3 400.00
SCS8UU bearing 180.00
LM8LUU 8mm bearing 100.00
625 2RS bearing 25.00
Flexible coupling 8mm*10mm 170.00
Allen key set 40.00
M5 Allen head/socket head bolts 100.00
M3 grub screw 20.00
8mm shaft support(SK8/SMA8) 170.00
Compression spring 30.00
Torsion spring 30.00
GT2 timing pulley AL 130.00
2020 t slot AL extrusion 350.00
Eccentric spacer 30.00
SD card adapter 170.00
Zip ties 2.2mm(150mm width) 50.00
PLA filament 1.75mm 1500.00
Kapton tape 12mm 250.00

18000.00 approx.
Total

54
 CHAPTER 5

CONCLUSION

In this project, a low cost table top 3D printer is custom built wherein PLA
filament is extruded to form a layer upon layer fabrication of prototypes. The
detailed investigation of PLA filaments and deposition gave an insight on 3D
printing of parts with greater dimensional accuracy. The integration of
thermistors and thermocouple sensors, linear actuators, belt drives and extruder
into arduino controller provided a glimpse on electronic assembly of 3D printer
and its fabrication. Assembled electronic units and extruder are tested for the
given tool path generated from CAD environment. It is evident that, the
developed 3D printer is able to produce parts with desired strength and
dimensional accuracy.

55
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2. Maintaining and Troubleshooting Your 3D Printer by Charles
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3. Mastering 3D Printing (Technology in Action) by Joan Horvath Paperback
4. Design for 3D Printing: Scanning, Creating, Editing, Remixing, and Making
in Three Dimensions by Samuel N. Bernier Paperback
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frequency Plasmon’s in metallic mesostructures. Phys. Rev. Lett. 76, 4773
(1996).
6. Pendry, J. B., Holden, A. J., Robbins, D. J. & Stewart, W. Magnetism from
conductors and enhanced nonlinear phenomena. IEEE Trans. Microwave
Theory Tech. 47, 2075–2084 (1999).
7. Smith, D. R., Padilla, W. J., Vier, D. C., Nemat-Nasser, S. C. & Schultz,
S. Composite medium with simultaneously negative permeability and
permittivity. Phys. Rev. Lett. 84, 4184 (2000).
8. Shelby, R. A., Smith, D. R. & Schultz, S. Experimental verification of a
negative index of refraction. Science 292, 77–79 (2001).
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