Fabrication of Layer Fused Three D Printer

Project Title

Fabrication of Layer Fused Three D Printer

Project Area of Specialization 3D/4D PrintingProject Summary

The project is about fabrication of 3D Printer. We are interested in creating 3D printers locally and economically in Pakistan for the development and advancement of manufacturing sector of Pakistan.

Our project is a startup base project, we are interested to establish a startup around our project. We have the aim to manufacture 3D Printers, 3D Printer filaments, injection molding machines, extruder machines, filament machines, cnc machines, laser printing machines locally and economically in Pakistan.

3D printing, also known as additive manufacturing, is a method of creating a three dimensional object layer-by-layer using a computer created design.

3D printing is an additive process whereby layers of material are built up to create a 3D part. This is the opposite of subtractive manufacturing processes, where a final design is cut from a larger block of material. As a result, 3D printing creates less material wastage.

3D printing is a form of additive manufacturing technology where a three dimensional object is created by laying down successive layers of material. It is also known as rapid prototyping, is a mechanized method whereby 3D objects are quickly made on a reasonably sized machine connected to a computer containing blueprints for the object. 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 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.

Additive manufacturing process or 3D printing process is now becoming more popular because of its advantages over conventional processes. A 3D printer is a machine that create objects out of plastic, nylon like many other materials.3Dprinters now days available are not so portable and also they are very costly. By analyzing this problem, we are trying to make a portable 3D printer The cost of this printer will be very less compared to other 3D printers. Making low cost 3Dprinter with price 15% lower than market.

Project Objectives

Our objective is to build a user friendly, low powered 3D printer which can print different variety of complex parts, and then work on it to make it available at the Industrial scale in Pakistan. We have chosen i2M4 as our model because of its simplicity, small size, high accuracy, inexpensive parts, and smartness which makes it as the most useable 3D Printer ever in the 3D Printing industry.

The targeted size of our printer and printing volume is 200mm cube which we have achieved 100%.

The primary goal of this project is to design a 3D Printer.

Make it SMEA where the Designers like me can share their ideas to help society through designing 3D Printers,

Turn it into a complete working company where the designers like me can design 3D Printers for helping the society in different fields.

Additive manufacturing process or 3D printing process is now becoming more popular because of its advantages over conventional processes. A 3D printer is a machine that create objects out of plastic, nylon like many other materials.3D printers now days available are not so portable and also they are very costly. By analyzing this problem, we are trying to make a portable 3D printer The cost of this printer will be very less compared to other 3D printers.

- Making low cost 3D printer with price 15% lower than market

- To print complex and intricate parts

- To build large printing volumes accurately

- To solve the problems of bed leveling

The benefits of the project are the fabrication of 3D Printer locally and economically in Pakistan. We are interested in creating 3D printers locally and economically in Pakistan for the development and advancement of manufacturing sector of Pakistan. Our project is a startup base project, we are interested to establish a startup around our project. We have the aim to manufacture 3D Printers, 3D Printer filaments, injection molding machines, extruder machines, filament machines, cnc machines, laser printing machines locally and economically in Pakistan.

The locally manufacturing of 3D printer and related machines can boost up the Pakistani manufacturing sector and hence can boost of economy of the Pakistan. The economic and local presence of 3D printers in Pakistan will provide opportunity to the students and people interested in 3D Printing a chance and hence they can get a lot of benefits from it ranging from prototyping to dental, from medical to architecture, from manufacturing to aerospace.

Project Implementation Method

The first step is to select one of the additive manufacturing process among many process of 3D printing our is FDM. Then an appropriate mechanism is selected for X, Y and Z axis movements, considering various factors such as cost of fabrication, simplicity of design, synchronization, accuracy etc. Once the mechanism is selected the next step is integration of electronics and software then the machine is designed and fabricated. The last step is, synchronization of mechanical, electrical and software elements of the machine. The FDM technology is clean, simple to use and it is environmentally stable. Complex shapes and intricate parts can be printed. FDM is at the very entry of the market as it mainly used by individuals. FDM is an affordable 3D printing process compared to other 3D printing technologies. Presently mechanisms such as, for example, SCARA, Cartesian, Polar, Delta and so on are utilized as a part of development of FDM 3D Printers. We have chosen cartesian arrangement of developments, where the bed moves in the vertical heading i.e., in Z pivot bearing and the extruder spout moves horizontal way i.e., both in X and Y hub course. Z hub development on such a 3D printer is extremely exact and requires low increasing speeds, however the bed should be lightweight with a specific end goal to look after precision, which makes it harder to include a completely programmed bed leveling framework. Controlling a straight Cartesian framework like this is mechanically straightforward and furthermore generally simple from a product point of view, which is the reason most 3D printers available today utilize this kind of plan. The Cartesian arrange frameworks has for quite some time been utilized for instruments like plotters, CNC processing machines, and 2D printers 3D Printer electronics are controlled by an inexpensive CPU such as the Atmel AVR processor. Atmel processors are what Arduino-based microcontrollers use. These processors are exceptionally weak contrasted with even the normal laptop you find in the landfill these days. However, so they do run primitive software. This primitive software they run is the firmware. The entire software chain that makes the 3D Printer work, the firmware portion of it is the closest you get to actual programming. In fact, the term for what you are doing with firmware is called cross compiling.

Benefits of the Project

3D printing-based manufacturing offers a lot of benefits compared to traditional manufacturing methods. These include those related to design, time, and cost, amongst others.

3D printing allows for the design and print of more complex designs than traditional manufacturing processes.

3D printing can manufacture parts within hours, which speeds up the prototyping process. This allows for each stage to complete faster. When compared to machining prototypes, 3D printing is inexpensive and quicker at creating parts as the part can be finished in hours, allowing for each design modification to be completed at a much more efficient rate.

Print on demand is another advantage as it doesn’t need a lot of space to stock inventory, unlike traditional manufacturing processes. This saves space and costs as there is no need to print in bulk unless required.

The 3D design files are all stored in a virtual library as they are printed using a 3D model as either a CAD or STL file, this means they can be located and printed when needed. Edits to designs can be made at very low costs by editing individual files without wastage of out-of-date inventory and investing in tools.

The main 3D printing material used is plastic, although some metals can also be used for 3D printing. However, plastics offer advantages as they are lighter than their metal equivalents. This is particularly important in industries such as automotive and aerospace where light-weighting is an issue and can deliver greater fuel efficiency.

Also, parts can be created from tailored materials to provide specific properties such as heat resistance, higher strength, or water repellency.

Depending on a part’s design and complexity, 3D printing can print objects within hours, which is much faster than molded or machined parts. It is not only the manufacture of the part that can offer time savings through 3D printing but also the design process can be very quick by creating STL or CAD files ready to be printed.

3D printing is being used in the medical sector to help save lives by printing organs for the human body such as livers, kidneys, and hearts. Further advances and uses are being developed in the healthcare sector providing some of the biggest advances from using the technology.

Technical Details of Final Deliverable

The design of the model has to be done in software where the actual model

with the required dimensions is developed so that it can be used to print the model.

To develop and fabricate thmodel there are many process and parameters involved

mainly design of the model. The design process started by keeping the print

volume as a basic design parameter. As the objective of the project is the

construction of economical and sizable 3D Printer, a print volume of 200 x 220 x

220 mm3 is selected. The 3 – Dimensional motion is achieved by synchronization

of movements in X, Y and Z directions. Hence mechanism of our 3D Printer is Z

plus core XY. This mechanism uses 5 stepper motors, one for X-axis movement, one for Y-axis movement

(to and fro movement), two for Z-axis movement (Vertical movement) and one for

Extruder filament. This mechanism uses the single motor to control lead screws to

which the print bed is connected to the movement in Z – direction. The lead screws

are driven by the motor which in turn moves the bed in the vertical direction. Two

motors have been used here because the print volume is large, there will be a

disruption in the movement if only a single motor is used. The conceptual design

has been initially visualized in Sketch-up software.

Selection of Motor for X and Y axis

Assumptions:

Constant speed of the motor = 400rpm=6.667rps v = r ?

= [2?N]/60

= 41.908rad/s

Therefore;

400 = r*41.908 r = 9.547mm Torque = Force*Radius

Force = 41.87N (considering NEMA 17 stepper motor having torque = 0.4Nm)

X – axis Movement

 Figure 6.3 shows the rendered CAD model of the mechanism of Lateral

movement. It consists of the pulleys, timing belt ,carriage, cylindrical rods, and

extruder nozzle (used in FDM process) arranged as shown.

The rotary motion of motor is converted into linear sliding motion by

timing belt – pulley connection as shown. The X – axis rods are fixed to the

carriages with the help of holes in side face of the carriages.

Build Volume 200L x 220W x 220H mm3

Method Fused Deposition Modeling

Layer Resolution Height 55 microns

Number of Extruders One

Machine Size 400mm(L) x 400mm(W) x 400mm(H)

Machine Weight 8Kg

Power Supply DC 12V, 5amp

Power Consumption 250v, 50-60Hz, 5amp, 600W

Connectivity USB,

Filament Diameter 1.75mm

Nozzle Diameter 0.4mm

Filament Material PLA, ABS,

Print File Type Gcode, STL, Obj

Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther Industries IT , Medical , Petroleum , Agriculture , Food , Energy , Finance , Transportation , Others Core Technology 3D/4D PrintingOther Technologies Internet of Things (IoT), Robotics, Shared Economy, Wearables and Implantables, Others, Clean TechSustainable Development Goals Zero Hunger, Good Health and Well-Being for People, Quality Education, Gender Equality, Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Reduced Inequality, Sustainable Cities and Communities, Responsible Consumption and Production, Life on Land, Partnerships to achieve the GoalRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
Sprial Pipe 8mm	Equipment	1	250	250
12864 Graphics Disply	Miscellaneous	1	2000	2000
20x20 Corner Bracket	Equipment	10	40	400
20x20 220mm Extrusion	Equipment	4	385	1540
20x20 400m Extrusion	Equipment	1	700	700
20x40 40m Extursion	Equipment	4	900	3600
40x40 400m Extrusion	Equipment	2	1600	3200
2RS Bearings	Equipment	1	40	40
3x8m B1	Equipment	10	1	12
Bed Springs	Equipment	6	10	60
400m Rod 8m	Equipment	6	200	1200
Lead 8mm 350	Equipment	2	1000	2000
GT2 20TC	Equipment	2	180	360
Ideal Pully	Equipment	1	350	350
12V 250W Supply	Equipment	1	1400	1400
Hotend + Board	Equipment	1	1600	1600
4m T Nut	Equipment	100	8	800
Coper 5x8	Equipment	2	250	500
Z left and right	Equipment	1	2000	2000
Limit Switch	Equipment	3	120	360
Extrusion, Motor, Bearing	Equipment	1	1400	1400
Stepper Motor	Equipment	5	450	2250
GT2 Bearing	Equipment	2	200	400
M4x8 Screw	Equipment	100	1	120
M3 Srew	Equipment	100	3	300
A4988	Equipment	5	180	900
220x220 Bed	Equipment	1	1700	1700
PLA Fileament	Equipment	1	3400	3400
Glass Plate	Equipment	1	100	100
Binder Clip	Equipment	4	15	60
Fott Rensher	Equipment	4	20	80
L Brecket	Equipment	4	100	400
T Bracket	Equipment	3	100	300
3D Part	Equipment	1	650	650
LM8W	Equipment	3	120	360
SCS 8VV	Equipment	4	350	1400
2004 LCD	Equipment	1	1200	1200
5Pcs 3D Printer CNC Stepper Motor cables 4pin to 6pin connector wire	Equipment	2	598	1196
Brushless DC Blower Fan Ultra Quiet Cooling Fan 2 Wires 5015S 12V 0.14	Equipment	1	389	389
2 Pin Jumper Connector	Equipment	30	5	150
2.54mm 2-Pin Dual Female to Female Connector with 350mm Wire	Equipment	7	15	105
2.54mm 4-Pin Dual Female to Female Connector with 350mm Wire	Equipment	7	28	196
Thermistor New type plug-in aircraft head NTC 100K	Equipment	3	510	1530
New 4010 DC 12V Cooling Fan 40x40x10mm Exhaust Heat sinking DC Ventila	Equipment	2	140	280
1.75mm Black Color 1KG PLA 3D Printer Filament	Equipment	1	2600	2600
2.54mm 4-Pin Male connector with Female Plugs	Equipment	3	20	60
2.54mm 2-Pin Male connector with Female Plugs	Equipment	3	10	30
2.54mm 6-Pin Male connector with Female Plugs	Equipment	3	30	90
Long Distance Bowden V6 Metal Hotend Extruder 1.75mm with Cooling Fan	Equipment	1	1600	1600
Aluminum improved Extruder feed Remote MK8 Left	Equipment	1	1200	1200
0.6mm Mk3 Brass Nozzle for 3D Printer	Equipment	1	150	150
0.5mm Mk8 Brass Nozzle for 3D Printer	Equipment	1	150	150
0.4mm Mk8 Brass Nozzle for 3D Printer	Equipment	1	150	150
RAMPS 1.4 Printing Control Board Arduino Mega Shield for Reprap Prusa	Equipment	1	650	650
1 meter 2 Core Twisted Hard Jumper Wires Cable	Equipment	10	25	250
4-Pins PCB Mount Removable Terminal Block Right Angle	Equipment	4	25	100
1.0mm Mk3 Brass Nozzle for 3D Printer	Equipment	1	150	150
0.8mm Mk3 Brass Nozzle for 3D Printer	Equipment	1	150	150
Nozzle Throat for Extruder RepRap 1.75mm 3D Printer M6x25	Equipment	1	200	200
LM6UU 6mm Linear Ball Bearing Bush Bushing	Equipment	8	190	1520
1.75mm Green Color 1KG ABS 3D Printer Filament	Equipment	1	2600	2600
8mm T8 Lead Screw 2mm Pitch Ball Nut For CNC & 3D Printer	Equipment	2	150	300
Nozzle Throat for Extruder RepRap 1.75mm 3D Printer M6x25	Equipment	1	200	200
LM8UU 8mm Linear Ball Bearing Bush Bushing	Equipment	8	250	2000
1.75mm Green Color 1KG PLA 3D Printer Filament	Equipment	1	2600	2600
1.75mm Green Color 1KG PLA 3D Printer Filament	Equipment	1	2800	2800
3D Printer Controller Board RAMPS 1.4 Arduino Mega Shield RepRap Prusa	Equipment	1	500	500
A4988 Stepper Motor Driver	Equipment	10	120	1200
Arduino Mega 2560 with Cable in Pakistan	Equipment	1	1800	1800
m3x8 screw	Equipment	50	2	100
m3x10 screw	Equipment	50	3	150
m3x12 screw	Equipment	50	4	200
m3x15 screw	Equipment	50	5	250
m3x20 screw	Equipment	50	6	300
m3x25 screw	Equipment