International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 7294
DESIGN AND DEVELOPMENT OF LOW COST 3D PRINTER
Asif Angadi1, Avinash Bhadvankar2, Pushkar Akole3, Pawan Nagargoje4
1Assistant Professor, Mechanical Dept, P G Moze COE Wagholi, Pune.
2,3,4Student, P G Moze COE Wagholi, Pune.
---------------------------------------------------------------------***----------------------------------------------------------------------
Abstract - This is on 3D printing which has become a notable
topic in today’s technological discussion. 3D printing is a form
of additive manufacturing technology where a 3D object is
created by laying down successive layers of material it is also
known as rapid prototyping [1], it is a mechanized method
where by 3D objects are quickly made on reasonably sized
machine connected to a computer containing blue prints for
the objects. Here in this technology 3 steps are included such
as Designing, Printing and Finishing. In 1st step we use any
CAD software to create 3D design in2nd step3D printercreates
an object using this design. And 3rd step finished object is
removed from printer. This technology saves time and cost, it
saves wastage of material. Fused Deposition Modeling (FDM)
is an additive manufacturing technology for printing 3D
objects layer by layer [2]. The main purpose of the research is
to develop 3D printing technologyforspecialpurpose machine
with low cost. Many industries use traditional methods for
developing prototype for analysis rather than using
technologies like 3D printing because it is expensive. Inthis CD
drives are used instead of stepper motor to develop a printer
which is cost effective and to encourage manufacturers to
adopt the method of 3D printing.3D printing significantly
challenges mass production processes in the future. This type
of printing is predicted to influence industrieslikeautomotive,
medical, education, equipment, consumer products industries
and various businesses.
Key Words: Rapid prototype, Arduino, 3D printing,Additive
manufacturing, FDM
1. INTRODUCTION
3D printing or additive manufacturing (AM) is a group of
technologies that are used to build prototypes, physical
models and finished parts from three-dimensional (3D)
computer aided design (CAD) data. Study showed the
technology has developed rapidly and has proven its
effectiveness, especially for design and small production.
According to research, AM technology allowed for the direct
fabrication of physically complex shapes from its
corresponding CAD with minimum adjustments by using a
layer-by-layer deposition technique [3,8].
Currently, high prices of rapid prototyping
equipment's limit the promotion and application of rapid
prototyping technology. So that we need to be reduce the
cost of 3D printing machine. The reason behindthisproblem
are high prices equipment’s like stepper motors, guideways,
etc. So that to eliminate this problem we need to be
integration of 3D printing technology with other machine
tools. We are integrating 3D printing machine with other
machine tools likes waste CD Drives and Floppy Drives in
which we are manipulating the CD DrivesandFloppyDrives.
Several parts of the 3D metal printer component are the
custom design of a mechanical component which printed on
RepRap 3D printer. After acquiring all the part need to the
3D printer is ready to assemble.
2. METHODOLOGY
Development of low-cost 3D printing machine was very
difficult task for us. So that we are integrating CD drives and
Floppy drives. We are eliminating the high cost stepper
motors. We purchased CD drives and Floppy drives from
scrap. Then this CD drives manipulated such that only
guideways and motor arrangement are used. We used
aluminium composite panel for base (floor), Acrylic plate
used for bed, L-frame used for making structure of machine.
To make machine fully automize we used Arduino ATmega
2560 Microcontroller with 1.4 Ramps for drive the motors
and other accessories of machine [4].
First, we design the structure of machine in CATIA,
according to this design drilled the aluminium composite
panel, L-frame structure, acrylic plates. After that L-frame
fitted by screws, also mount CD drives and Floppy drives on
the structure,assemble the extruder headonthefloppydrive
with the help of fixture which is designed, bed is mounted on
Y-axis of CD drive, adjust the clearance between nozzle and
bed is 0.01mm. Do soldering all CD drives,floppydrives,limit
switches. After that fix the position of Arduino and wiring is
done according to circuit diagram which shown in fig.3.1.
Attachedspoolfeedingmechanismtosteppermotor,material
which is to be printed (ABS, PLA) feed through this
mechanism [7,9]. After manufacturing of machine, we are
done various trials on it.
Fig -2.1: Circuit Diagram
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 7295
3. PARAMETERS CONSIDER TO DEVELOP 3D PRINTER
USING CD DRIVES
1. Extruder Temperature: We are using PLA and ABS
materials for that PLA printing temperature 205 0C
and ABS material printing temperature is 230 0C[5].
Therefore, we are choosing extruder temperature
1800C to 2700C.
2. Extruder Diameter:Generally,extruderdiametercan
be varied as per the requirement, it is need to be
simply change the extruder. Accuracy depends on
nozzle diameter, as reducing diameter accuracy will
increase. That’s why we use standard diameter of
0.2mm to 0.4mm.
Table - 3.1: Technical Specifications of 3D printer
integrated with CD and floppy drives
Parameters Specifications
Maximum Printable Area 60mm x 60mm x 30mm
Input Power 230V AC ->12V DC
Extruder Diameter 0.2mm/0.3mm/0.4mm
Extruder Temperature 180⁰C - 270⁰C
Number Of Extruders 1
Filament Diameter 1.75mm
Recommended Materials ABS, PLA
Maximum Print Speed 80mm/s - 200mm/s
Software Supported Repetier, Cura,
Pronterface
Layer Thickness Range 0.1-0.25mm
Print Monitoring System Through Computer
4. COMPLETE DESIGN AND FABRICATION OF 3D
PRINTER USING CD DRIVES
For developing low cost 3D printing machine, material
required as follows: guide ways and motors of CD drive
and floppy drive, limit switch, stepper motor, poly-tetra-
fluoro-ethylene (PTFE) tube and various fastener. The 3D
printer consists of three axis which is x-axis, y-axis, and
z-axis. Each axis has its respective function while moving,
which is controlled by microcontroller [6]. The y-axis
functions to move the printed bed where, the movement
from rotating to linear is converted by a lead screw. The
x-axis component is attached to the top of the printed bed
and its function same as the y-axis but is different in terms
of movement direction. The x-axis and y-axis are moves
with the help of mechanism of CD drives. The third axis is
the z-axis, on which extruder headismountedanditmoves
the z-direction using mechanism of floppy drive. We using
the Pronterface software for the slicing purpose.
Fig - 4.1: Assembly of 3D Printer machine
5. CUSTOM DESIGN FOR MOUNTINGS OF EXTRUDER
HEAD AND FLOPPY DRIVE
This custom design printed from other 3D Printer then it
assembles to the floppy drives.
Table - 5.1: Custom Design for mountings of extruder
head and floppy drive
Image Printed component Number
Fixture -1 for extruder head
which is mounted on floppy
drives.
1
Fixture-2 for extruder head
which is mounted on fixture-1
1
6. TESTING
We are tested 3D printer machine by printing a simple
component like cube. First, we draw the cube in CATIA
software which is shown in fig.6.1. Then it saves as STL
format for slicing the component in slicing software. We
are using Pronterface software.
Fig - 6.1: CATIA Model of Cube
1.The file created is then loaded in the pronterface
which connects Arduino with the computer.
2.From the pronterface software we can give print
command. The Arduino mega will thus send
3D Printed part building
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 7296
command to the stepper motor & we get a 3D
model.
3.Figure above is a snap shot of pronterface
software showing the wagon wheel through
which the motions of the 3D printer can
controlled.
Fig - 6.2: Pronterface Software
Fig - 6.3: After printing object
7. FUTURE SCOPE
1. Scaling of machine.
2. Flexibility in choosing raw materials.
3. Increase productivity of machine.
4. Integration of system with laser.
8. COST ESTIMATION
Table - 8.1: Cost Estimation for developing low
cost 3D printer
9. CONCLUSION
3D printing has lot of problems, such as slow
printing speeds [10]. The cost of 3D printing is decreasing
and the number of 3D printers sold worldwide has been
growing progressively. The main aim of our project was to
reduce cost of 3D printer with replacing the high cost
stepper motor (1 stepper motor price is near about 18000
Rs Indian High Quality) by CD drives and floppy drives. We
have been successfully reduced the cost of 3D printer
machine. We are developed 3D printer machine with use of
CD drives in 9000 Rs.
REFERENCES
[1]. L.G. BLOK, M.L. LONGANA, H.YU, B.K.S. WOODS: “An
Investigation Into 3D Printing of Fabre Reinforced
Thermoplastic Composites.”//(ACCIS), Bristol, BS8
1TR, UK 22(2018) 176-186.
[2]. UGANDHAR DELLI, SHING CHANG: “Automated
Process Monitoring in 3D Printing Using Supervised
Machine Learning.”//Kanas State University, 2061
Rathbone Hall, 1701B Platt St, Manhattan KS 66502,
United states of America 26(2018) 865-870.
[3]. NGOC-HIEN TRAN, VAN-NAM NGUYEN, ANH-VU
NGO, VAN-CUONG NGUYEN: “Study on The Effect of
Fused Deposition Modeling Process Parameters on
The Printed Part Quality”//ISSN: 2248-9622, Vol.7,
Issue 12, Hanoi, Vietnam.
[4]. MARY B. HALLI, NARAYANA SWAMY R: “Design and
Implementation of Arduino Based 3D Printing Using
FDM Technique.”//T. John Institute of Technology,
Karnataka, India.eISSN:2319-1163.
[5]. VINOD G. SURANGE, PUNIT V. GHARAT: “3DPrinting
Process Using Fused DepositionModelling.”//SJCET,
Palghar (MH), e-ISSN:2395-0056.
[6]. R.M. Miranda, G. Lopes, L. Quintino, J.P. Rodrigues, S.
Williams: “Rapid prototyping with high power fiber
lasers.”// a Faculty of Sciences and Technology,New
University Lisbon, Portugal b IDMEC, Instituto
Superior, MaterialsandDesign29(2008)2072–
2075.
[7]. J.L. Song, Q.L. Deng, D.J. Hu: “Rapid prototyping
manufacturing of silica sand patterns based on
selective laser sintering.”//school of mechanical and
power engineering, Shanghai Jiao tong University,
Shanghai 200030.
[8]. Danezan, G. Delaizir, N. Tessier-Doyen, G. Gasgnier,
J.M. Gaillard, P. Duport: “Selective laser sintering of
porcelain.” // Journal of the European Ceramic
Society38(2018)769–77.
[9]. Feng Ma, Hua Zhang, K.K.B. Hon, Qingshan Gong: “An
optimization approach of selective laser sintering
considering energy consumption and material
cost.”// of Mechanical Transmission and
Manufacturing Engineering (Wuhan University of
Sr no Parameters Price
1. Arduino mega with ramps &
connecters
2700/-
2. Neema 17 stepper motor 995/-
3 0.4mm hot end (extruder) 570/-
4. 12 volt power supply 620/-
5. End stop 370/-
6. 3d printer filament 1250/-
7. CD drives 200/-
8. Floppy drive 100/-
9. L shape plates 200/-
10. Acrylic plate 250/-
11. Aluminium panel 250/-
12. Tools and accessories 2000/-
Total 9505
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 7297
Science &Technology), Wuhan 430081,Journal of
Cleaner Production 199 (2018)52.
[10]. H. Lipson and M. Kurman, Factory at Home: The
Emerging Economy of Personal Manufacturing.
Washington: U.S. Office of Science and Technology,
2010, n.p.

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IRJET- Design and Development of Low Cost 3D Printer

  • 1. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 7294 DESIGN AND DEVELOPMENT OF LOW COST 3D PRINTER Asif Angadi1, Avinash Bhadvankar2, Pushkar Akole3, Pawan Nagargoje4 1Assistant Professor, Mechanical Dept, P G Moze COE Wagholi, Pune. 2,3,4Student, P G Moze COE Wagholi, Pune. ---------------------------------------------------------------------***---------------------------------------------------------------------- Abstract - This is on 3D printing which has become a notable topic in today’s technological discussion. 3D printing is a form of additive manufacturing technology where a 3D object is created by laying down successive layers of material it is also known as rapid prototyping [1], it is a mechanized method where by 3D objects are quickly made on reasonably sized machine connected to a computer containing blue prints for the objects. Here in this technology 3 steps are included such as Designing, Printing and Finishing. In 1st step we use any CAD software to create 3D design in2nd step3D printercreates an object using this design. And 3rd step finished object is removed from printer. This technology saves time and cost, it saves wastage of material. Fused Deposition Modeling (FDM) is an additive manufacturing technology for printing 3D objects layer by layer [2]. The main purpose of the research is to develop 3D printing technologyforspecialpurpose machine with low cost. Many industries use traditional methods for developing prototype for analysis rather than using technologies like 3D printing because it is expensive. Inthis CD drives are used instead of stepper motor to develop a printer which is cost effective and to encourage manufacturers to adopt the method of 3D printing.3D printing significantly challenges mass production processes in the future. This type of printing is predicted to influence industrieslikeautomotive, medical, education, equipment, consumer products industries and various businesses. Key Words: Rapid prototype, Arduino, 3D printing,Additive manufacturing, FDM 1. INTRODUCTION 3D printing or additive manufacturing (AM) is a group of technologies that are used to build prototypes, physical models and finished parts from three-dimensional (3D) computer aided design (CAD) data. Study showed the technology has developed rapidly and has proven its effectiveness, especially for design and small production. According to research, AM technology allowed for the direct fabrication of physically complex shapes from its corresponding CAD with minimum adjustments by using a layer-by-layer deposition technique [3,8]. Currently, high prices of rapid prototyping equipment's limit the promotion and application of rapid prototyping technology. So that we need to be reduce the cost of 3D printing machine. The reason behindthisproblem are high prices equipment’s like stepper motors, guideways, etc. So that to eliminate this problem we need to be integration of 3D printing technology with other machine tools. We are integrating 3D printing machine with other machine tools likes waste CD Drives and Floppy Drives in which we are manipulating the CD DrivesandFloppyDrives. Several parts of the 3D metal printer component are the custom design of a mechanical component which printed on RepRap 3D printer. After acquiring all the part need to the 3D printer is ready to assemble. 2. METHODOLOGY Development of low-cost 3D printing machine was very difficult task for us. So that we are integrating CD drives and Floppy drives. We are eliminating the high cost stepper motors. We purchased CD drives and Floppy drives from scrap. Then this CD drives manipulated such that only guideways and motor arrangement are used. We used aluminium composite panel for base (floor), Acrylic plate used for bed, L-frame used for making structure of machine. To make machine fully automize we used Arduino ATmega 2560 Microcontroller with 1.4 Ramps for drive the motors and other accessories of machine [4]. First, we design the structure of machine in CATIA, according to this design drilled the aluminium composite panel, L-frame structure, acrylic plates. After that L-frame fitted by screws, also mount CD drives and Floppy drives on the structure,assemble the extruder headonthefloppydrive with the help of fixture which is designed, bed is mounted on Y-axis of CD drive, adjust the clearance between nozzle and bed is 0.01mm. Do soldering all CD drives,floppydrives,limit switches. After that fix the position of Arduino and wiring is done according to circuit diagram which shown in fig.3.1. Attachedspoolfeedingmechanismtosteppermotor,material which is to be printed (ABS, PLA) feed through this mechanism [7,9]. After manufacturing of machine, we are done various trials on it. Fig -2.1: Circuit Diagram
  • 2. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 7295 3. PARAMETERS CONSIDER TO DEVELOP 3D PRINTER USING CD DRIVES 1. Extruder Temperature: We are using PLA and ABS materials for that PLA printing temperature 205 0C and ABS material printing temperature is 230 0C[5]. Therefore, we are choosing extruder temperature 1800C to 2700C. 2. Extruder Diameter:Generally,extruderdiametercan be varied as per the requirement, it is need to be simply change the extruder. Accuracy depends on nozzle diameter, as reducing diameter accuracy will increase. That’s why we use standard diameter of 0.2mm to 0.4mm. Table - 3.1: Technical Specifications of 3D printer integrated with CD and floppy drives Parameters Specifications Maximum Printable Area 60mm x 60mm x 30mm Input Power 230V AC ->12V DC Extruder Diameter 0.2mm/0.3mm/0.4mm Extruder Temperature 180⁰C - 270⁰C Number Of Extruders 1 Filament Diameter 1.75mm Recommended Materials ABS, PLA Maximum Print Speed 80mm/s - 200mm/s Software Supported Repetier, Cura, Pronterface Layer Thickness Range 0.1-0.25mm Print Monitoring System Through Computer 4. COMPLETE DESIGN AND FABRICATION OF 3D PRINTER USING CD DRIVES For developing low cost 3D printing machine, material required as follows: guide ways and motors of CD drive and floppy drive, limit switch, stepper motor, poly-tetra- fluoro-ethylene (PTFE) tube and various fastener. The 3D printer consists of three axis which is x-axis, y-axis, and z-axis. Each axis has its respective function while moving, which is controlled by microcontroller [6]. The y-axis functions to move the printed bed where, the movement from rotating to linear is converted by a lead screw. The x-axis component is attached to the top of the printed bed and its function same as the y-axis but is different in terms of movement direction. The x-axis and y-axis are moves with the help of mechanism of CD drives. The third axis is the z-axis, on which extruder headismountedanditmoves the z-direction using mechanism of floppy drive. We using the Pronterface software for the slicing purpose. Fig - 4.1: Assembly of 3D Printer machine 5. CUSTOM DESIGN FOR MOUNTINGS OF EXTRUDER HEAD AND FLOPPY DRIVE This custom design printed from other 3D Printer then it assembles to the floppy drives. Table - 5.1: Custom Design for mountings of extruder head and floppy drive Image Printed component Number Fixture -1 for extruder head which is mounted on floppy drives. 1 Fixture-2 for extruder head which is mounted on fixture-1 1 6. TESTING We are tested 3D printer machine by printing a simple component like cube. First, we draw the cube in CATIA software which is shown in fig.6.1. Then it saves as STL format for slicing the component in slicing software. We are using Pronterface software. Fig - 6.1: CATIA Model of Cube 1.The file created is then loaded in the pronterface which connects Arduino with the computer. 2.From the pronterface software we can give print command. The Arduino mega will thus send 3D Printed part building
  • 3. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 7296 command to the stepper motor & we get a 3D model. 3.Figure above is a snap shot of pronterface software showing the wagon wheel through which the motions of the 3D printer can controlled. Fig - 6.2: Pronterface Software Fig - 6.3: After printing object 7. FUTURE SCOPE 1. Scaling of machine. 2. Flexibility in choosing raw materials. 3. Increase productivity of machine. 4. Integration of system with laser. 8. COST ESTIMATION Table - 8.1: Cost Estimation for developing low cost 3D printer 9. CONCLUSION 3D printing has lot of problems, such as slow printing speeds [10]. The cost of 3D printing is decreasing and the number of 3D printers sold worldwide has been growing progressively. The main aim of our project was to reduce cost of 3D printer with replacing the high cost stepper motor (1 stepper motor price is near about 18000 Rs Indian High Quality) by CD drives and floppy drives. We have been successfully reduced the cost of 3D printer machine. We are developed 3D printer machine with use of CD drives in 9000 Rs. REFERENCES [1]. L.G. BLOK, M.L. LONGANA, H.YU, B.K.S. WOODS: “An Investigation Into 3D Printing of Fabre Reinforced Thermoplastic Composites.”//(ACCIS), Bristol, BS8 1TR, UK 22(2018) 176-186. [2]. UGANDHAR DELLI, SHING CHANG: “Automated Process Monitoring in 3D Printing Using Supervised Machine Learning.”//Kanas State University, 2061 Rathbone Hall, 1701B Platt St, Manhattan KS 66502, United states of America 26(2018) 865-870. [3]. NGOC-HIEN TRAN, VAN-NAM NGUYEN, ANH-VU NGO, VAN-CUONG NGUYEN: “Study on The Effect of Fused Deposition Modeling Process Parameters on The Printed Part Quality”//ISSN: 2248-9622, Vol.7, Issue 12, Hanoi, Vietnam. [4]. MARY B. HALLI, NARAYANA SWAMY R: “Design and Implementation of Arduino Based 3D Printing Using FDM Technique.”//T. John Institute of Technology, Karnataka, India.eISSN:2319-1163. [5]. VINOD G. SURANGE, PUNIT V. GHARAT: “3DPrinting Process Using Fused DepositionModelling.”//SJCET, Palghar (MH), e-ISSN:2395-0056. [6]. R.M. Miranda, G. Lopes, L. Quintino, J.P. Rodrigues, S. Williams: “Rapid prototyping with high power fiber lasers.”// a Faculty of Sciences and Technology,New University Lisbon, Portugal b IDMEC, Instituto Superior, MaterialsandDesign29(2008)2072– 2075. [7]. J.L. Song, Q.L. Deng, D.J. Hu: “Rapid prototyping manufacturing of silica sand patterns based on selective laser sintering.”//school of mechanical and power engineering, Shanghai Jiao tong University, Shanghai 200030. [8]. Danezan, G. Delaizir, N. Tessier-Doyen, G. Gasgnier, J.M. Gaillard, P. Duport: “Selective laser sintering of porcelain.” // Journal of the European Ceramic Society38(2018)769–77. [9]. Feng Ma, Hua Zhang, K.K.B. Hon, Qingshan Gong: “An optimization approach of selective laser sintering considering energy consumption and material cost.”// of Mechanical Transmission and Manufacturing Engineering (Wuhan University of Sr no Parameters Price 1. Arduino mega with ramps & connecters 2700/- 2. Neema 17 stepper motor 995/- 3 0.4mm hot end (extruder) 570/- 4. 12 volt power supply 620/- 5. End stop 370/- 6. 3d printer filament 1250/- 7. CD drives 200/- 8. Floppy drive 100/- 9. L shape plates 200/- 10. Acrylic plate 250/- 11. Aluminium panel 250/- 12. Tools and accessories 2000/- Total 9505
  • 4. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 7297 Science &Technology), Wuhan 430081,Journal of Cleaner Production 199 (2018)52. [10]. H. Lipson and M. Kurman, Factory at Home: The Emerging Economy of Personal Manufacturing. Washington: U.S. Office of Science and Technology, 2010, n.p.