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1. Introduction
Popular 3D printing technique fused deposition modeling (FDM) produces

customized products with less waste and provides additional benefits over

conventional production processes. Similar to injection molding, FDM creates new

forms by melting and forming raw materials. The substance is supplied into a

temperature-controlled nozzle head after being heated to a semiliquid state and

dragged by a driving wheel. The nozzle uses software-defined layer outlines (usually

CAD) that are integrated into the FDM work system to accurately extrude and guide

materials in ultrathin layers. The three types of manufacturing procedures are additive

manufacturing (or 3D printing), manufacturing with layer removal (CNC, drilling,

and turning), and formative manufacturing (injection molding, casting, stamping, and

forging). 3D printing allows for the accurate, rapid, and cost-effective creation of

valuable materials for complicated designs. The needed form is built up piece by

piece, with plastics typically being used as the material. The FDM technique requires

software that can handle the STL file format, which is often used in stereolithography.

The majority of low-cost 3D printers for personal use or small enterprises that are new

to the market employ FDM. A geometric model is exported from a CAD program as

STL (surface tessellation language). Throughout development, the 3D model must

remain "watertight," manifold, and oriented outward. The orientation of the printer,

the need for support materials, and the availability of "escape holes" to remove

polyamide powder after printing are all important concerns for FDM models. When

the design is removed from the 3D printer, the wall thickness must be sufficient to

allow powder flow. Polymerization, material jetting, binder jetting, material extrusion,

sheet lamination, powder bed fusion, and directed energy deposition are among the

techniques used in additive manufacturing (AM), formative, and subtractive processes

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to produce items. Fused deposition modeling, a subset of material extrusion, has

recently received a lot of development and attention. This technology manipulates a

nozzle filled with molten filament in a two-dimensional plane to manufacture a single

layer of the component's cross-section. Although Crump initially applied for an FDM

patent in 1988 and established Stratasys in 1989, the patent has expired, allowing

consumers to buy low-cost FDM printers.

1.1 Background of the Study

Dr. Hideo Kodama is credited with creating both the fast-prototyping approach

and the layer-by-layer assembly procedure. Additionally, he used UV light to

polymerize a photosensitive glue to create a precursor for SLA. Several other

breakthroughs in 3D printing were made in the 1990s, including stereolithography

(SLA), ballistic particle manufacturing (BPM), and solid ground curing (SGC), which

was patented by Itzchak Pomerantz and associates. The use of 3D printers by medical

researchers in the 1990s led to potential for a wide range of customers and the growth

of the 3D printing and pharmaceutical businesses. Stratasys, a well-known maker of

3D printing systems, has created a range of 3D printers for both home and

commercial usage. This year, 3D Systems developed the stereolithographic (SLA)

equipment by combining a liquid with the viscosity and hue of honey with a UV laser-

solidifying photopolymer. Between 1993 and 1999, the major players in the 3D

printing business emerged using a variety of methodologies. These included Sanders

Prototype (later Solidscape), Z Corporation, and Arcam, which was founded in 1997.

These technologies served not only the high-end manufacturing of pricey and intricate

things but also industrial applications. In 2000, advances in 3D printing enabled the

production of models with a broader range of characteristics at a cheaper cost. The

technique of employing inkjet printers to deposit cells onto a substrate to create

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ordered 3D matrices was patented in 2003 by Thomas Boland of Clemson University.

The first functional 3D-printed kidney of the new millennium was produced using the

process of bioprinting, or the printing of biological parts. One of the additional

printing techniques that has been researched and used as a manufacturing method is

extrusion bioprinting. The proliferation of FDM desktop 3D printers and the

subsequent rise in popularity of 3D printers may be attributed to the RepRap project,

which got underway in 2004. The first color and high-definition 3D printer as well as

the first SLS device to be sold commercially since 2000 was the Spectrum Z510,

which Z-Corp unveiled in 2005. Object, a 3D printing firm, created a machine capable

of printing several materials, allowing a single item to be made and constructed with

various material qualities. FDM patents became available in 2009, ushering in a new

era of FDM printer development. Sculpteo, a French firm, provided 3D printing cloud

and online printing services utilizing stereolithography or laser sintering, improving

3D printing technology. S. Scott Crump received the first patent for the additive

manufacturing (AM) process in 1989. He found that layer-by-layer melting and

extrusion of thermoplastic filaments might result in solid 3D objects, which led to the

creation of the 3D Modeler, the first commercial FDM printer. This approach is

currently widely used in a number of industries, including automotive, aerospace, and

medical. FDM technology has evolved throughout time, with new materials and

printing processes enabling the printing of increasingly elaborate and complex

patterns with greater accuracy and precision. For example, Stratasys' most recent

material, FDM Nylon 12CF, incorporates carbon fiber for increased strength and

durability. Multi-material printers, which can print objects in two or more materials

simultaneously, are significant advancements in FDM technology. This has improved

accessibility for the general public, hence increasing the maker movement and DIY
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culture. However, surface finish is still a significant challenge for FDM technology.

The layer-by-layer printing approach can produce layer lines and uneven surfaces;

however, post-processing techniques like sanding and polishing have helped to

mitigate this problem. Since its beginnings in the 1980s, FDM has been a popular

additive manufacturing process for both prototypes and completed items across a

wide range of industries. As technology advances, new advancements in FDM

technology should emerge.

1.2 Problem Statement

The present 3D printing technology is very time consuming with a high

manufacturing cost. This project aims not only to reduce the cost of the 3D Printer but

also working upon its accuracy and time constraints.

 1.3 Significance / Justification of the Study

This study's key contribution is the development of an FDM 3D printer that

will print practically any 3D form or item for around 30% of the market price. By

focusing on the restrictions of the FDM printer, I will attempt to further enhance it.

There are a number of shortcomings with FDM 3D printers that can be fixed. This

study is required because I am going to propose a printer model that anyone can

simply manufacture at home, use, and sell to make a lot of money. For the average

person, purchasing a 3D printer from the market is challenging. Making printers more

affordably will help everyone in this way. There are several difficulties with FDM 3D

printers, including overhang and bridging, stringing, warping, hygroscopicity, and

structural inhomogeneity. Rough surface finishing, nozzle clogging, longer print

times, layer adhesion issues (layer shift), weak construction, frequent bed calibration

requirements, and structural integrity issues are all things that will be worked to fix.
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1.4 Objectives of the Study/Research Questions

The objectives of our present work are as follows:

 A 3D printer is a device that can make things out of many different materials,

including nylon and plastic. The current generation of 3D printers are

expensive and not very portable. Through problem analysis, our goal is to

create a portable 3D printer, size of 2x2 feet or 60x60cm or 600x600mm.

 The cost of this printer will be considerably less when compared to other 3D

printers available in the market. I started building a printer that costs

approximately $118.

 The FDM 3D printer costs around $400 (PKR 118,000) in the open market.

Our goal is building a low-cost 3D printer with a price of just 30% of the

market pricing.

 To print and build complicated components.

 Accurately building big printing volumes, for example this printer will print

moveable and unmovable objects that do not have exact dimensions.

 This printer has capability to print objects with length and width 250mm by

250 mm.

 We try to address bed leveling issues, which is a major problem in the 3D

printer.

 This printer is inexpensive as compared to another 3D printer.

 After building a home FDM 3D printer, our goal is also, attempt to enhance it.

 I will work to analysis by changing some parameters like travel speed, nozzle

diameter and layer height.

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1.5 Limitations of the Study

The most common limitations, challenges or drawbacks associated with printing parts

with the FDM technology include:

 Nozzle Clogging

 Structural inhomogeneity

 Rough Surface Finishing

 Longer Printing Time

 The price to purchase and set up a 3D printer is very high.

 Overhang and bridging

 Starting the print without extrusion. Plastic is not extruded by the printer at the

start of the print

 Substandard extrusion

 Not Sticking to the Bed

 Extrusion to excess

 Gaps in the top layers

 Excessive heat

 Warping

 Hygroscopicity

 Oozing or stringing

 Layer Adhesion Problem (Layer Shifting/ switching)

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2. Literature Review

2.1 Theoretical and Conceptual Framework

[Shahrubudin & Ramlan (2019)] 3D printing, or additive manufacturing, technology

creates objects from different materials. This technology is used in many fields, like

agriculture, healthcare, the automotive industry, the locomotive industry, and aviation.

This technology uses a computer-aided design (CAD) model to print the 3D objects

layer by layer from bottom to top. A 3D printer was first created by Charles Hull in

1980. 3D printing technology will reduce costs if it increases production speeds. This

study gives an overview of types of 3D printing technology, applications of 3D

technology, and materials used in this technology for creating objects in industries.

Types of 3D printing technology include binder jetting, directed energy dispensing,

material extrusion, material jetting, powder bed fusion, sheet lamination, and Vat

photopolymerization. Materials that are used in 3D printing technology are metals,

polymers, ceramics, composites, smart materials, and special materials like food,

lunar dust, and textiles. Applications of 3D printing in manufacturing technology are

in the aerospace industry, automotive industry, food industry, healthcare and medical

industry, architecture, building, and construction industry, fabric and fashion industry,

and electric and electronic industries.

[Schubert, Van Langeveld & Donoso (2014)] The researcher discussed 3D

printing, which is a procedure for creating three-dimensional objects using materials

such as plastic or metal. The molten filaments are deposited one after another in

layers. 3D printing technology is different from 2D printing technology. 3D printing

is used in medicine, including ophthalmology, the manufacturing of eyeglasses,

custom prosthetic devices, and dental implants. Printers like dot matrix, laser, inkjet,

and digital printers print two-dimensional images; however, in 1980, Charles Hull
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invented the 3D printer. 3D printing technology is vastly used in the medical field,

including ophthalmology, the culture of cells, blood vessels, and vascular networks,

bandages, bones, ears, exoskeletons, windpipes, dental prosthetics, including a jaw

bone, and future corneas for diseases such as diabetes, creating prosthetics, stem cells,

testing new drugs using printed tissues, and customized drugs. 3D printing is also

being checked as a source to replace organs like kidneys, hearts, or skin and has the

potential to print new organs that perform the same functions, such as the pancreas in

diabetes. So, 3D printing is very helpful in the medical field.

[Rajan, Samykano, Kadirgama, Harun & Rahman] 3D printing technology has

been discussed, and it has been shown that by using 3D printing technology, we can

fabricate customized products at low and minimum costs. FDM is a 3D printing

technique used in different sectors, but due to a lack of materials, this technology is

limited. Techniques in FDM technology and various polymers and their composites

are discussed, and search gaps are pointed out in this study. Fused modeling is a well-

known additive manufacturing technology due to its production capability and ability

to produce complex objects. The object is created on a plan surface three-

dimensionally per CAD design using filaments. Once the initial layer is printed, the

second layer is printed over the previous layer, and so on. Acrylonitrile butadiene

styrene (ABS) and polylactic acid (PLA) materials are used in FDM. Other materials

are nylon, ULTEM, polyetheretherketone (PEEK), polypropylene (PP),

polyphenylsulphone (PPSF), thermoplastic polyurethanes (TPU), polyvinyl alcohol

(PVA), high-impact polystyrene (HIPS), and composite filaments used in FDM

techniques. The ISO and ASTM categorized various techniques of 3D printing

technology like sheet lamination, material extrusion, powder bed fusion, direct energy

deposition, binder jetting, material jetting, and vat photopolymerization. Techniques

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like stereolithography (SLA), selective laser sintering (SLS), inkjet printing (IP),

laminated object manufacturing (LOM), and fused deposition modeling (FDM) are

used in 3D printing technology. Thermoplastic polymers and other low-melting-

temperature materials are used in FDM. The researchers are attempting to improve the

quality and properties of polymers. The important parameters used in the FDM

printing technology are infill pattern, infill density, raster angle, raster width, layer

thickness, build orientation, printing speed, air gap, and operating temperature. Infill

patterns are the shapes and structures of the polymers and other materials inside the

part. Many infill pattern densities such as triangular, grid, cubic, honeycomb,

concentric, rectilinear, rectangular, octet, and wiggle are used in Fused Deposition

Modelling. Applications of the FDM are in aerospace, electronics, biomedical,

construction, automotive, and other sectors. There are various challenges and

limitations to FDM technology. Significant studies like design freedom,

customization, and the ability to print complex structures are required. In the limited

materials, quality, accuracy, anisotropic mechanical properties, limited application in

large production, mass production, printing time, clogging, and void formation, also

needed research.

[Long, Gholizadeh, Bunt & Seyfoddin (2017)] In three-dimensional

technology, fused deposition modeling is an extrusion-based technique that prints

objects layer by layer from bottom to top. In this article, the researcher reviewed

FDM-based 3D printing applications like drug delivery systems and the fabrication of

personalized tablets. Computer-aided design techniques are used in 3D printing

technology. In 2015, the US Food and Drug Administration approved the first 3D-

printed drug, spritam. Computer-aided design (CAD) software is used in 2D and 3D

printing. 3D models reduce errors. 3D printing techniques are applied in drug delivery
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systems, divided into different categories; however, the procedure of fabrication is

different, but all techniques use layer-by-layer deposition to form an object. The

categories are 3D printing inkjet-based systems, 3D printing extrusion-based

deposition systems, 3D laser-based printing systems, and 3D printing powder-based

distribution systems. FDM is a 3D printing technology that create physical objects

using X, Y and Z axes. This technique is also helpful for drug delivery systems to

manufacture patient tablets and capsules with great accuracy and fabricate geometric

devices. Fused deposition is a thermo-based technique in which heat is transferred to

melt the polymers to create an object. Commonly used polymers for FDM drug

delivery systems are polyvinyl alcohol, polylactic acid, and ethylene vinyl acetate.

FDM-based 3D printing is a low-cost, effective manufacturing technology that offers

high precision and versatility. The major benefit of FDM 3D printing is that it is

simple to develop and produce custom tablets or devices with individualized doses.

Due to the ability to print objects with different geometries and drug and polymer

proportions, the release profiles of the loaded drug may be regulated and altered. Due

to these benefits, FDM printing is a potential new technique that may be used to

create customized tablets and other medication delivery systems. Compared to

established manufacturing processes for drug delivery devices, FDM-based 3D

printing has competitive advantages. However, as with many emerging technologies,

the limitations of FDM 3D printing must also be recognized and addressed. First, pre-

FDM drug-loading methods are still problematic due to the use of heat, and even

though HME could offer more advanced and tunable drug-loading, drug candidates

are limited to heat-stable compounds. Thermosensitive agents are not suitable for

FDM-based printing, limiting biomedical and pharmaceutical applications.

Furthermore, when additives are incorporated into the polymer matrix, they can alter
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the thermoplastic properties of the polymer filaments, altering their viscosity and

flexibility. Second, the printing process requires high temperatures to melt the

filament at the point of extrusion to build the object, which can lead to physical

instability and degradation issues. Third, the support structure that needs to be built as

a base for the printed object is a source of material waste, especially if the object has a

complex shape or a large footprint. Additionally, it is difficult to remove the internal

supports required to support hollow objects in large-scale processes.

[Kristiawan, Imaduddin, Ariawan, Ubaidillah & Arifin (2021)] Fused

deposition modeling is a 3D printing method under the additive manufacturing class.

Additive manufacturing technique is used to create various complex objects and

structures. In the FDM manufacturing process, the basic material is only melted and

molded to produce new shapes. The material is a rolled-up filament that is pulled by a

driving wheel, heated to a semi-liquid condition, and then injected into a temperature-

controlled nozzle head. The nozzle precisely extrudes and guides materials in ultrathin

layers to build structural elements layer by layer. This conforms to the layer contours

as defined by the software, often CAD, that has been integrated into the FDM work

system. After creating object, it then solidifies at room temperature after printing. The

polymers, used in FDM are PLA, ABS and PP. Researchers and companies have

created polymer composites as a 3D printing filament material to create systems with

structural features and functional advantages that cannot be produced by single

elements. Extruding polymer pellets or raw materials is used to create FDM filament.

Creating filament from polymer composites or strengthening is done by combining

the materials and preparing each composition in advance. Various techniques can be

used to combine the materials, such as dry mixing or combining the solution and

letting it dry before extracting. The filament's diameter, regularity, and filler direction
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are influenced by variables such as die temperature, roller puller speed, spindle speed,

and intake temperature. Polymer filament has two types, pure polymer filament and

composite filament. The quality and mechanical properties of the FDM engineering

process were influenced by all aspects and input parameters, according to the

literature review. The composition of the filament, the extrusion working parameters,

such as extrusion speed and temperature, the FDM machine specifications, the

extrusion machine specifications, the type of filament polymer, and the FDM work

parameters used when printing the filament have all been identified as having an

effect on the results. The field of additive manufacturing has been defined by this

study's usage of a polymer filament 3D printing technology to analyses and improve

FDM procedures and materials. It has been emphasized that what makes FDM special

are a number of process factors that impact mechanical characteristics and the quality

of outputs. FDM involves a variety of process factors that affect mechanical qualities

and caliber.

[Cevik & Kam (2020)] FDM is a widely used additive manufacturing

technique. This approach is used in many fields. It was found that high mechanical

properties can be achieved by adding composite reinforcements in different ratios.

Therefore, it was expected that the composite materials created in this study could use

a wider range of applications. Instead of using conventional manufacturing processes

and standardized manufacturing techniques, additive manufacturing (AM) is the

process of applying materials one layer at a time to construct things from 3D model

data. The idea behind conventional manufacturing processes is to separate chip

materials from raw materials during the part manufacturing process. 3rd dimension

printer was first developed by Charles Hull in the year 1984. Advantages of 3D

printing technology are minimal waste, low cost, the ability to produce parts with
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complex geometries without the use of molds, the ability to produce parts with the

desired composition, use in an office work environment, measurement accuracy, chip

removal, deburring and lack of other operations. The use of 3D printing technologies

in the automotive, aerospace, defense and aerospace industries, as well as in product

and machine design, prototyping parts manufacturing, educational equipment, textiles,

toys and medical devices is becoming more common. Selective Laser Sintering

(SLS), Selective Laser Melting (SLM), Electron Beam Melting (EBM), Laser Metal

Deposition (LMD), Fused Deposition Modeling (FDM), Stereolithography (SLA),

and Digital Light Processing (DLP) technologies are the most applied technologies

for additive manufacturing. In the FDM technology, the first step is to model the

object using computer-aided design environment and model is then converted to the

STL format. After slicing of the 3D model, the model in the STL format transmitted

to the 3D printer. The superposition of thermoplastic molten material, known as

filament, which is deposited from the nozzle of the 3D printer, yields the 3D geometry

of the object specified in the computer environment. The FDM method involves

layering the molten material onto a heated flat table surface using a hot nozzle. The

FDM manufacturing method is based on the principle of using a polymer as the

printing material and melting and bonding the thermoplastic material. Due to the

advantages of the thermoplastic materials used, cheap, long service life, high

toughness, easy to find, recyclable, some species dissolve quickly in nature, low

forming temperature, heating then it will be molded. Now even home users can use

this method to make a variety of parts. Due to the simple functional principle and low

capital investment, the cost of devices manufactured using the FDM method is lower

than those manufactured using other AM methods. Because of these properties, the

FDM method has been used to create devices called 3D printers that are suitable for
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desktop use. FDM techniques are also used by private users due to the low cost and

other advantages of the device and thermoplastic materials. The thermoplastics used

in FDM manufacturing are polymer class materials. By heating the solid at a low

temperature, it becomes soft and can be shaped. Once the thermoplastic molding

process is complete, it cools and solidifies to create the desired shape of the product.

Acrylonitrile Butadiene Styrene (ABS), Polylactic Acid (PLA), and Polyethylene

Terephthalate-Glycol (PET-G) are the filament types that are frequently used in

production, but in recent years, metal/polymer composite materials have also been

used. These materials are created by adding metal or thermoplastic materials in

varying proportions. The mechanical characteristics of the materials must be

understood in order for them to be utilized successfully, and if required, these

properties should be modified in accordance with the usage area. Tensile strength,

impact strength, elastic modulus, yield strength, fatigue strength, hardness, etc., are

attributes that spring to mind when the mechanical properties of the material are

stated. The impact of 3D printing settings on the mechanical qualities of 3D printed

items has been the subject of several research in the literature. Here, the filling ratio,

printing speed, layer thickness, filament, and nozzle diameter constant are six distinct

filling test samples that are given.

[Ambade Padole & Badole (2023)] Fused deposition Modelling or fused

filament fabrication is the additive manufacturing process. The fundamental concept

of the additive manufacturing technology is to design a model in software and slice

the model and then translate this model to the 3D printing to create the physical object

layer by layer. Additive manufacturing has many types including polymerization,

material jetting, binder jetting, materials extrusion, sheet lamination, powder bed

fusion, and directed energy deposition. FDM technique is simple and low in cost, used
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in many applications. Filaments in FDM are heated, extruded with the help of a

nozzle, and printed layer by layer on a platform. All the layers are fused and solidify

when the temperature falls. The interaction of the molecules will result in bonding

between the layers when one layer is connected to the solid layer while it is still in a

liquid state. However, gaps may form between the layers if molten fibers freeze

quickly or if the extruded material and the solidified material don't overlap. Assessing

the mechanical properties of the fused deposition model is a challenging task.

Figure 2.1.Diagram of FDM 3D printer

The mechanical properties of the printed object are influenced by the thickness,

breadth, and infill density of the layer. The FDM technique has disadvantages like

poor surface quality, lower mechanical qualities, and visibility of layer thickness. In

this research, the researcher described the overview of the FDM process, the influence

of process parameters on the strength of FDM parts, the effect of infill density, the
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effect of infill patterns, and the effect of extrusion temperature. Major gaps are

identified in this research, such as tensile qualities of the manufactured part, linear

and circular features, an inquiry on the strength properties of different materials such

as plastic and metal, infill pattern and infill density, Coating is another pre- and post-

enhancement procedure that requires careful consideration. Impact of the sterilization

method on the strength qualities.

[Mazurchevici Nedelcu & Popa (2020)] There are three categories of

manufacturing techniques: formative manufacturing, manufacturing with layer

removal, and additive manufacturing. The first two types are traditional

manufacturing. 3D printing is useful for rapid prototyping and designing complex 3D

models. The last category (additive manufacturing) has been divided into seven main

categories, such as vat photo-polymerization, direct light processing, multi-jet fusion,

direct metal laser sintering, selective laser sintering, selective laser melting, and

selective laser melting. These all-use plastic and metal elements to build 3D Models.

The term fused deposition modelling is used by Stratasys. The FDM process has

many phases while creating the 3D physical objects: design phase (the 3D model of

the object is built in the CAD software), Manufacturing phase (slice the 3D design

and transmit it to the 3D printer for creating physical objects), and Testing phase (The

FDM-obtained prototype is put through physical and mechanical testing to learn more

about how well it performs). Many useful applications have been made by 3D

printing, like parts of the human body, implants and devices for medical use, biotech

(human tissue replacement), building implants after a certain shape (for example,

dental or bone implants), skeletons, and corpse replicas. The mechanical, thermal, and

structural characteristics of the PLA material were examined in the experimental

findings. The Effect of Process Parameters on PLA Mechanical Properties

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(Experimental Methodology, Construction Orientation, Thickness of Layer) and the

Effect of Continuous Fiber Reinforcement on the Mechanical Properties of PLA

Samples The lack of results in scientific studies of potential variables, such as build

material, extruder temperature, shell, etc., highlights the need for research in this area

in order to better understand the behavior of 3D prototyped parts from a mechanical

standpoint and to determine their optimal settings. The mechanical qualities of the

3D-printed items are greatly improved by utilizing fibers to strengthen the PLA

material using FDM technology. In terms of PLA material reinforcement, the

conventional reinforcing technique has been enhanced, bringing additive

manufacturing by material extrusion closer to many industrial industries. One of these

enhancements entails combining continuous carbon fibers in the printing head of the

apparatus, enhancing the PLA matrix and fiber adhesion. Due to its benefits in terms

of pricing, product quality, functionality, and production time, FDM technology is

being used more and more by research organizations, businesses, and consumers.

[Stephanie Torta Jonathan] Examples of 3D fabrication technology are

Architecture/Engineering, Art, Biology, Chemistry, Computer Science, Geography,

History, Math, Performing Arts, Writing. The Seven types of additive manufacturing

methods and 3D printers include are Powder Bed Fusion (PBF), Binder Jetting,

Material Jetting, Directed Energy Deposition (DED), Material Extrusion, Sheet

Lamination, Vat Photopolymerization. PBF employs melting to fuse together

fragments of a powder substance (metal or plastic). An electron beam, laser, or heated

print head can all conduct full or partial melting. By applying a small layer of material

to the print chamber region, the build layers are accomplished. The layer that defines

the print object has melted. The procedure is repeated until only the layer-containing

object particles are melted, creating the desired item. The newly formed item is then
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shown once the un-melted material is blown away. Because of its great strength and

variety of post-print finishing options, this process is frequently employed for the

production of finished goods. Several 3D printers employ the PBF technique. Direct

Metal Laser Melting (DMLM), Direct Metal Laser Sintering (DMLS), Electron Beam

Melting (EBM), Selective Heat Sintering (SHS), Selective Laser Melting (SLM),

Selective Laser Sintering (SLS). Binder jetting employs nozzles to drop material onto

the print area in a manner akin to an inkjet printer. In this technique, a binder

substance is placed onto a layer of powdered metal, glass, or ceramic material. A fresh

layer is prepared to be added on top of the preceding layer once the powdered

material has been bonded. This technique occasionally results in brittle prints and

requires finishing after the print is finished. It is suitable for more aesthetic

applications as a result. Inkjet printers use nozzles to drop waxy photopolymer onto a

print bed, cured or hardened using UV radiation. Supports are deployed, and the

process is repeated for accurate, smooth, and precise printing in various colors. DED,

or Direct Metal Deposition, uses thermal energy to melt and fuse materials like metal

powder and wire filament in heated or vacuumed print regions. This technique is used

for repairing original or damaged objects. The process of material extrusion involves

heated thermoplastic filament that is sprayed in layers through a nozzle onto the print

surface. During cooling, these layers combine with the preceding layer. The materials

utilized in this approach include plastics and polymers that have been infused with

other materials, however they may not be as strong as those used in other additive

manufacturing processes. Rapid prototyping is made possible by the method's overall

speed and cost efficiency. Fused deposition modeling (FDM)/Fused Filament

Fabrication (FFF) – this type of 3D printer is one of the more commonly known by

the public. It is widely used by both industry and DIY enthusiasts. Very thin layers of
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material are adhered to one another during sheet lamination. Layers of glue and

material are alternated to accomplish this. You may use a number of materials,

including metal and paper. After the layers have dried, they are sliced into a print

using a laser or blade. Vat photopolymerization employs liquid photopolymer resins in

a number of deployment techniques that fuse/cure the resins in layers to create the

object using light rather than heat. One deployment technique, for instance, places the

construction area inside a vat of liquid resin. An object's outline is traced by a laser.

Layer by layer, the resin is solidified by the laser light as it outlines the item. Printing

things with fine features and smooth surfaces is done using this technique. The

components of FDM printer are Mechanical components, Bed, Motor, and Frame

Components and Electrical Components. Extruder is the main component of any 3D

FDM printer. It pulls, melts and extrudes filaments through a nozzle. The extruder has

two parts such as the cold end which draws the filament in from the spool and pushes

it through to the hot end and the hot end that melts the filament with a heating element

and extrudes it out through a nozzle. Subcomponents of cold end are Hobbed Gear,

Idler Gear, Direct Drive and Bowden Drives. The Hot end consists of PEEK/PTFE or

All-Metal Insert, Heater Cartridge, Heater Block, Thermistor/Thermocouple, Heat

Break, Heat Sink/Hot End Fan, Layer Cooling Fan(s), Nozzle. Bed, Motor, and Frame

Components are Print Bed, Bed Surfaces, Bed Leveling and Tramming Mechanisms,

End Stops (one for each axis), Threaded Rods or Leadscrews, Stepper Motors, Belts,

Frame, Enclosure and Filament and Holder. Electrical Components are Power Supply,

Motherboard/Controller Board, SD Card Slot, USB Connector, Stepper Drivers,

Screens and User Interfaces, Screens and User Interfaces, Enclosure Fan and Filter.

[Ian Gibson, David Rosen, Brent Stucker (book)] Additive manufacturing

technology involve the following eight steps. 1) Computer Aided Design: In this step,
 20

we used any professional CAD modeling software to design any 3D model. 2)

Conversion to STL: Every CAD software can output an STL format. We convert the

CAD design to STL format. 3) Transfer to AM Machine and STL File Manipulation:

The STL is then transferred to the AM machine for 3D printing. 4) Machine Setup:

Before starting the build process, the AM machine has to be correctly configured.

These options would be in relation to the construction parameters, such as the material

restrictions, energy supply, layer thickness, timings, etc. 5) Build: The process of

making the part is largely automated, and the machine may operate mostly

unattended. To verify that no mistakes have occurred, such as running out of material,

electricity, or software, etc., only cursory monitoring of the machine is required at this

stage. 6) Removal: The components need to be removed when the AM machine has

finished building them. In order to accomplish this, you might need to communicate

with the machine, which might include safety interlocks to make sure, for instance,

that the operating temperatures are low enough or that there are no actively moving

parts. 7) Post-processing: Parts may need some further cleaning after being taken out

of the machine before being put to use. At this point, parts might be fragile or contain

extraneous components that need to be removed. As a result, doing so frequently calls

for patience and precise, skilled physical manipulation. 8) Application: Possibly now

is the time to use the parts. Before they are suitable for usage, they can also need extra

treatment. For instance, they can need painting and priming to get a surface quality

and texture that is suitable. Treatments could be difficult and drawn out if the

finishing standards are exceedingly strict. Additionally, they might need to be put

together with other mechanical or electrical parts to create a finished model or item.

The Municipal Industrial Research Institute printed the physical object from a digital

design, but the 3D printer was first designed by Charles Hull in 1984 while he was
 21

working for 3D Printer Corp. Charles A. Hull is credited with developing the

stereolithography solid imaging technique and the STL (stereolithographic) file

format, which is still the most used 3D printing file type today. Fused deposition

modeling (FDM) is the name given by Stratasys to the plastic extrusion method that is

most commonly linked with the phrase "3D printing" and was developed in 1990.

Additive manufacturing is also called desktop manufacturing, rapid manufacturing,

and agile tooling on demand manufacturing. 3D models are created with the help of

computer-aided design. In 3D printing, data is analyzed and collected on the shape

and object, and then a 3D object can be produced. A 3D model is basically a .stl file,

and this file is sliced to convert the .stl file to a series of layers and produce G-code.

Cura, KISSlicer, Slic3r, etc. are slicing software used today. After converting to G-

code, the 3D printer follows the G-code instructions to build the physical model.

Selective Laser Sintering, Fused Deposition Melting, Stereolithography, and

laminated object manufacturing are AM processes. S. Scott Crump created the merged

deposition modeling (FDM) technique in the late 1980s, and Stratasys designed it in

1990. The following materials are used in 3D printing: Acrylonitrile Butadiene

Styrene [ABS] is one of the materials that has been utilized the most since 3D printing

first became popular. This substance is ideal for 3D printing since it is lightweight,

somewhat flexible, and extremely robust. Compared to PLA, another common 3D

filament, it extrudes with less force. For tiny pieces, extrusion is facilitated by this

characteristic. The fact that ABS demands a higher temperature is a drawback. Its

glass transition temperature is around 105°C, and temperatures between 210 and

250°C are often employed for ABS printing. Another negative of this material is the

printing process, which produces strong fumes that can be harmful to animals or

humans with respiratory problems. So, a well-ventilated location is required for the
 22

placement of 3D printers. Avoiding inhaling fumes when printing is also a good idea

because 3D materials are expensive. Because ABS is the least expensive, it has

historically been a favorite in the printing industry. Poly Lactic Acid [PLA]: Another

popular material among those who enjoy 3D printing is poly lactic acid (PLA), which

can be made from maize and is biodegradable. It is a thermoplastic that degrades

naturally and is made from renewable materials. As a result, compared to other plastic

materials, PLA products are more ecologically friendly. The biocompatibility of PLA

with the human body is one of its other outstanding qualities. PLA melts at a lower

temperature than ABS, between 180 and 220 degrees Celsius, and has a tougher

structural makeup than ABS. Because the glass transition temperature for PLA is

between 60 and 65 °C, using PLA and ABS together might be a smart choice for any

of your projects. High Impact Polystyrene [HIPS]: Another example of a support 3D

material is HIPS filament, which is constructed of High Impact Polystyrene. In the

food business, this material is often used for packaging. Naturally, this filament has a

dazzling white hue and is also biodegradable, so there are no negative effects when it

is placed in close contact with a human or animal body. It is also used to pack CD

discs and manufacture trays in the medical industry. By utilizing a heated bed when

printing, curling and adhesion issues with HIPS filaments can be lessened. HIPS

material that may be dissolved in a clear liquid hydrocarbon solution after serving as a

printing support structure There are many advantages like Time-to-Market, Mitigate

Risk, provide feedback, Get the Feel, Personalize It, Build Your Imagination, Square

Holes, Fail Fast, Fail Cheap. Disadvantages include Intellectual property issues,

Limitations of size, Limitations of raw materials, Cost of printers, Fewer

Manufacturing Jobs, and unchecked production of dangerous items.

 23

[Reddy, Sriramoju & Mahammad (2022)] In this article, a 3D printer is

constructed using the Arduino Mega 2560. The hardware design consists of the

following components: Arduino Mega 2560, Stepper Motor, Heat Bed, Extruder, End

stop switch, and Rams 1.4 shield. The Arduino Mega 2560's microcontroller board is

seen in Figure 2.2. There are 54 digital I/O pins. It can accept 16 analog inputs. Four

Universal Asynchronous Receiver Transmitters make up the device. The quartz

crystal oscillator has a 16-MHz frequency.

Figure 2.2 Arduino Mega 2560

The suggested concept makes use of NEMA 17 stepper motors. It is a hybrid stepping

motor with a 1.8° step angle, which translates to 200 steps per revolution. Using a

holding torque of 3.7 kg/cm, each phase will drain 1.2 A at 4 V. The motor has six

lead wires and a rated potential of roughly 12 volts. The construction of the heat bed

is seen in Figure 3. Another component of a 3D printer will be a heated bed. It offers

the cooling system needed to provide optimal printing results. To prevent thermal
 24

runaway, heat beds. Additionally, prevent issues like poor adherence to the print bed

and low adhesion between layers.

Figure 2.4 illustrates the Figure 2.3. Heat Bed 3D extruder, a crucial

component of a 3D printer that immerses material in liquid or semi-liquid to store it in

successive layers inside the 3D

printing volume.

Figure 2.4. Extruder

 25

The extruder often only aids in depositing the bonding agent and solidifying more

material. The End Stop Switch Module is seen in Figure 2.5. When the bound was

reached, those end-stops' primary function was to align the logical state of a pin on

the ATmega (or other controller board) to point. Hardware end-stops will signal when

the end stop condition has occurred and are electrically connected to the end-stop

ports on the printer control board.

Figure 2.5. End Stop Switch

Figure 2.6.Ramps 1.4 Sheild

Ramps 1.4 shield's module is seen in Figure 2.6.

The RAMPS offers plenty of room for expansion and connects an Arduino Mega to

the sturdy Arduino MEGA stage. On an Arduino MEGA shield, it includes of stepper

drivers and extruder control hardware for clear help, component replacement,
 26

redesign capability, and expansion. The softwares that are used in this 3D printing are

Arduino Integrated Development Environment (IDE), Pronterface, is a set-up of host

interfaces for 3D printers and CNC is printrun, and SLIC3R.

The following steps are involved in the construction of 3D printing model.

1: Using CAD software, create a 3D model.

2: A high-quality Standard Tessellation Language (STL) file is created from the CAD

model.

3: The STL file is sent to the computer that manages the 3D printer. The user

configures printing settings and determines the printer's size and orientation.

4: Every machine has different setup needs, such as replenishing the polymers,

binders, and other consumables the printer will need.

5: Start the machine and wait for the construction to be finished.

6: Printing of the item is complete. The item will be removed.

7: Post-processing is the final stage in 3D printing. Many 3D printers need to be

postprocessed in some way, such ignoring and chopping out extra material.

[Salentijn, Oomen, Grajewski & Verpoorte (2017)] 3D printing technology has

been used for over 30 years. A rapid increase was seen in the use of 3D printing in

analytical and microfluidics research. 3D printing was also used for the fabrication of

channels, sample cartridges, hydrophobic patterning, labware, and customized setups.

Such types of works can be achieved with several 3D printing approaches like SL,

FDM, inkjet 3D printing, DLP, and SLS. In this study, the researcher describes FDM

3D printing and describes the possibilities and limitations concerning biological

analytical devices. A polymer filament is melted and extruded as the foundation of

FDM. A heated metal cylinder with a nozzle is where the filament is fed and melted.

The molten polymer is forced out of the nozzle and forms a thread that is roughly the
 27

diameter of the nozzle, as long as fresh filament is continually fed into this

component. The nozzle is positioned above a metal plate (print bed) at a distance that

depends on the required resolution to form this thread into a plastic object. The

filament is discharged from the nozzle and placed on this print bed, which may be

heated to facilitate adhesion. We can create a two-dimensional figure on the print bed

that is one polymer thread thick when the print bed and nozzle are both moveable in

perpendicular directions. The relationship between (i) the distance between the nozzle

and the print bed and (ii) the flow rate of the filament through the nozzle and the

printing speed determines this thickness, which is typically between 0.1 and 0.3 mm.

When the first layer is complete, the print bed is lowered by a predetermined amount

(i.e., the thickness of a single layer), allowing for the printing of a second layer on top

of the first. These actions are repeated to produce an item in an additive fashion. A

3D-drawn model must first be converted into a file that instructs the printer how to

operate before it can be printed. Gross and colleagues go into great depth about this

procedure. In essence, the 3D artwork (typically a vector file) is saved in the

triangular surface mesh *.STL format. The solid object is then transformed into a

digital representation of filament threads by using this file to carve a route for the

extruder to follow (creating G-code). A number of 12 FDM filament materials were

discussed in this study that are available for FDM and have different polymers and

varying degrees of elasticity. In the context of this study, biocompatibility is the

feature of a substance that prevents cells and tissues from losing viability when

exposed to it in in vitro culture settings. Characterizations of a Benchtop FDM 3D

Printer are Resolution, Surface roughness, overhang, prevention of leakage,

transparency, combining materials, and warping. Polymers for FDM 3D Printing are

Polymer Printability, Autofluorescence, Solvent Compatibility, and biocompatibility.

 28

Applications of FDM 3D Printing are 3D-Printed Masters for PDMS Casting, 3D-

Printed Channels, Patterning in Paper Microfluidics, Customizing Laboratory

Equipment, and 3D-Printed Tools. FDM is perhaps the most accessible printing

method in comparison to other printing techniques. The printer itself is affordable, as

are the supplies. The simplicity with which various materials may be changed during

a print and the ability to include and embed external components into a single product

are further benefits of the FDM technology. Other advantages include the large variety

of printing materials available and the biocompatibility of most FDM materials with

tissue and cells. The resolution and surface smoothness issues are the primary

drawbacks (although these issues are partially improved with alternative 3D printing

techniques, including DLP). However, given the speed at which technology is

developing, we anticipate that higher-resolution (FDM) printers will soon be

accessible.
 29

[Melnikova, Ehrmann & Finsterbusch (2014)] The 3D model has to be

manifold and impermeable. One industry where 3D printing is applied is the textile

industry. We produce several apps and physical things using 3D printing. 3D printing

may be used to create clothing as well. German RepRap created the first FDM printer,

the X400. Weft knitted constructions may be 3D printed using a CAD model as a

starting point. Single-face weft knitted fabric CAD model created using Blender

(upper left

panel), 3D

printed using SLS

(upper right

panel), FDM

using Bend Lay

with support

structures (lower left

panel), and FDM

using soft PLA without support structures (bottom right panel). Measurements are

shown via the ruler.

Figure 2.7. Weft Knitted Fabric

 30

With the use of FDM technology, several layered structures have been created. In

order to determine if single strings may be placed on top of reasonably open structures

without any support structures, a test construction is shown in Figure 7. A three-

stacked layer test pattern for a layered construction . Designers have made lace with a

base layer that unites mostly floral and circular motifs by taking their cues from the

well-known Figure 2.8. Three-stacked layer

Plauen lace. Since there are no free-floating zones, printing with the FDM process is

simple if all connecting lines have enough width. A multi-layer, multi-material

structure is shown in BlenderTM as having three distinct layers and a separate ring

made of a different material that is colored red (left panel), and the printed object is

shown in the right panel with a hard Bend Lay ring made of soft PLA layers. The

Figure 2.9. Multi-material Structure

pattern is 8 cm by 8 cm in size. being partially fixed by the bottom and top layers after

the design is complete. Such a multi-material model can be produced in this manner.
 31

Similarly, reinforced pieces made of hard PLA or Bend Lay may be included in lace

forms that have three or more layers of soft PLA.

[Kun, K (2016)] The FDM printer is flexible and can handle the lower layers

easily. It has some restrictions, like the fact that it cannot produce undercuts without

supporting material. Materials like ABS and PLA are used to create physical objects.

The outer frame of the printer must be strong to protect it from any kind of damage

while carrying it from one place to another. Their mechanical parts as well as

electronic parts must be well assembled and fitted. We used reverse engineering to

retrieve the original documentation and dimensions in order to implement this. The

next phase describes the method's essential elements. Reverse engineering is a labor-

intensive engineering procedure where we use 3D digitalization to determine the

CAD geometry of an actual, physical product. Reverse engineering starts with the

finished product. It is intended for rebuilding. There are several steps in Reverse

engineering, such as Scanning, Preliminary processing of the point cloud after

scanning, Final processing of the point cloud, The use of RapidForm XOR for

creating a model or virtual prototype is not recommended because, after printing, the

undercut surfaces collapse. We intended to incorporate two extrusion head units into

the planned printing unit because of this. Design of the extrusion head unit (The

retortion unit and Structure of the extrusion head unit) implementation of the X-Y

movement with the new extrusion head unit and Belt tension. The author described

how to create a machine using FDM technology and how to reverse engineer it. After

learning from the printer, they began to create an experimental printer unit to address

the shortcomings of the earlier model. A head-holder console and a small, user-

friendly jog unit make up the intended printing unit. The aim was to build a structure

that could print support material and have the X-Y movement performed
 32

simultaneously by the extrusion head unit. They included two extrusion heads in the

printing machine because of this. As a result, they have created a unit that makes a

fantastic assembly of an existing or completely new machine.

[Vithani, Goyanes, Jannin, Basit, Gaisford & Boyd (2019)] Three steps make

up the FDM process: (1) extrusion of molten material, (2) layer deposition of

material, and (3) layer solidification (usually cooling of the printed layers). In a

nutshell, heating elements melt the thermoplastic polymeric filaments (printing

materials) slightly above the softening point when they are fed through the nozzle tip

of the printer head. On the build plate, these semi-molten ingredients are extruded via

the printer head's nozzle tip to create a thin layer of material. Typically, the outside

layer is printed first, followed by layer-by-layer printing of the inside structures, with

an extruded polymer known as the "infill" filling in any internal spaces. FDM has

been widely used with a variety of polymeric materials, including thermoplastic

polyurethane (TPU), high-impact polystyrene (HIPS), acrylonitrile butadiene styrene

(ABS), polylactic acid (PLA), polyvinyl alcohol (PVA), aliphatic polyamides (nylon),

and polyvinyl alcohol (PVA).

[Nivetha1, P. Durga1, R. Kavya1 (2019)] 3D printing is a rapid prototyping

technique using small, light machines and CAD tools like Cura and Pronterface. This

technology reduces acquisition costs and allows for the creation of intricately formed

items. However, most 3D printers operate in open-loop systems, resulting in

incomplete results. A closed-loop system uses a stepper motor controller to count

steps and resume printing when they are missed. The principle behind 3D printing is

additive manufacturing, which involves layer-by-layer printing. Fused filament

manufacturing is the most popular, using materials like plastic, metal, or powdered

metal. 3D printing is an open-loop system that doesn't check for errors and requires
 33

extra time. It doesn't detect skipped steps or excessive filament extrusion, leading to

ringing on the printing surface. The process is complicated due to excessive

formatting, parameters, and mechanical tinkering. The main issue is that 3D printing

may not produce a flawless result due to factors like overheating, skipped procedures,

and failure to try again. Most 3D printing equipment is not user-friendly, and users

need basic knowledge of Arduino programming and g-code to fix errors. Building a

3D printer is costly, with each component costing around $3. Plastic and metal-based

3D printers also contribute to pollution and energy consumption. 3D printing

primarily uses plastic, including polystyrene, polycarbonate, and acrylonitrile

butadiene styrene, for toys and home goods. Metals like stainless steel, bronze, gold,

nickel, aluminum, and titanium are widely used, with direct metal laser sintering

being the aerospace sector's method.

 34

Other materials include paper, graphite, graphene, nitinol, and carbon fiber. Fused

deposition modeling (FDM) and material extrusion are other 3D printing methods that

use resins in the vat processing process, resulting in detailed and flawless products for

various applications. Fused filament printing involves using polylactic acid (PLA)

filament and a 3D printer setup. The setup includes an Arduino Mega 2560 R3,

RAMPS 1.4 shield, stepper motors, stepper motor driver, extruder, hotend, heatbed,
 35

and end stops. Cura is used to divide the item into horizontal layers, and a g-code file

is created using Pronterface. The printer monitors the process and recreates missing

steps, resulting in a finished product. Proteus software can be used to simulate the

process.

[P.Raja, Ragul Kanna, Bazeer and Arunpandiyan (2020] The open-source

software known as the Arduino IDE is used to create and upload code to Arduino

boards. For different operating systems, including Windows, Mac OS X, and Linux,

the IDE program is appropriate. The programming languages C and C++ are

supported. Integrated Development Environment is referred to in this sentence.

Sketches are computer programs created using the Arduino Software (IDE). These

drawings are created in a text editor and saved as files with the.ino extension. The

editor offers functions for text replacement and text searching. When saving and

exporting, the message section provides feedback and shows errors. The console

shows text generated by the Arduino Software (IDE), including error messages in

their entirety and other data. The configured board and serial port are visible in the

window's bottom right corner. You may create, save, and save drawings, validate and

Figure 2.11. Arduino Software IDE

 36

upload programs, view the serial monitor, and more using the toolbar buttons. Marlin

is an open-source firmware created for FDM 3D printers used in the RepRap project

that runs on the Arduino platform. It is controlled by a mainboard that has built-in

hardware and general-purpose I/O pins and accepts G-code commands via USB ports

or other sources of input or media. Real-time operations, including stepper motors,

heaters, sensors, lighting, displays, and user interfaces, are managed by the main loop.

Marlin supports a number of 3D printing robot platforms, including less traditional

models like Hang printer and Belt printer as well as Cartesian, Core XY, Delta, and

SCARA printers. Any equipment that has to be controlled and interacted with may use

it, including SLA and SLS 3D printers, specialized CNC mills, laser engravers, laser

cutters, vinyl cutters, pick-and-place devices, foam cutters, and robots that paint eggs.

[Hanchate & Jagtap (2022)] Printing history began with stamp replication,

followed by flatbed printing in the 18th century, and then chromolithography in the

19th century. The 2D printer revolutionized color printing, leading to the development

of 3D printers. Current research focuses on designing and developing low-cost 3D

printers. The main idea behind a 3D printer is to create items layer by layer, giving the

product its "three-dimensional" name. However, 3D printers are more expensive due

to the printing technique and materials used. This project aims to reduce the price of

3D printers by recycling leftover materials and creating a frame. The main goal is to

make 3D printing accessible to the general public by making the machinery simple to

use and automating operations. The goal is to reduce interaction time and make the

gadget reasonable and accessible to everyone. This project targets those with cost

constraints, making 3D printers useful in school laboratories, fake jewelry production,

automobiles, and other sectors. The goal was to research, develop, and build a 3D

printer. The team purchased a complete toolkit and used Solid Works to create a CAD
 37

model. They created the necessary components and assembled them on the Solid

Works CATIA V5R21 workbench. The voltage converter and microcontroller were

Figure 2.12 Circuit Diagram of 3D printer

used to control the components. Characteristics such as bed temperature, extruder

temperature, feed rate, and flow rate were considered before producing a product.

Fans were necessary for cooling the bed and metallic elements. After programming

the Arduino Mega 2560, the system was tested for the first time, and the display was

functional. The 20 mm x 20 mm x 20 mm cube was manufactured in 90 minutes. A

bed heating issue was fixed by switching the wire to a heavy-duty wire (2.5 mm). The

updated setup was used to create the new cube, which was calibrated for precision,

ensuring accurate dimensions within 0.5%.

[Stephanie Torta and Jonathan Torta Mercury] The most popular desktop

printer uses FDM, stereolithography, and DLP, using light-sensitive resin media cured

by ultraviolet light. Repeated printing of tiny layers produces 3D items. These printers
 38

are relatively new to DIY and small business markets, but are increasingly used for

miniatures and dental accessories. Despite their high costs and challenges, these

printers are becoming more popular for small-scale production. An FDM 3D printer is

a hot glue gun with a small nozzle and mechanical carriage, drawing an object's

contour and increasing height with each layer. Portable versions, called 3D pen, are

used for impromptu drawing. 1) The extruder, which is connected to a 3-axis system

for accurate movement in the X, Y, and Z axes, is loaded by the printer with a spool of

thermoplastic filament. 2) The printed item is outlined by tiny strands of filament that

are extruded one layer at a time. 3) The filament hardens as it cools, and cooling may

be sped up by using a cooling fan. 4) To support top layers and maintain the item

sturdy, infill is frequently required. 5) Up until the item is finished, the procedure is

repeated as the extruder advances to create way for the following layer. There are a

few main types and configurations of FDM printers.

1) Freehand pen, 2) Cartesian , 3) Delta, 4) Polar, 5) Robotic arm.

Components of FDM printer include: Mechanical components and electrical

components. Mechanical components are extruder, Bed, Motor, and Frame

Components. An extruder contains two parts 1) The cold end and 2) The hot end. The

cool end consists the filament drive. Cold end’s subcomponents are Hobbed Gear,

Idler Gear, Direct Drive and Bowden Drives. Hot End consists of all parts used to heat

and extrude the material. Hot end’s subcomponents are Heater Cartridge, Heater

Block, Thermistor/Thermocouple, Heat Break, Heat Sink/Hot End Fan, Layer

Cooling Fan(s), Nozzle. Bed, Motor, and Frame components comprising Print Bed,

Bed Surfaces, Bed Leveling and Tramming Mechanisms, End Stops (one for each

axis), Threaded Rods or Leadscrews, Stepper Motors, Belts, Frame, Enclosure,

Filament and Holder. Electrical Components of the FDM printer are Power Supply,
 39

Motherboard/Controller Board, SD Card Slot, USB Connector, Stepper Drivers,

Screens and User Interfaces, Lights (LEDs), Camera, Enclosure Fan and Filter.

Table 2.1 FDM 3D Printer Components and Quantity

S# Description of the Components Quantity Budget in PKR

1 NEMA 17 Stepper Motor 5 2000
2 Arduino Mega 2560 1 4500
3 Ramps1.4 Shield 1 1000
4 A4988 Stepper motor Drivers 5 2000
5 V6 J-Head Hot end Bowden Extruder 1 1500
6 Mk8 Extruder Aluminium Block DIY Kit 1 4500
7 Smooth rod m8 500 mm 6 2100
8 T8 Trapezoidal Lead Screw 8MM 6 500
9 Flexible Coupling Coupler 6 2100
10 LM8UU 8 mm Linear Ball Bearing 6 2100
11 End stop switch 3 600
12 GT2 6MM Open Timing Belt +Pulley 2m 500
13 20 Teeth Pulley 5mm Bore 2 500
14 S-240 12 Volt 20-amp DC power supply 1 4000
15 PLA 1.75 mm filament 100m 1500
16 2 x 1.5-inch Aluminium Channel -- 2000
30cm Pin to Hole Arduino Jumper Wire
17 -- 200
Dupont
18 M5 Threaded Rod 8 3000
19 4mm glass for printed Bed 1 500
20 Total Budget in PKR 35000

[Gibson David Rosen Brent Stucker (book)] Stratasys' FDM machines are

effective because to their inexpensive price and advantageous material characteristics.

They do, however, suffer from limitations in terms of material density, construction

precision, and speed. Longer construction durations result from the layer thickness

choice of 0.078 mm available on the most expensive machines. The nozzle,

acceleration and deceleration traits, and viscoelastic behavior of the material all affect

the form that is created. An FDM system's speed is determined by the feed rate and

plotting speed. On early Quantum machines, Stratasys employed Magna drive

technology to move the plotting head, which decreased friction and made it simpler to
 40

move the heads at greater speeds. A specific construction method seeks to strike a

compromise between the speed of utilizing thick layers and the accuracy of using

small layers. In the most modern FORTUS 900MC machine, conventional ball screw

drives have taken the place of this strategy. When designing using FDM, it's crucial to

take different stacking techniques and a part's anisotropic nature into mind. It is

preferable to construct sections with significant stress axes aligned with the x-y plane

rather than in the z-direction for portions that experience stress in a certain direction.
 41

3. Research Methodology
The following flow chart shows the methodology used by me in the construction of a

3D printer. The first step is to download the 3D model or design from the website,

upload the model to Cura (3D modeling software), and generate an STL file. After

generating the STL file, slice the model, add support, generate G-code, and upload the

G-code file to the Arduino board through for further processing and printing the

Figure 3.1 Functional Diagram for the 3D printing

physical object. We upload the G-code to Pronterface software for printing the object,

and the machine does level processing and layer processing, and the object is printed

layer by layer. After printing the object, remove the support and clean the surface.

Finally, the model is ready after printing.

3.1 Selection of Process

The 3D printing industry is constantly evolving, with advancements in hardware, raw

materials, and production techniques. FDM technology, which is environmentally

friendly, clean, and user-friendly, is a popular choice for printing complex pieces and

forms. It is a more economical and environmentally friendly option compared to other

3D printing methods. FDM begins with creating an STL file and cutting and

positioning the model for construction. It can distribute various materials to achieve

various goals. The filament is extruded into the proper form layers, hardening after
 42

leaving the nozzle. A metal or plastic wire is released, supplying material to an

extrusion nozzle that controls flow. The filament is pushed into the nozzle at a

regulated pace using a worm drive, and an ejection head protects the thermoplastics.

The nozzle can be moved by numerically controlled components on both even and

vertical bearings, and the part is created from the last layer at a time. FDM is flexible

but excels at handling fine details by reducing the number of layers.

3.2 Selection of Mechanism

We have chosen cartesian arrangement of developments. The most prevalent type of

FDM 3D printer available now is cartesian models. This technology employs three

orthogonal axes—X, Y, and Z—to calculate the proper placements and directions of

the print head in accordance with the mathematical Cartesian coordinate system.

Depending on the printer's model and maker, the Z axis will be controlled by the print

platen, allowing the X and Y axes to be used to position the extruder such that it may

travel in four directions. The main advantage of these solutions is that they are

generally inexpensive and are sold as kits to be assembled by the user. [26]

3.3 Softwares used (CAD and CAM)

3.3.1 CAD

Computer Aided Design (CAD) is a software used to create 2D and 3D models and

designs. It is a manufacturing method that uses computer software and automatable

machinery to create products with high accuracy and precision. CAD software is used

across various industries and occupations, including architectural designs, building

plans, floor plans, electrical schematics, mechanical drawings, technical drawings,

blueprints, and special effects. It is used to create 3D parts for printing and is used to

improve efficiency, configuration, documentation, and manufacturing databases.

 43

CAD files are essentially parametric records, representing parts as a tree of Boolean

operations on primitive shapes like cubes, spheres, cylinders, and pyramids.

3.3.2 CAM

Computer-aided manufacturing, or CAM, technologies manage the intermediate step

of turning CAD data into a machine-friendly form used by our 3D printer electronics.

We'll be using software that combines object slicing, G-code and M-code creation,

object positioning, and other printer settings in this situation. When CAM software

transforms a 3D object into a machine format, it frequently needs an STL file. The

machine-friendly printing format is known as G-code. A product model developed in

CAD software is used by a CAM tool. The former handles production and translates

the computer models into a language that the machining tool can understand.

3.4 How FDM printer works

The most popular kind of Cartesian printers are FDM ones. Cartesian describes the

coordinate system that the printer uses to move the build plate and print head. Three

rails are present in these printers, one for each of the three axes (X, Y, and Z). The

Build platform moves in the Z-direction, whilst the Printhead (the complete Extruder

and nozzle assembly) moves in the X and Y directions. The extruder is first supplied

with filament, the raw material. The two diameters of FDM printer filaments are 1.75

mm, which is the most popular size, and 3 mm. One specific printer only utilizes one

kind of filament. The filament is pulled up by the gear mechanism in the extruder and

pushed down to the heater, where it melts. According on the filament type, the

melting temperature typically ranges from 190°C for PLA to 300°C for

polycarbonate. The nozzle is then reached by this molten filament. The nozzle is

typically offered in two diameters (0.2 & 0.4 mm), while it is also available in

additional sizes. The layer thickness and print quality can be impacted by the nozzle
 44

diameter. The material is applied by the nozzle to the build platform in the precise

geometry required by the model that will be printed. The initial layer of the print is

laid down by the nozzle, which travels in an X and Y direction. The key processes of

the 3D printing using fused deposition modeling are as follows:

Step 1: After entering the CAD data, the already-loaded solid construction material

filament is heated in the liquefier head to liquify it.

Step 2: Using an extrusion nozzle that travels in all directions according to the CAD

data, this liquid plastic that is molten is fed onto the foam construction platform as a

layer. The liquid/semi-solid layers are repeatedly added one on top of the other in this

manner. Support structures are employed if the design has overhangs or other

Figure 3.2 FDM Working principles

elements that might possibly strain or bend. Depending on the option, the support

material may be the same as the building material.

Step 3 – In case support structures were used, they are later removed once the build is

complete.
 45

4. Description of various Components of FDM Printer

4.1 Smooth rod m8 500 mm

These are the straight rods that come with 3D printer kits. They are composed of high-

carbon steel that has been chrome-plated, and when used with linear bearings, they

offer smooth, reliable motion. These smooth rods, which are made for use in CNC and

linear motion applications as well as hydraulic and 3D printing, can withstand heavy

use without breaking down. It has the following features.

 High stability, hardness, and accuracy.

 Control every precise procedure rigorously to guarantee quality.

 Simple construction, robust material, high-temperature preheating, and precise

outside hole sizing.

 It has been used in numerous sectors due of its mild hardness.

 Made of stainless steel, which has good wear resistance, high strength, and

resistance to corrosion.

Figure 4.1 Smooth rod M8 500 mm

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4.2 T8 Trapezoidal Lead Screw 8mm

For use with a CNC machine, this 8mm T8 brass screw nut is available. With ACME

shaft lead, this 2mm lead screw is utilized in common machine equipment like 3D

printing. Brass T8 lead screws are extremely dependable when used in applications

involving linear motion. This lead screw for a 3D printer has anti-corrosion, wear

resistance, and is non-slip. Simple to use; no processing required. It has the following

features.

 resistant to wear, corrosion, and slipping. Simple to use; no processing

required.

 8mm lead screw is appropriate for 3D printers.

 8mm lead screw size.

 Hole spacing for screws is 4 * 3.5mm.

 Compact craftsmanship, high-quality brass material.

 applicable to step motor, machine tool guide rail, and other equipment

supported by screw rod.

 This will make it simple to install and practical to use.

Figure 4.2 T8 Trapezoidal Lead Screw 8mm

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4.3 Flexible Coupling Coupler

Your driving shaft and the driven shaft can be connected by a 5x8mm flexible

coupling shaft. 5x8mm Flexible Coupling Shaft is particularly effective in eradicating

misalignment to the greatest degree feasible. Another fantastic benefit of this

aluminum flexible coupling is very minimal backlash. This flexible connection is

made of machined aluminum and has an outside diameter of 19mm and a length of

25mm. The first bore has a diameter of 5 mm, while the second bore has an 8 mm

diameter as well.

Since it has a spiral cut through the center of its length, it is flexible and can fit to two

shafts even if they are not precisely co-linear, which will lessen the impacts of

binding. These couplings are also referred to as Flexible coupling, Beam coupling,

and Helical coupling. It has the following features.

 shaft end-play, parallel misalignments, and angular misalignments are all

absorbed by spring action.

 High durability and resistance to corrosion.

 connect the shaft for a small torque.

 a single-piece design that offers durable performance.

 Consistent velocity is provided by a low moment of inertia.

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 Torsionally

flexible coupling is

frequently utilized in drive

systems for encoders,

instruments, lead

screws, tiny pumps, feed

rollers, Figure 4.3 Flexible Coupling Coupler and anyplace

light to medium duty coupling is needed.

4.4 LM8UU 8 mm Linear Ball Bearing

You may get a very accurate, secure, and dependable linear motion system with the

LM8UU 8 MM Linear Motion Bearing. These CNC (Computer Numerical Control)

machines and 3D printers are the main applications for such linear motion bearings.

An LM8UU 8 MM Linear Motion Bearing may offer low friction motion along a

single axis, making it useful for a variety of robotics and do-it-yourself projects.

This LM8UU 8 MM Linear Motion Bearing closed type ball bushing, which has a

15mm outer diameter and an 8mm bore, can be used to transport components in a

mounted sliding unit. There is no need to worry about replacing any worn components

because these Bearings have a variety of standardized parts that are interchangeable.
 49

Figure 4.4 LM8UU 8 mm Linear Ball Bearing

4.5 GT2 6MM Open Timing Belt:

Highest level of accuracy Black Open Timing Belt For 3D Printer, GT2 Width 6mm.

Manufactured from NEOPRENE, a synthetic rubber that has been strengthened with

Figure 4.5 GT2 6MM Open Timing Belt

fiberglass strands. On April 17, 1930, DuPont scientists created neoprene, a synthetic

rubber that resists oil. The mechanical drive belt of the timing belt, also known as the

synchronous belt, is well recognized for not sliding. It is made out of a flexible belt

with a row of teeth implanted on the inner surface. The timing belt and timing pulley

function when their toothed components mesh.

4.6 Teeth Pulley

The linear motion is the only use for the GT2 20T pulley. 20 teeth and an 8mm inner

bore can be found on this GT2 timing pulley. It may be securely fastened to any 8mm

diameter shaft using two set screws. These are extremely lightweight and robust since

they are made entirely of aluminum. When you reverse the pulley direction, there is

no room for the belt to move in the groove because they employ a rounded tooth

profile, which ensures that the belt tooth fits smoothly and properly in the pulley
 50

groove. For building 3D printers, the GT2 8mm pulley wheel with 20 teeth or grooves

is a good option. The 20 teeth, 8mm diameter GT2 series of belts and pulleys are

made exclusively for linear motion.

When you reverse the pulley

orientation, there is no room for the belt

to move in the groove because

they employ a rounded tooth

profile that ensures that the belt tooth

fits smoothly and properly in the

pulley groove.

Figure 4.6 Teeth Pulley

4.7 Aluminium Channel Frame

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These channels are most frequently used for framework, tracks, slides, safety edges,

railings, rails, rims, and ornamentation.

Figure 4.7 Aluminium channel frame

4.8 V6 J-Head Hotend Bowden Extruder

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This is a cooling fan-equipped 3D Printer Short Distance V6 J-head All Metal Hotend

Extruder. This hotend extruder for a 3D printer uses a 1.75/3mm 12V 0.4mm Nozzle.

Before depositing the filament in the building area, the hotend is a group of

components designed to melt and extrude the filament. Whether mounted directly or

indirectly, the hotend always functions in tandem with the extruder (bowden).

Figure 4.8 V6 J-Head Hotend Bowden Extruder

To put it simply, the filament is pushed into a tiny chamber by the extruder, where it

melts. Under pressure, the molten material escapes through a tiny hole and deposits

itself on the foundation of the building or the piece, where it solidifies. Because the

filament is being pushed, maintaining maximum stiffness prior to entering the melting

zone is crucial. To do this, the hotend must have two clearly distinct sections: a cold

zone and a hot zone, with as little time as possible passing between them. These

characteristics are present.

 53

 High temperature and heat ventilation: 12V/40W NTC heater, which doesn't

burn or break often; 304 stainless steel nozzle throat and high-quality

resistance; 12V high-speed fan, which swiftly loses heat.

 Design features that prevent material spilling and blockage include a smooth

connection between the nozzle and tube.

 NTC connection with terminal makes installation simple; just do it.

 Compatible with all 1.75mm V6 3D printers.

4.9 MK8 Extruder Aluminium Block DIY Kit

This aluminum alloy block is a premium MK8 extruder replacement. Replace your

broken or clogged extruder with it. This block is provided in kit form, and the user

must assemble it. You may find several assembly instructions and tutorials on the

internet to assist you in building your extruder because it is a widely used model.

There are three different varieties of the MK8 Extruder: right side, left side, and right

short. The direction in which the filament is extruded with regard to the extruder

block differs between these extruders. Any extruder may be utilized with single

extruders. One right side and one left side extruder can be used when employing twin

extruders.
 54

4.10 PLA 1.75 mm filament

3D printers use PLA Filament as a material. There is 1.75mm wire diameter filament

available in Pakistan. Army Green, Black, Blue, Bronze, Brown, Coffee, Dark Blue,

Dark Orange, Dark Purple, Gold, Green, Grey, Lake Blue, Light Green, Orange, Pink,

Purple, Red, Silver, Skin, Sky Blue, White, Wood, and Yellow are the hues that are

Figure 4.9 MK8 Extruder Aluminium Block DIY Kit

readily accessible. For finer details where dependability and extruder efficiency are

crucial, 1.75mm filament is preferable. There is no other option than 3.00mm

Figure 4.10 PLA 1.75 mm filament

filaments if you want to print with a 2.00mm nozzle.

4.11 NEMA 17 Stepper Motor

The stepper motors are the motors of choice for machines requiring precise position

control because they move in perfectly repeatable increments. At 1.2A current per

phase, the NEMA17 4.2 kg-cm Stepper Motor is capable of producing 4.2 kg-cm of
 55

torque. Stepper Motor Drivers enable the motor's position to be ordered to move or to

remain in a single position. The NEMA17 4.2 kg-cm Stepper Motor responds to

starting, halting,

and reversing

pulses from the

Stepper Motor

Driver with

remarkable accuracy. They are quite helpful in a variety of applications, particularly

those that need for low speed and great precision. Numerous devices, including 3D

printers, CNC mills and routers, camera platforms, XYZ plotters, etc.

Figure 4.11 NEMA 17 Stepper Motor

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4.12 Arduino Mega 2560

A microcontroller board called the Arduino Mega 2560 is based on the ATmega2560

(datasheet). It contains 16 analog inputs, 4 hardware serial ports (UARTs), a 16 MHz

crystal oscillator, 54 digital input/output pins (14 of which may be utilized as PWM

outputs), a USB connector, a power jack, an ICSP header, and a reset button. It comes

with everything needed to support the microcontroller; to get started, just plug in a

USB cable, an AC-to-DC converter, or a battery. The majority of shields made for the

Arduino Uno, Duemilanove, or Diecimila are compatible with the Mega. Features of

Arduino Mega are: -

 Microcontroller: ATmega2560

 Operating Voltage: 5V

 Input Voltage (recommended): 7-12V

 Input Voltage (limits): 6-20V

 Digital I/O Pins: 54 (of which 15 provide PWM output)

 Analog Input Pins: 16

 DC Current per I/O Pin: 40 mA

 DC Current for 3.3V Pin: 50 mA

 Flash Memory: 256 KB of which 8 KB used by bootloader

 SRAM: 8 KB

 EEPROM: 4 KB

 Clock Speed: 16 MHz

 57

 USB Host Chip: MAX3421E

Figure 4.12 Arduino Mega 2560

4.13 Ramps 1.4 Shield

 58

The main function of the 3D printer controller board RAMPS 1.4 Arduino Mega

Shield RepRap Prusa Model is to use pololu stepper driven boards (comparable to

4988 driven boards). Only when attached to its mother board Mega 2560 and

4988/DRV8825 can RAMPS function. due to its excellent interoperability with the

majority of 3D printers (all Reprap models, including the Pursa i2 and i3) and

operational stability. The Ramps1.4 + MEGA2560 + A4988/DRV8825 combo is

Figure 4.13 Ramps 1.4 Shield

quickly gaining popularity as a DIY 3D printer control board. As long as the primary

RAMPS board is retained at the top of the stack, the system may also accommodate a

number of Arduino extension boards. Ramps boards are the brains of the majority of

commercially available DIY 3D printers and a great, tidy, small approach to

incorporate all the systems into a mountable, compact enclosure structure.

4.14 A4988 Stepper Motor Drivers

Pakistan offers the A4988 driver Stepper Motor Driver, a comprehensive micro-

stepping motor driver with a built-in converter that is simple to use. It can give up to 1

A per phase without a heat sink or forced air flow while operating between 8 V and 35

V. It is rated for 2 A per coil with enough supplementary cooling. A fixed off-time

current regulator is included in the A4988 driver Stepper Motor Driver; the regulator
 59

may operate in either slow or mixed decay mode. The converter is essential for the

A4988's simple implementation. Phase sequence tables, programming for the high-

frequency control interface, etc. are not present. When a complicated microprocessor

is not accessible or is overloaded, the application of the A4988 interface is particularly

Figure 4.14 A4988 Stepper Motor Drivers

suited. The A4988's chopping control automatically chooses the current decay mode

(slow or mixed) throughout the stepping process. The mix decay current control

system can enhance step precision, decrease power consumption, and minimize

audible motor noise.

4.15 End Stop Switch

Lever switches are used in CNC 3D Printer Mech Endstop Switch to determine when

they are triggered. The CNC end stop switch is configured to draw the signal to LOW

when engaged. On the board, there is also an LED that will turn on when the switch is

turned. This top limit switch accepts a regular, vintage CD-ROM audio connection

cable and uses a conventional 4 pin, 100′′ pitch header. We want to be able to

determine when an X/Y/Z stage has achieved its lowest or maximum. Rather than

fiddling with flags or intricate light beam interruption, we employ a mechanical

switch as the mechanical end stop. If the switch is placed in the stage's route, the stage
 60

will simply close the switch module when it passes over it. We don't need to change

the stage in any way other than where the switch should be. You may get a good

Figure 4.15 End Stop Switch

night's sleep even if you are concerned about dependability. The limit switch modules

we employ have a 1 million operation failure rate rating. You may print one million

times before needing to replace the switches because we only utilize them once every

print.

4.16 12 Volt 20-amp DC power supply

A dependable switching power supply that is made of high-quality materials, long-

lasting, and secure to use is the LED Switching Power Supply. a novel design for a

power supply that can maintain voltage stability at 12 volts dc. For residential

appliances, a great switching mode power supply. A universal AC input with a wide

range and an automated on-off cooling fan provides cooling. Tested at full load. One

of the most widely used power sources in use today is the 12V power supply (also

known as the 12VDC power supply). Transformers, diodes, and transistors are often

used in conjunction to convert a 110VAC or 220VAC input into a 12VDC output.

 61

Figure 4.16 12 Volt 20-amp DC power supply

4.17 Heat Bed

RepRap MK2B heatbed for 3D printer A heated bed called the Dual Power Supply is

made for 3D printers like the Reprap Prusa and the Mendel. It is also compatible with

various 3D printers. The newest heat bed model, the MK2B, has LED lighting and

dual power supply choices for 12 and 24 volts. This heatbed has a high heat output

and offers uniform, even heating since it is directly engraved on 35 m of copper clad.

Features of 3d Printer Heated bed:

 Color: Red

 Etching: 35um copper

 Dimensions 214 x 214mm

 Laminate FR4 1.6+-0.15mm

 2 layer, 35μm copper

 Red Solder Mask – both sides

 White Silkscreen – both sides

 62

 Power Input: 12V or 24v

 Copper plated holes

 Resistance between 1.0 and 1.2 ohm

Figure 4.17 Heat Bed

 63

5. Results
64
 65

6. Conclusion and Recommendations

 66

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