METHODOLOGY

Flow chart
The following flow chart shows the methodology used by us in construction of 3D printer. The first
step is to select one of the additive manufacturing processes among many processes explained in
chapter 2. Then an appropriate mechanism is selected for X, Y and Z axis movements, considering
various factors such as cost of fabrication, simplicity of design, synchronization, accuracy etc. Once
the mechanism is selected the next step is integration of electronics and software then the machine
is designed and fabricated. The last step is, synchronization of mechanical, electrical and software
elements of the machine.

The FDM technology is clean, simple to use and it is environmentally stable. Complex shapes and
intricate parts can be printed. FDM is at the very entry of the market as it mainly used by individuals.
FDM is an affordable 3D printing process compared to other 3D printing technologies.

FDM starts with a product procedure which forms an STL file (stereolithography file format),
scientifically cutting and situating the model for the building procedure. In the event that required,
support structures might be created. The machine may apportion numerous materials to accomplish
diverse objectives. The model or part is created by extruding little amount of thermoplastic material
to the desired shape layers as the material solidifies promptly after expulsion from the nozzle. A
plastic filament or metal wire is loosened up from a loop and supplies material to an extrusion nozzle
which can turn the flow on and off. There is commonly a worm drive that pushes the filament into
the nozzle at a controlled rate. The nozzle is warmed to soften the material. The thermoplastics are
warmed past their glass change temperature and are then saved by an expulsion head.

The nozzle can be moved in both even and vertical bearings by a numerically controlled component.
The nozzle takes an instrument way controlled by a PC helped producing (CAM) programming
bundle, and the part is developed from the last, one layer at any given moment. Stepper engines or
servo engines are commonly utilized to move the expulsion head. The system utilized is frequently
an X-Y-Z rectilinear outline, albeit other mechanical plans have been utilized.
 Selection of Mechanism
Presently mechanisms such as, for example, SCARA, Cartesian, Polar, Delta and so on are utilized as a
part of development of FDM 3D Printers. We have chosen cartesian arrangement of developments,
where the bed moves in the vertical heading i.e., in Z pivot bearing and the extruder spout moves
horizontal way i.e., both in X and Y hub course. Z hub development on such a 3D printer is extremely
exact and requires low increasing speeds, however the bed should be lightweight with a specific end
goal to look after precision, which makes it harder to include a completely programmed bed levelling
framework. Controlling a straight Cartesian framework like this is mechanically straightforward and
furthermore generally simple from a product point of view, which is the reason most 3D printers
available today utilize this kind of plan. The Cartesian arrange frameworks has for quite some time
been utilized for instruments like plotters, CNC processing machines, and 2D printers.

y – rails
X – rails

Z – rails

Electronics
Controller
The controller is the brains of our 3D Printer. Almost all 3D Printer controllers are based on the of
the Arduino microcontroller. While a lot of variations exist. they are exchangeable and basically all
do the same thing. Now and then the controller is a remain solitary circuit load up with chips on it, in
some cases the controller is an Arduino Mega with an extra board (called a "shield').

Stepper Motors
A stepper motor (or step motor) is a brushless DC electric motor that partitions a full pivot into a
numerical of equivalent advances. The motor's position would then be able to be instructed to move
and hold at one of these means with no criticism sensor, as long as the engine as deliberately
measured to the application. Stepper motor moves a known break for each beat of vitality. This beat
of vitality is given by a stepper driver and is suggested as a stage. As every movement moves the
motor a known partition it makes them helpful gadgets for repeatable arranging. We will utilize
stepper motor to move the bed carriage and different gatherings in their individually X - Axis, Y -
Axis, Z-Axis.
End stops
Mechanical switches are less complicated to implement and cheaper than optical end stops because
they do not require a circuit board and only use 2 wires for connecting the switch. Resistors Pull up
and down can put close to the main board. Contact-less magnetic switches are called read switches.
They are proximity switches that close (or switch over) if a magnet comes close enough (usually 1
mm or less) and open if the magnet moves away. Reed switches are utilized as sensors in home
caution frameworks to identify open windows and doors.

Heated Bed
A heated build platform HBP improves in the printing quality of the 3d model by helping prevent
warping. As extruded plastic cools it shrinks slightly. When this shrinking process does not occur
throughout the printed part evenly, the result is the warped part. This warping is very commonly
seen as corners being lifted off of the build platform. Printing on a warmed bed permits the printed
part to remain warm amid the printing procedure and permit all the more notwithstanding
contracting of the plastic as it cools underneath softening point. The warmth bed prompts higher
complete quality that works with materials, for example, ABS and PLA. A HBP can likewise enable
clients to print without rafts.

Stepper Drives
A stepper driver is a motor that acts as the kind of intermediate person between a stepper motor
and the controller. It streamlines the signs that should be sent to the stepper motor keeping in mind
the end goal to motivate it to move. Here and there the stepper drivers are on independent circuit
sheets that are connected to the controller through links. Now and then the stepper drivers are on
little circuit sheets that connect straightforwardly to the controller itself. For this situation, the
controller Will have space for no less than 4 of these little circuit sheets (one for every stepper
motor). Finally, sometimes the stepper drivers are soldered right onto the controller itself.
 Software
CAD Tools
Computer Aided Design are used to design 3D parts for printing. Computer aided design (CAD) is
where we use the computer system to assist in the creation modification analysis or optimization of
a design. Computer aided design software is utilized to expand the efficiency of the creator, enhance
the nature of configuration, enhance interchanges through documentation, and to make a database
for manufacturing.

Computer-aided design files in the most genuine sense are intended to enable you to effectively
change and control parts in view of parameters. Now and then CAD files are alluded to as parametric
records. The parts which are being represented as a tree of Boolean operations which are performed
on primitive shapes such as cubes, spheres, cylinders, pyramid

CAM Tools
Computer Aided Manufacturing, or CAM, tools handle the intermediate step of translating CAD files
into a machine-friendly font used for our 3D printer electronics. Here we will be using a software
which will be an integration of object slicing, Generation of G codes and M codes, Object Placement
and other printer settings. Usually to turn a 3D part into a machine format, CAM software needs a
STL file. The machine friendly format that is used for printing is called G-code.

Firmware 3D
Printer electronics are controlled by an inexpensive CPU such as the Atmel AVR processor. Atmel
processors are what Arduino-based microcontrollers use. These processors are exceptionally weak
contrasted with even the normal 10 to 15-year-old PC you find in the landfill these days. However,
these are CPUs so they do run primitive software. This primitive software they run is the firmware.
The entire software chain that makes the 3D Printer work, the firmware portion of it is the closest
you get to actual programming. In fact, the term for what you are doing with firmware is called cross
compiling.

Objectives of our present work

• To print complex and intricate parts

• To build large printing volumes accurately

• To solve the problems of bed levelling