Proceedings of National Conference on Technological Developments in Civil and Mechanical Engineering (NCTDCME-18)

SPVP,S.B. Patil College of Engineering, Indapur

JournalNX- A Multidisciplinary Peer Reviewed Journal (ISSN No: 2581-4230)
15th -16th March- 2018
DESIGN AND DEVELOPMENT OF 3D PRINTER
Saurabh Rajaram Wagh Shubham Krushna Gajbhiye
Mechanical Engineering S.B.P.C.O.E Indapur , India Mechanical Engineering S.B.P.C.O.E Indapur , India
[email protected] [email protected]

Shivkumar manohar masalge Sachin C. kulkarni

Mechanical Engineering S.B.P.C.O.E Indapur , India Assistant Professor S.B.P.C.O.E Indapur , India
[email protected] [email protected]

Abstract: This is a research paper on 3D printing which II. LITERATURE REVIEW

has become a notable topic in today’s technological 3D printing technology was 1 st invented by Charles Hull in
discussion. 3 D printing is a form of additive 1984, he gives the name to this technique as stereo
manufacturing technology where a 3 D object is lithography. This technology had become popular in
created by laying down successive layers of material it 1990’s and others technology where introduced like fused
is also known as rapid prototyping, it is a mechanized deposition molding and selective laser sintering. In 1993
method where by 3D objects are quickly made on MIT Institute of technology was change the name from
reasonably sized machine connected to a computer stereo lithography to 3D printing technology. In 1996
containing blue prints for the objects. Here in this three major products where introduced by three different
technology 3 steps are included such as Designing, companies such as “Genisys” from “Stratasys”, “Actua
Printing and Finishing. In 1 st step we use any CAD 2100” from 3D system and “Z402” from z corporation [2].
software to create 3D design in 2 nd step 3D printer Winsun uses a massive printers 490’*33’*20’ to print
create an object using this design. And 3 rd step finished pieces of houses in a factory and then assembles them on
object is removed from printer. This technology saves sites, winsun makes the houses using recycled
time and cost, it saves wastage of material. It has the construction materials, industrial waste which are then
potential to radically transform many design, reinforced with fiber glass and, most impressively, winsun
production and logistic processes. has printed ten houses in less than a day, each measure in
200 sq.meters and costing less than 5000$.the company
Keywords: 3DPrinter, Rapid Prototyping, Successive even constructed it’s own 10,000 sq.meter office in month
Layer, Fused Deposition Modeling using assembly line of four 3D printers [3].
Engineers at the University of Southampton design and
I. INTRODUCTION -y the world’s 1st 3D-printed aircraft. This unmanned
3D printing technology means 3 dimensional physical aircraft is built in seven days for a budget of £5,000. 3D
object creating process also known as additive printing allows the plane to be built with elliptical wings, a
manufacturing processes. Here in this technology 3D normally expensive feature that helps improve
printer creates an object by laying down the material on aerodynamic efficiency and minimizes induced drag
the platform of printer until the desired object is formed. For Ecologic unveils Urbee, a sleek, environmentally
In this melted material or powder used to create object. friendly prototype car with a complete 3D-printed body at
Printing is nothing but the process of producing text or the TEDxWinnipeg conference in Canada. Designed to be
images. This technology mostly used in the industry to turn fuel efficient and inexpensive, Urbee gets 200 mpg
ideas into reality. This is leading technology now a day’s highway and 100 mpg city. It is estimated to retail for
which attracts the educated students and industries [8] $10,000 to $50,000 if it becomes commercially viable.
Manufacturing, a fundamental industry provide people materialize becomes the 1st 3D printing service
with daily used products and services, has been revitalized worldwide to offer 14K gold and sterling silver as
in recent years[6]. Under the fused deposition modeling materials potentially opening a new and less expensive
technique in which a plastic filament is melted by a nozzle manufacturing option for jewelry designers
and placed layer by layer on the table where the part is III. METHODOLOGY
build from the bottom up[4]. The printing based on fused The methodology that was followed in his case study
deposition modeling (FDM) using thermoplastic is was to first identify and understand the problem of having
particularly widespread because of simplicity and brand new 3D printer. Some background research
potential ability of the method. However, the mechanical technology together with AR was done to understand the
properties of metal fabricated by conventional FDM 3D state of art and capability of each of them.
printing are inherently poor because of thermoplastic
resins used, the mechanical properties of thermoplastic a) Fused Deposition Modelling
resin parts of 3D printing has primarily been used for trial It was developed by strat a sys in Eden Prarie Minnesota.
products or toys, the application of 3D printing to obtain In this process, a plastic or wax material is extruded
mechanically strong components for aerospace and through a nozzle that traces the part cross sectional
automotive structure is a major goal of industrial geometry layer by layer. FDM is a second most widely used
fabrication.[9] rapid prototyping technology, after steriolithography. A
plastic filament is unwound from a coil and supplies
material to an extrusion nozzle. The nozzle is heated to
melt the plastic and has a mechanism which allows the

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 Proceedings of National Conference on Technological Developments in Civil and Mechanical Engineering (NCTDCME-18)
SPVP,S.B. Patil College of Engineering, Indapur
JournalNX- A Multidisciplinary Peer Reviewed Journal (ISSN No: 2581-4230)
15th -16th March- 2018
flow of melted plastic to be turn ON and OFF. The nozzle is Step (1) :- Computer Aided Design
mounted to an X-Y plotter type mechanism which traces In this process the CAD file is created using a 3D
out the part counters; there is second extrusion nozzle for modelling programme, either from scratch or beginning
the support material (Different from the model material). with a 3D model created by a 3D scanner .
As the nozzle is moved over the table in required The program creates a file that is send to the 3D printer
geometry, it deposits a thin bed of extruded plastic to form along the way software slices the design into hundreds, or
each layer. The plastic hardens immediately after being more likely thousands of horizontal layers. This layers will
squirted from the nozzle and bounce to the layer below. be printed one a top the other until the 3D object is done.
The object is built on mechanical stages which moves Many programs are used for designing 3D objects such as
vertically downward layer by layer as the part is formed. solid works, AutoCAD and have a steep learning curve,
The entire system is contained within a chamber which is there are number of other programs, many free that are
held at a temperature just below the melting point of the easy to learn the free version of goggle sketch up, for
plastic support structure are automatically generated for example is very popular for it is ease of use and the free
overhanging geometry and later removed by breaking blender program is popular for its advanced features.[1]
them away from the object. A water-soluble support
material is also available for ABS parts. A range of Step(2):- Motoring
materials are available including ABS, polymide and The operating of 3D printer requires motoring with
polycarbonate. [3] low torque, high accuracy the best motor to do this
function is stepper motor, ’is an electromagnetic device
that converts digit pulses into mechanical shaft rotation.
advantages of step motors are low cost, high reliability
high torque at low speed and a simple they are special type
of synchronous motors which are design to rotate specific
number of degrees of every electric pulses received by its
control unit, attraction of degree could be done using gears
in order to move the printer head a specific displacement
,in 3D printer four stepper motors were needed to do the
specific function, three of them were used for moving in
X,Y,Z direction of the printer head, the fourth one was
needed to move the plate(Bed).[1]

Step(3):- Processing
The AM335x microprocessors are enhanced with
image, graphics processing and industrial interface
Fig. Fused Deposition Modelling (FDM) Process options. The device supports the following high level
operating system (HLOSs), The AM335x microprocessor
IV. WORKING PROCESS contains this sub systems. 1) Microprocessors unit (MPO).
2) Graphics accelerator sub system for 3D graphics
acceleration to support display.[1]

Step(4):- MOSFET drive

By polar stepper motor with MOSFET drive which
will allows the motor to move in both direction, since
stepper motor is one loop system, high accuracy
components will used in order to print in the specific space
so that MOSFET was used, because it has the fast frequency
operations.[1]

V. ADVANTAGES
1. High strength of part: with ABS plastic as a
material, FDM process can fabricated fully
functional parts that have the strength equal to
90% of the actual injection of moulded part.[1]
2. Temperature Stability: The FDM process
produces the parts which are stable over the wide
temperature range.[6]
3. Easy support Removal: In FDM process the
supports can be easily broken or dissolved during
Fig. Steps in 3D Printing post processing.[5]
4. Minimum Material Wastage: In FDM process the
parts are build by extrusion process, only that
much material is used during extrusion which is
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 Proceedings of National Conference on Technological Developments in Civil and Mechanical Engineering (NCTDCME-18)
SPVP,S.B. Patil College of Engineering, Indapur
JournalNX- A Multidisciplinary Peer Reviewed Journal (ISSN No: 2581-4230)
15th -16th March- 2018
required to build a part therefore, the wastage of
material is at minimum level.[7]
5. Safe Operation: In FDM process there is no use of
laser hence it is a safe operation.[4]

VI. LIMITATIONS
1. Limited Accuracy of Parts: The material used
in FDM process is in the form of filament.[2]
2. Slow Building Process: Speed of FDM process
is restricted by the rate of extrusion of material
from nozzle.[1]
3. Poor shear stress of parts: The part build by
FDM process are weak direction
4. perpendicular to built axis i.e. shear
strength.[3]
5. Possibility of Shrinkage and Distortion
The extruded material cool rapidly on
deposition, Hence there is danger of shrinkage
and distortion of the parts.[11]

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1877050915036674
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2212827116000706
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IJMET_07_03_036/IJMET_07_03_036.pdf
9. https://www.researchgate.net/publication/2978963
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10. https://www.nature.com/articles/srep19207?proof=
true
11. https://www.nature.com/articles/srep09875
12. https://individual.troweprice.com/staticFiles/Retail/
Shared/PDFs/3D_Printing_Infographic_FINAL.pdf

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