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    4001,4130 Batch 15

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    jvanandh
    This document discusses the design and development of an affordable 3D printer. The proposed design includes a carriage and roller drive system on aluminum extrusions. This design aims to provide a compact, portable 3D printer with features like auto bed leveling and no filament blockages. The design can be customized and upgraded. Calculations are provided for motion system components like carriages, rollers, lead screws. Designs of subsystems like the extruder head, heated bed and direct drive filament feed are also detailed. The document outlines the timeline and concludes this design will provide an affordable option for customized digital fabrication.

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    © All Rights Reserved
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    4001,4130 Batch 15

    Uploaded by

    jvanandh
    67 views41 pages
    This document discusses the design and development of an affordable 3D printer. The proposed design includes a carriage and roller drive system on aluminum extrusions. This design aims to provide a compact, portable 3D printer with features like auto bed leveling and no filament blockages. The design can be customized and upgraded. Calculations are provided for motion system components like carriages, rollers, lead screws. Designs of subsystems like the extruder head, heated bed and direct drive filament feed are also detailed. The document outlines the timeline and concludes this design will provide an affordable option for customized digital fabrication.

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    4001,4130 BATCH 15

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    This document discusses the design and development of an affordable 3D printer. The proposed design includes a carriage and roller drive system on aluminum extrusions. This design aims to provide a compact, portable 3D printer with features like auto bed leveling and no filament blockages. The design can be customized and upgraded. Calculations are provided for motion system components like carriages, rollers, lead screws. Designs of subsystems like the extruder head, heated bed and direct drive filament feed are also detailed. The document outlines the timeline and concludes this design will provide an affordable option for customized digital fabrication.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    67 views41 pages

    4001,4130 Batch 15

    Uploaded by

    jvanandh
    This document discusses the design and development of an affordable 3D printer. The proposed design includes a carriage and roller drive system on aluminum extrusions. This design aims to provide a compact, portable 3D printer with features like auto bed leveling and no filament blockages. The design can be customized and upgraded. Calculations are provided for motion system components like carriages, rollers, lead screws. Designs of subsystems like the extruder head, heated bed and direct drive filament feed are also detailed. The document outlines the timeline and concludes this design will provide an affordable option for customized digital fabrication.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 41

    DESIGN AND DEVELOPMENT

    OF 3D PRINTER
    Guided by
    By
    Dr. L. BALA MURUGAN
    S.AAKASH 312311114001 Associate Professor
    G.VIGNESH- 312311114130
    Department of Mechanical
    Engineering

    MOTIVATION

    Lead time
    Unaffordable for the masses
    Manufacturing of complex shapes
    Customized digital manufacturing

    Conventional Lathe
    Image Source: Google

    Makerbot Replicator 3D
    Printer

    ABSTRACT
    Digital desktop fabrication technologies such as 3D printing
    are currently being lauded in the popular press as a potential
    socially transformative technology.
    This work discusses the design and development of an
    affordable Fused Deposition Modeling machine.
    This particular design includes carriage and roller drive on
    aluminium extrusion which best meets the functional
    requirements after comparing the designs based on factors
    such as complexity and controllability.
    This design aims at providing an extremely compact and
    portable 3D printer which holds all features such as auto bed
    leveling and no filament blockage. This machine can be
    upgraded as required which will provide way for fully
    customizable digital fabrication.

    OUTLINE
    Motivation
    Current Scenario
    Proposed design
    Design calculations of carriage for X and Y motions
    Design of V-rollers
    Design of direct drive filament feed mechanism
    Design of extruder head
    Advantages from existing design
    Timeline
    Conclusion
    Future steps ahead

    STUDY OF EXISTING
    DESIGNS
    Spiderbot
    Delta 3D Printer

    Info source:

    Print technology
    : Fused deposition
    modelling
    Price
    : 93,870 INR
    Print area
    : 180x150x300
    mm
    X,Y,Z motion drive mechanism :Timing belt and
    pulley drive
    Filament drive mechanism
    : Lego worm drive
    extruder
    Extruder cooling
    : Air cooled
    Weight
    : 15 Kg.
    Firmware
    : Marlin derivative
    firmware
    Microcontroller
    : Standard arduino
    board
    Advantages:
    1. Inbuild power supply unit
    2. Stable aluminium chassis
    3. Heated print bed can print ABS
    Disadvantage:
    4. Unaffordable

    Makerbot replicator 2

    Info source:

    Print technology
    : Fused deposition
    modelling
    Price
    : 1,55,000 INR
    Print volume
    : 250 X 152 X
    152mm
    X,Y,Z motion drive mechanism : Timing belt and
    pulley drive
    Filament drive mechanism
    : Spring type
    extruder
    Extruder cooling
    : Air cooled
    Weight
    : 12.6 Kg.
    Firmware
    : Makerbot
    makerware
    Microcontroller
    : Standard arduino
    board
    Filament diameter
    : 1.75mm
    Nozzle diameter
    : 0.4mm
    Advantages:
    1. Stable powder coated steel chassis
    2. Heated print bed can print ABS
    3. High precision
    4. Dual extruder
    Disadvantage:

    FabX 3D Printer

    Info source:

    Print technology
    modelling
    Price
    Print volume
    100mm
    X,Y,Z motion drive mechanism
    block
    Filament drive mechanism
    extruder drive
    Extruder cooling
    Weight
    Firmware
    firmware
    Microcontroller
    arduino board
    Filament diameter
    Nozzle diameter
    Advantages:
    1. Acrylic chassis
    2. Affordable
    3. Portable
    Disadvantage:
    4. No heated bed

    : Fused deposition
    : 20,000 INR
    : 100 X 100 X
    : Series rails and
    : Gear type
    : Air cooled
    : 5.5 Kg.
    : Marlin
    : Standard
    : 1.75mm
    : 0.3mm

    PROPOSED DESIGN

    Vertical carriage

    Split to accommodate smooth


    rod

    Printer base

    Horizontal carriage

    Y motor mount

    Z motor mount

    3D printed horizontal carriage

    Manufactured delrin rollers

    DESIGN CALCULATIONS
    Drive selection
    X and Y movement
    Z movement
    Filament feed

    Positioning of end stops


    Auto bed Levelling
    Assembly of electronic circuit
    Microcontroller coding

    SELECTION OF STEPPER
    MOTOR

    X MOTION CALCULATIONS
    1. DETERMINATION OF DESIGN LOAD
    P = VI =12*2=24W=0.032HP
    DESIGN HP = P * SERVICE FACTOR=
    0.032*1.4 = 0.045 HP
    2. SELECTION OF BELT PITCH
    CHECKING BELT PITCH SELECTION BASED ON
    THE INDIVIDUAL GRAPHS
    Rated speed = V/L*I/Steps/rev = 8.33rps =
    500rpm
    Rated torque = 4.2Kg cm =0.412 N m
    For the rated torque and corresponding rated
    speed the belt pitch selection is GT2 2mm
    pitch and hence the design never conflicts.
    3. DETERMINE SPEED RATIO
    Speed ratio = Diameter of drive/ Diameter of
    Driven
    = 15/15 = 1
    Pulley Pitch Diameter = = 1.732mm
    4. BELT SPEED
    V=0.0000524*Pitch Diameter (mm) * Pulley
    RPM
    V = 0.0000524*12.732*500 = 0.333526 m/s

    X motion Timing belt and pulley


    drive

    Fabricated X-motion mechanism


    Idler pulley

    Stepper
    driven GT2
    pulley

    Linear
    bearing for
    x motion

    Y motion Timing belt and pulley


    drive
    Idler pulley
    Bed mount
    to
    accommodat
    e toothed
    belt

    Sliding
    rollers on Al
    extrusion

    Z MOTION CALCULATIONS
    1.CALCULATION OF LOAD TORQUE

    We used M5 Threaded rod with 0.8mm pitch.


    F-Frictional Force needed to overcome
    E-Efficiency
    C=0.16 (steel)
    = 3.19 N
    = 1.35 x 10-3 Nm
    2.DUE TO THE EFFECT OF ROTARY MOTION THE
    EFFECT OF INERTIA IS SEEN
    Inertia due to load,
    J = 0.032 *10-3 kg
    m2
    Inertia of Screw,

    Mass of the screw,

    M = 0.153 Kg
    Inertia of screw,
    J=

    4.78 * 10-7Kg m2

    3. MAXIMUM TRAVERSE SPEED


    Smax = RPM max *p
    Smax = 500 *0.8
    Smax = 400 rpm
    4. MAXIMUM LINEAR SPEED
    For 200 step motor linear speed = 1000*60*0.8*10 -3 / 200
    Max. Linear speed = 240mm/min
    5. ANGULAR VELOCITY OF THE SCREW

    6. TORQUE NEEDED TO ACHIEVE ACCELERATION


    If we need acceleration of about 3000 rad/s 2 , The torque required to achieve is
    T = J*a
    T = (4.78 * 10-7+ (2* 0.032 *10-3 )) * 3000
    T=0.1934 Nm is required to achieve acceleration of 3000 rad/s 2

    Z motion Lead screw


    mechanism

    Fabricated Z drive
    mechanism
    Sliding
    rollers on Al
    extrusion

    Spring
    tensioned
    carriage

    Flexible
    couplin
    g

    Code snippets for drive


    control
    //// MOVEMENT SETTINGS
    #define NUM_AXIS 4 // The axis order in all axis related arrays is X, Y,
    Z, E
    #define HOMING_FEEDRATE {50*60, 50*60, 4*60, 0} // set the
    homing speeds (mm/min)
    #define DEFAULT_AXIS_STEPS_PER_UNIT {80,80,4000,148}
    #define DEFAULT_MAX_FEEDRATE
    {500,500,2.5,25} //
    (mm/sec)
    #define DEFAULT_MAX_ACCELERATION
    {1000,1000,100,500}
    // X, Y, Z, E maximum start speed for accelerated moves.
    #define DEFAULT_ACCELERATION
    800 // X, Y, Z and E max
    acceleration in mm/s^2 for printing moves
    #define DEFAULT_RETRACT_ACCELERATION 800 // X, Y, Z and E max
    acceleration in mm/s^2 for retracts

    X, Y, Z drive connections to
    Arduino
    Stepper motor
    connections
    Potentiomete
    r to limit
    current to
    stepper driver
    Stepper driver
    (1/16th
    microstepping)

    Heated bed calculation


    Resistance, R

    = U2/P
    = 122/140 = 1.02
    The width of one track part,

    Where
    Rs,Cu, Specific resistance of copper = 1.68 x 10-5 mm
    tCu, Thickness of copper = 35m=0.035mm
    2wtr =
    wtr = 2.62 mm
    Number of tracks,
    ntr = = 46.53

    Wtr = 2.62mm ; Ltr = 9890


    Length of entire track, ltr = lbntr
    mm
    Ntr = 47
    ; R = 1.02
    ltr = 215 x 46 = 9890 mm (approx.)
    ohm

    Extruder head design


    Servo Motor
    to actuate
    bed level
    probe

    Nozzle
    head

    Z probe

    Heater
    catridge

    Extruder Head

    Duct to
    cool
    printed
    layers

    Fan to cool
    extruder
    head

    Fabricated extruder head

    Connecting thermistors, heated bed


    and heater catridge

    Connections to thermistors

    Connections to heated bed, fan


    and heater catridge

    Configuring temperature sensors


    and heated bed
    #define TEMP_SENSOR_0 -1
    #define TEMP_SENSOR_1 -1
    #define TEMP_SENSOR_2 0
    #define TEMP_SENSOR_BED 0
    If the temperatures difference between these sensors is too high the print will be aborted.
    #define MAX_REDUNDANT_TEMP_SENSOR_DIFF 10
    // The minimal temperature defines the temperature below which the heater will not be enabled It is
    used
    // to check that the wiring to the thermistor is not broken.
    #define
    #define
    #define
    #define

    HEATER_0_MINTEMP 5
    HEATER_1_MINTEMP 5
    HEATER_2_MINTEMP 5
    BED_MINTEMP 5

    #define
    #define
    #define
    #define

    HEATER_0_MAXTEMP 275
    HEATER_1_MAXTEMP 275
    HEATER_2_MAXTEMP 275
    BED_MAXTEMP 150

    Direct drive filament feed


    mechanism

    Filament
    adapter

    MK8 gear

    Spring
    tensioned
    drive
    mechanism

    Indicating the delay and setting


    limits for filament feed rate
    #define FILAMENT_SENSOR_EXTRUDER_NUM 0
    //The number of the extruder that has the filament sensor (0,1,2)
    #define MEASUREMENT_DELAY_CM 14
    //measurement delay in cm. This is the distance from filament sensor to middle of barrel
    #define DEFAULT_NOMINAL_FILAMENT_DIA 3.0
    //Enter the diameter (in mm) of the filament generally used (3.0 mm or 1.75 mm) - this is then
    used in the slicer software. Used for sensor reading validation
    #define MEASURED_UPPER_LIMIT 3.30
    //upper limit factor used for sensor reading validation in mm
    #define MEASURED_LOWER_LIMIT 1.90
    //lower limit factor for sensor reading validation in mm
    #define MAX_MEASUREMENT_DELAY 20
    //delay buffer size in bytes (1 byte = 1cm)- limits maximum measurement delay allowable
    (must be larger than MEASUREMENT_DELAY_CM and lower number saves RAM)

    Connections to Arduino
    Mega 2560

    Connecting endstops and


    heated bed to Arduino

    Connecting SMPS to ramps

    Overall printer connections

    Connecting SMPS to Arduino

    Specifying the printer homing point


    and travel limits
    // Disables axis when it's not being used.
    #define DISABLE_X false
    #define DISABLE_Y false
    #define DISABLE_Z false
    #define DISABLE_E false // For all extruders
    #define DISABLE_INACTIVE_EXTRUDER true //disable only inactive extruders and keep active extruder enabled
    #define
    #define
    #define
    #define
    #define
    #define

    INVERT_X_DIR true
    INVERT_Y_DIR false
    INVERT_Z_DIR true
    INVERT_E0_DIR false
    INVERT_E1_DIR false
    INVERT_E2_DIR false

    // for Mendel set to false, for Orca set to true


    // for Mendel set to true, for Orca set to false
    // for Mendel set to false, for Orca set to true
    // for direct drive extruder v9 set to true, for geared extruder set to false
    // for direct drive extruder v9 set to true, for geared extruder set to false
    // for direct drive extruder v9 set to true, for geared extruder set to false

    // ENDSTOP SETTINGS:
    // Sets direction of endstops when homing; 1=MAX, -1=MIN
    #define X_HOME_DIR -1
    #define Y_HOME_DIR -1
    #define Z_HOME_DIR -1

    // Travel
    #define
    #define
    #define
    #define
    #define
    #define

    limits after homing


    X_MAX_POS 205
    X_MIN_POS 0
    Y_MAX_POS 205
    Y_MIN_POS 0
    Z_MAX_POS 200
    Z_MIN_POS 0

    Code snippets for Auto bed levelling


    and specifying grid points
    #define Z_PROBE_REPEATABILITY_TEST // If not commented out, Z-Probe Repeatability test will be included if
    Auto Bed Leveling is Enabled.
    #ifdef ENABLE_AUTO_BED_LEVELING
    #define AUTO_BED_LEVELING_GRID
    // with AUTO_BED_LEVELING_GRID, the bed is sampled and least squares solution is calculated
    #ifdef AUTO_BED_LEVELING_GRID
    // set the rectangle in which to probe
    #define LEFT_PROBE_BED_POSITION 15
    #define RIGHT_PROBE_BED_POSITION 170
    #define BACK_PROBE_BED_POSITION 180
    #define FRONT_PROBE_BED_POSITION 20

    #define X_PROBE_OFFSET_FROM_EXTRUDER -25


    #define Y_PROBE_OFFSET_FROM_EXTRUDER -29
    #define Z_PROBE_OFFSET_FROM_EXTRUDER -12.35
    #define Z_RAISE_BEFORE_HOMING 4
    #define XY_TRAVEL_SPEED 8000

    // (in mm) Raise Z before homing (G28) for Probe Clearance.


    // X and Y axis travel speed between probes, in mm/min

    #define Z_RAISE_BEFORE_PROBING 15 //How much the extruder will be raised before traveling to the first
    probing point.
    #define Z_RAISE_BETWEEN_PROBINGS 5 //How much the extruder will be raised when traveling from between

    Code snippets for specifying


    acceleration and feed rate
    //Manual homing switch locations:
    #define MANUAL_X_HOME_POS 0
    #define MANUAL_Y_HOME_POS 0
    #define MANUAL_Z_HOME_POS 0
    // MOVEMENT SETTINGS
    #define DEFAULT_AXIS_STEPS_PER_UNIT {78.7402,78.7402,200.0*8/3,760*1.1} // default steps per
    unit for printing
    #define DEFAULT_MAX_FEEDRATE
    {500, 500, 5, 25} // (mm/sec)
    #define DEFAULT_MAX_ACCELERATION
    {9000,9000,100,10000}
    #define DEFAULT_XYJERK
    #define DEFAULT_ZJERK
    #define DEFAULT_EJERK

    20.0 // (mm/sec)
    0.4
    // (mm/sec)
    5.0 // (mm/sec)

    // Custom M code points


    #define CUSTOM_M_CODES
    #ifdef CUSTOM_M_CODES
    #define CUSTOM_M_CODE_SET_Z_PROBE_OFFSET 851
    #define Z_PROBE_OFFSET_RANGE_MIN -15
    #define Z_PROBE_OFFSET_RANGE_MAX -5
    #endif

    Bill of materials

    Fabricated Printer without heated


    bed

    Printer Specifications
    Print technology
    modelling
    Price
    Dimentions
    Print volume
    X,Y drive mechanism
    pulley drive
    Filament drive mechanism
    extruder
    Extruder cooling
    Weight
    Firmware
    Microcontroller
    board
    Filament diameter
    Nozzle diameter
    Power consumed

    : Fused deposition
    : 28000 INR
    : 250x250x300
    : 200x200x250mm
    : Timing belt and
    : Spring type
    : Air cooled
    : 1.5 kgs.
    : Marlin
    : Standard arduino
    : 1.75mm
    : 0.4mm
    : 210 W

    Advantages of new design over


    existing design

    Affordability
    Auto bed levelling feature
    Portable
    Self powered data transmission
    Adaptability to different firmwares
    Simpler X and Y motion mechanisms
    Can be upgraded to dual extruder

    References
    How Stuff Works Website
    www.computer.howstuffworks.com/3-d-printing.htm
    How 3d printing Actually works
    www.mashable.com/2013/03/28/3d-printing-explained
    Stratasys the developer of FDM www.stratasys.com/3D_Printing
    Rapid prototyping-assisted fabrication of the customized
    metatarsophalangeal joint implant (SamKu), C. Raghatate
    Sameer, M. Kuthe Abhaykumar, R. Deshmukh Tushar, W. Dahake
    Sandeep. 2014
    Issues in additive manufacturing, E.S.A. Nasr, A. Al-Ahmari, K.
    MoiduddinCAD 375-399.
    Dario Croccolo, Massimiliano De Agostinis, Giorgio Olmi. 2013.
    Experimental characterization and analytical modelling of the
    mechanical behaviour of fused deposition processed parts made
    of ABS-M30. Computational Materials Science.

    Timeline

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