Design and Fabrication of Dual Extruder Three D printer

Project Title

Design and Fabrication of Dual Extruder Three D printer

Project Area of Specialization 3D/4D PrintingProject Summary

When it comes to manufacturing, 3D printing is one of the
driving technologies of the 21st century that has huge potential and very low investment risks.FDM technology is been used as the adopted process. Three-dimensional printing or additive manufacturing is a process of producing three-dimensional solid objects using design software. Nozzle limitations for simultaneous usage and relatively low printing speeds are the major problems of fused deposition modeling (FDM).

In this project, an extrusion model with two separate nozzles is used to reduce deficiencies. The proposed 3D Printer model permits printing with twin different colors and
materials simultaneously without ending the operational process while switching the filaments.

• The major advantage of the proposed model is that the two nozzles work separately which means the bigger part can be created by distributing the work to both nozzles to create a single object.
• The secondly proposed extrusion model provides the ability to work two operations at a single time on a single 3D printer. This proposed model is very helpful for domestic as well for industrial purposes, it means not required to invest in another 3D printer.

Project Objectives

The main objective/outcomes for the above project are as follows

• To operate two different products at the same time on a single 3D printer.
• To reduce the time for creating two different or same objects.
• The cost is less than two 3D printers. 
• Both nozzles have their own degree of freedom.
• To use two different color filaments at a single time to create two objects.

Project Implementation Method

After a thorough market survey, we come to a conclusion that 3D printers available in the market are priced around Rs.
80,000 – Rs. 11,00,000 due to the type of supporting material used, accuracy, and printing area size. Firstly, we will do calculations and then design our 3D printer entirely in 3D modeling software like SOLIDWORKS.

In a mean, we will also continue our research The main object of research is to develop a printer that is cost-effective and to encourage manufacturers to adopt the method of 3D printers like two separate extruders.

After that, we will do the machining operations required to cut out the aluminum frame and drill to assemble the frame body. For making a complete model we will assemble all the parts like stepper motors, rods, bed, extruder e.t.c with the frame. Then in order to print 3D parts, we will select slicing software which will give command of 3d printing to the controller board

Current 3D printers available in the market come with only a single nozzle and 2 nozzles but it’s not free to move
separately. Also, it takes more time to create any product. if we sell objects which are created on 3D printers then the
seller required more products to sell, but The 3D printer takes more time to create a single object. Also, he required another
printer whose cost is the same as 1st 3D printer. It means he will need to invest more money.

Here in our project, we will design The 3D printer which comes with 2 separate working extruders and its own degree of freedom. Also, these 2 nozzles create any objects or prototypes on the same platform at the same time without stopping or waiting for another one. It reduces the time to make 2 objects. Also, in this setup, the heat bed is also bigger in size to create a large-size object.

Its design and fabrication are the same as a normal 3D printer but the changes are, that we decided to add one more nozzle to operate separately. In the normal 3D printer, single
the nozzle comes with its own degree of freedom to operate in any direction. Also, its bed is move-in 1 degree of freedom i.e. forward and backward in directions. But we add one more nozzle which is also come with a free degree of motion and moves in all directions like 1st nozzle.

This helps to make any objects on a single platform, also it reduces the time which is required in the single nozzle to create the different products on the same 3D printer. We can use different color filaments at the same time by putting them inside the 2 nozzles while performing on the same object or on different objects
 

Benefits of the Project

This project covers a lot of applications in the industrial and commercial sectors, but some of the major benefits of this project based on which this project is chosen are

• 3D printing is an energy-efficient technology that can employ up to 90% of standard materials, and therefore, create less waste as compared to other manufacturing processes.
• Originally, additive manufacturing was used mainly to create prototypes quickly and cheaply. However, we’re now seeing a shift towards this method being used for manufacturing mass products. That’s where it has the power to transform business models. The massive technological advancements that have taken place mean this tech now has the potential to disrupt the manufacturing industry across almost every sector – from food to aerospace – and replace traditional manufacturing methods.
• 3D printing is one of the major emerging technologies businesses can use for good. Switching traditional manufacturing processes to additive manufacturing (3D printing) has the potential to significantly reduce the impact manufacturing has on the planet – while having the added bonus of also being good for the bottom line.  
• A three-dimensional printer equipped with two extruders can print even faster than a 3D printer with only one. This is because you don’t need to exchange filaments during printing. A dual extruder printer enables you to make objects in two-tone or with two colors. The ability of the dual extruder printer to keep printing instead of requiring you to stop and replace the filament if the design asks for a different color also lessens the risk of getting burned or electrocuted while changing filaments.
• Having two extruders in your 3D printers means that one is usually the primary extruder that performs the main functions while the other one is there for support. But when the primary extruder breaks down, the secondary extruder can step in and continue the printing task.
• Another benefit is the way it can improve the share of GDP that is derived from industry, by allowing more economies access to the tools necessary to manufacture complex products. It also increases access for small-scale producers – by making the capital cost of manufacturing complex products lower. 

Technical Details of Final Deliverable

Basic technical parameters of designed dual head:

• Printing method: FDM
• Printing size: 400 x 400 x 500 (mm)
• Max. print speed: 150 mm/s
• Layer thickness: 0.1–0.4 mm
• Weight of head about: 1.5 [kg]
• Head dimensions (H x W x D): 90 x 100 x 75 [mm]
• Distance of nozzles: 10 [mm]
• Used nozzles diameter: 0.4 [mm]
• Range of temperature regulation
• power supply 12V/24V
• Stepper motors-NEMA

(Independently for each nozzle) 70 – 270 [°C]

• Input power of heaters 2 x 40 [W]

So the final deliverable contains.

• Printer frame aluminum A20x40mm
• stepper motors with wider pulleys and rods
• power supply
• 8-bit microcontroller board
• display screen
• filament-PLA/ABS
• Heating bed and Pad

Final Deliverable of the Project Hardware SystemCore Industry ManufacturingOther Industries Education , Medical Core Technology 3D/4D PrintingOther Technologies RoboticsSustainable Development Goals Good Health and Well-Being for People, Quality Education, Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Sustainable Cities and Communities, Responsible Consumption and ProductionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	66400
Aluminum frame A20X40	Equipment	7	500	3500
Extruder	Equipment	2	450	900
Hotened	Equipment	2	5000	10000
Cooling fan	Equipment	2	300	600
Printing Bed	Miscellaneous	1	2000	2000
Heating pad	Equipment	1	4000	4000
Filament-PLA	Miscellaneous	2	3000	6000
Smooth rods	Equipment	4	500	2000
Screw rods	Equipment	2	600	1200
belt-6mm	Equipment	1	1500	1500
idler pulleys	Equipment	4	200	800
stepper motors	Equipment	7	2000	14000
3D parts	Miscellaneous	1	2000	2000
Power supply	Equipment	1	3500	3500
8-bit microcontroller board	Equipment	1	10000	10000
switches	Equipment	3	200	600
joints and screws	Equipment	8	100	800
Display screen	Equipment	1	3000	3000