MINOR PROJECT REPORT

ON
“Fused deposition modeling (FDM) Filament test and
fabrication of 9 models by 3D printing”

Submitted in Partial Fulfillment of requirements for the Award of Degree of

Bachelor of Engineering in Mechanical Engineering

Session: 2019-20

Submitted By: Project Guide:

1. OM PRAKASH (16EJCME070) Mr. Ashish
Nagpal
2. NEHAL SHAMS (16EJCME069) Assistant
professor
3. RAMUMESH CHOUDHARY (16EJCME082)
4. VIKASH KUMAR (16EJCME121)
5. HIMANSHU JAIN (16EJCME042)

DEPARTMENT OF MECHANICAL ENGINEERING

JAIPUR ENGINEERING COLLEGE & RESEARCH CENTRE

Shreeram Ki Nagal, Sitapura RIICO, Opp. EPIP Gate, Tonk Road, Jaipur-
302022
 DECLARATION

We, Omprakash, Nehal Shams, Ramumesh Choudhary, Himanshu Jain, and Vikash Kumar hereby
declare that the work presented in this project entitled
“Fused deposition modeling (FDM) Filament test and fabrication of 9 models by 3D
printing”

In partial fulfillment of the requirements for the award of Degree of Bachelor of Technology,
submitted in the Department of Mechanical Engineering of JECRC, Jaipur. This submission
is an authentic record of our own work under the supervision of Mr. Satyendra Kumar.

We also declare that the work embodied in the present report is our original work and has not
been copied from any journal/thesis/book and has not been submitted by us for any other
Degree/Diploma.

1. OM PRAKASH (16EJCME070)

2. NEHAL SHAMS (16EJCME069)

3. RAMUMESH CHOUDHARY (16EJCME082)

4. VIKASH KUMAR (16EJCME121)

5. HIMANSHU JAIN (16EJCME042)

i
 CERTIFICATE

This is to certify that Project Report entitled “Fused deposition modeling (FDM) Filament test
and fabrication of 9 models by 3D printing “which is submitted by Omprakash, Nehal Shams,
Ramumesh Choudhary, Himanshu Jain, and Vikash Kumar in partial fulfillment of the
requirement for the award of degree B. Tech. in department of mechanical engineering of Rajasthan
Technical University, is a record of the candidate own work carried out by him under my/our
supervision. The matter embodied in this report is original and has not been submitted for the award
of any other degree.

(Ashish Nagpal) Dr. M.P. Singh

HOD, ME

Date:

ii
 LIST OF FIGURES

FIGURE.NO FIGURE NAME PAGE NO.

3.1. Types of 3d printing 8

3.2. Layer by layer FDM process 8

3.3. Layer Adhesion 10

3.4. 3D printer 11

3.5. ABS structure 13

3.6. PETG structure 14

3.7. Nozzle of printer 17

3.8 Head of printer 18

iii
 LIST OF TABLES

TABLE NO TABLE NAME PAGE NO.

1 Mechanical properties of ABS 12

2. Detailed project SCHEDULE 17

3 Cost estimation of project 18

iv
 TABLE OF CONTENTS

DECLARATION......................................................................................................... i
CERTIFICATE ......................................................................................................ii
LISTOF FIGURE…………………………………………………………………....iii
LIST OF TABLE…………………………………………………………………… iv
CHAPTER 1:

1. INTRODUCTION ………………………………………………………………..1

CHAPTER 2:

2.1 LITERATURE REVIEW ………………………………………………………..2

2.2 PROBLEM DEFINITION………………………………………………………..7

CHAPTER 3:

3.1 DESIGN/FABRICATION/ANALYSIS DETAILS…………………………….9

3.2 DETAILED PROJECT SCHEDULE (MONTH WISE)……………………....22
3.3 COST ESTIMATION OF PROJECT…………………………………………...23
CHAPTER 4:

4. EXPECTED OUTCOME …………………………………………………………24

REFERENCES……………………………………………………………......................25

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 CHAPTER 1
INTRODUCTION
3D printing or additive manufacturing (AM) is any of various processes for making a three-
dimensional object of almost any shape from a 3D model or other electronic data source
primarily through additive processes in which successive layers of material are laid down
under computer control. A 3D printer is a type of industrial robot.

Early AM equipment and materials were developed in the 1980s. In 1984, Chuck Hull of 3D
Systems Corp invented a process known as stereo lithography employing UV lasers to cure
photopolymers. Hull also developed the STL file format widely accepted by 3D printing
software, as well as the digital slicing and infill strategies common to many processes today.
Also during the 1980s, the metal sintering forms of AM were being developed (such as
selective laser sintering and direct metal laser sintering), although they were not yet called 3D
printing or AM at the time.

In 1990, the plastic extrusion technology most widely associated with the term “3D printing”
was commercialized by Stratasys under the name fused deposition modeling (FDM). In 1995,
Z Corporation commercialized an MIT-developed additive process under the trademark 3D
printing (3DP), referring at that time to a proprietary process inkjet deposition of liquid
binder on powder. AM technologies found applications starting in the 1980s in product
development, data visualization, rapid prototyping, and specialized manufacturing.

Their expansion into production (job production, mass production, and distributed
manufacturing) has been under development in the decades since. Industrial production roles
within the metalworking industries achieved significant scale for the first time in the early
2010s. Since the start of the 21st century there has been a large growth in the sales of AM
machines, and their price has dropped substantially.

According to Wohler’s Associates, a consultancy, the market for 3D printers and services
was worth $2.2 billion worldwide in 2012, up 29% from 2011. Applications are many,
including architecture, construction (AEC), industrial design, automotive, aerospace, military,
engineering, dental and medical industries, biotech (human tissue replacement), fashion,
footwear, jewellery, eyewear, education, geographic information systems, food, and many
other fields.

1
 CHAPTER 2

2.1 LITERATURE REVIEW

[1] Dongkeon Lee, Takashi Miyoshi, Yasuhiro Takaya and Taeho Ha, “3D Micro fabrication of
Photosensitive Resin Reinforced with Ceramic Nanoparticles Using LCD 3D printing or additive
manufacturing (AM) is a process for making a 3D object of any shape from a 3D model or other
electronic data sources through additive processes in which successive layers of material are laid
down under computer controls. [1]Hideo Kodama of Nayoga Municipal Industrial Research Institute
is generally regarded to have printed the first solid object from a digital design. However, the credit
for the first 3D printer generally goes to Charles Hull, who in 1984 designed it while working for the
company he founded, 3D Systems Corp. Charles a Hull was a pioneer of the solid imaging process
known as stereo lithography and the STL (stereo lithographic) file format which is still the most
widely used format used today in 3D printing. He is also regarded to have started commercial rapid
prototyping that was concurrent with his development of 3D printing. He initially used photopolymers
heated by ultraviolet light to achieve the melting and solidification effect. [2]Since 1984, when the
first 3D printer was designed and realized by Charles W. Hull from 3D Systems Corp., the technology
has evolved and these machines have become more and more useful, while their price points lowered,
thus becoming more affordable.

Acrylonitrile Butadiene Styrene [ABS]

One of the most widely used material since the inception of 3D printing. This material is very durable,
slightly flexible, and lightweight and can be easily extruded, which makes it perfect for 3D printing. It
requires less force to extrude than when using PLA, which is another popular 3D filament. This fact
makes extrusion easier for small parts. The disadvantage of ABS is that it requires higher temperature.
Its glass transition temperature is about 105°C and temperature about
210 – 250°C is usually used for printing with ABS materials. Also another drawback of this material
is quite intense fumes during printing that can be dangerous for pets or people with breathing
difficulties. So 3D printers need to be placed in well-ventilated area. Also good advice is to avoid
breathing in fumes during printing considering the cost of 3D materials ABS is the cheapest, which
makes it favorite in printing communities until now.

Poly Lactic Acid [PLA]

Poly lactic acid (PLA) (is derived from corn and is biodegradable) is another well-spread material
among 3D printing enthusiasts. It is a biodegradable thermoplastic that is derived from renewable
resources. As a result PLA materials are more environmentally friendly among other plastic materials.
The other great feature of PLA is its biocompatibility with a human body. The structure of PLA is
harder than the one of ABS and material melts at 180 220°C which is lower than ABS. PLA glass
transition temperature is between 60 65 ° C, so PLA together with ABS could be some good options
for any of your projects.

[2] Ruben Perez Mananes, Jose Rojo-Manaute, Pablo Gil, “3D Surgical printing and pre contoured
plates for acetabular fractures”, Journal of ELSEVIER 2016
Preoperative 3D modeling enables more effective diagnosis and simulates the surgical procedure.
MATERIAL AND METHODS:
We report twenty cases of acetabular fractures with preoperative planning performed by pre-
contouring synthesis plates on a 3D printed mould obtained from a computarized tomography (CT)
scan. The mould impression was made with the DaVinci 1.0 printer model (XYZ Printing). After
obtaining the printed hemipelvis, we proceeded to select the implant size (pelvic Matta system,
Stryker®) that matched the characteristics of the fracture and the approach to be used.
RESULTS:

2
Printing the moulds took a mean of 385minutes (322-539), and 238grams of plastic were used to print
the model (180-410). In all cases, anatomic reduction was obtained and intra-operative changes were
not required in the initial contouring of the plates. The time needed to perform the full osteosynthesis,
once the fracture had been reduced was 16.9minutes (10-24). In one case fixed with two plates, a
postoperative CT scan showed partial contact of the implant with the surface of the quadrilateral plate.
In the remaining cases, the contact was complete.
CONCLUSIONS:
In conclusion, our results suggest that the use of preoperative planning, by printing 3D mirror imaging
models of the opposite hemipelvis and pre-contouring plates over the mould, might effectively
achieve a predefined surgical objective and reduce the inherent risks in these difficult procedures.

[3] Alexandru Pirjan, Dana-Mihaela Petrosanu, “The Impact of 3D Printing Technology on the
society and economy”, Journal of Information Systems and Operations Management, Volume 7, Dec
2013

In 1981, Hideo Kodama of the Nagoya Municipal Industrial Research Institute (Nagoya,
Japan) has studied and published for the first time the manufacturing of a printed solid model,
the starting point of the “additive manufacturing”, “rapid prototyping” or “3D printing
technology” [1]. In the next decades, this technology has been substantially improved and has
evolved into a useful tool for researchers, manufacturers, designers, engineers and scientists.
As the term suggests, “additive manufacturing” is based on creating materials and objects,
starting from a digital model, using an additive process of layering, in a sequential manner.
Most of the traditional manufacturing processes are based on subtractive techniques: starting
from an object having an initial shape, the material is removed (cut, drilled) until the desired
shape is obtained. Unlike the above-mentioned technique, the 3D printing is based on adding
successive material layers in order to obtain the desired shape. Since 1984, when the first 3D
printer was designed and realized by Charles W. Hull from 3D Systems Corp. [2], the
technology has evolved and these machines have become more and more useful, while their
price points lowered, thus becoming more affordable. Nowadays, rapid prototyping has a
wide range of applications in various fields of human activity: research, engineering, medical
industry, military, construction, architecture, fashion, education, computer industry and many
others. The 3D printing technology consists of three main phases - the modeling, the printing
and the finishing of the product:
 In the modeling phase, in order to obtain the printing model, the machine uses virtual
blueprints of the object and processes them in a series of thin cross-sections that are being
used successively. The virtual model is identical to the physical one.
 In the printing phase, the 3D printer reads the design (consisting of cross-sections) and
deposits the layers of material, in order to build the product. Each layer, based on a virtual
cross section, fuses with the previous ones and, finally, after printing all these layers, the
desired object has been obtained. Through this technique, one can create different objects of
various shapes, built from a variety of materials (thermoplastic, metal, powder, ceramic,
paper, photopolymer, liquid).
 The final phase consists in the finishing of the product. In many cases, in order to obtain an
increased precision, it is more advantageous to print the object at a higher size than the final
desired one, using a standard resolution and to remove then the supplementary material using
a subtractive process at a higher resolution.

3
[4] Gabriel Gaala, Melissa Mendesa, Tiago P. de Almeida, “Simplified fabrication of
integrated microfluidic devices using fused deposition modeling 3D printing” Science Direct.
I have done a research on a 3D printer, its designing, manufacturing and it various operations.
This machine is a complete compact CNC machine, which can be used as a 2d plotter, leaser
cuter & even milling by changing its tool. It is less costly than any other 3D printer which can
function in the way as mentioned above, it is user friendly, and its filaments are easily
available in various colors and various materials. Tofhis machine is of lowest maintenance. I
believe this machine will change the INDIAN manufacturing ways, In future u will see this
machine in larger scale of making houses as well. Materials used in 3D printing and their
properties will become a notable topic in technological aspects.

3D printing or additive manufacturing (AM) is a process for making a 3D object of any shape
from a 3D model or other electronic data sources through additive processes in which
successive layers of material are laid down under computer controls. [1]Hideo Kodama of
Nayoga Municipal Industrial Research Institute is generally regarded to have printed the first
solid object from a digital design. However, the credit for the first 3D printer generally goes
to Charles Hull, who in 1984 designed it while working for the company he founded, 3D
Systems Corp. Charles a Hull was a pioneer of the solid imaging process known as
stereolithography and the STL (stereo lithographic) file format which is still the most widely
used format used today in 3D printing. He is also regarded to have started commercial rapid
prototyping that was concurrent with his development of 3D printing. He initially used
photopolymers heated by ultraviolet light to achieve the melting and solidification effect.
[2]Since 1984, when the first 3D printer was designed and realized by Charles W. Hull from
3D Systems Corp., the technology has evolved and these machines have become more and
more useful, while their price points lowered, thus becoming more affordable.

Nowadays, rapid prototyping has a wide range of applications in various fields of human
activity: research, engineering, medical industry, military, construction, architecture, fashion,
education, the computer industry and many others. In 1990, the plastic extrusion technology
most widely associated with the term "3D printing" was invented by Stratasys by name fused
deposition modeling (FDM). After the start of the 21st century, there has been a large growth
in the sales of 3D printing machines and their price has been dropped gradually. By the early
2010s, the terms 3D printing and additive manufacturing evolved senses in which they were
alternate umbrella terms for AM technologies, one being used in popular vernacular by
consumer - maker communities and the media, and the other used officially by industrial AM
end use part producers, AM machine manufacturers, and global technical standards
organizations. Both terms reflect the simple fact that the technologies all share the common
theme of sequential-layer material addition/joining throughout a 3D work envelope under
automated control.

Other terms that had been used as AM synonyms included desktop manufacturing, rapid
manufacturing, and agile tooling on-demand manufacturing. The 2010s were the first decade
in which metal end use parts such as engine brackets and large nuts would be grown (either
before or instead of machining) in job production rather than obligatory being machined from
bar stock or plate.

4
[5] Pshtiwan Shakor, Jay Sanjayan, Ali Nazari, Shami Nejadi, “Modified 3D printed powder to
cement-based material and mechanical properties of cement scaffold used in 3D printing”, Science
Direct. Additive manufacturing is a common technique used to produce 3D printed structures.
These techniques have been used as precise application geometry in different fields such as
architecture and medicine, and the food, mechanics and chemical industries. However, in
most cases only a limited amount of powder has been used to fabricate scaffold (structure). In
this study, a unique mix of cements (calcium aluminate cement passed through a 150 μm
sieve and ordinary Portland cement) was developed for Z-Corporation’s three-dimensional
printing (3DP) process.
This cement mix was blended and the resulting composite powders were printed with a
water-based binder using a Z-Corporation 3D printer. Moreover, some samples were added
lithium carbonate to reduce the setting time for the cement mixture. The aims of the study
were to firstly, find the proper cementitious powder close to the targeted powder (Z-powder);
and secondly, evaluate the mechanical properties of this material.
Cubic specimens of two different batches with varying saturation levels were cast and cured
in various scenarios to enhance the best mechanical properties. The samples were
characterised by porosity analyses, compression tests, Olympus BX61 Microscope imaging,
3D profiling Veeco (Dektak) and the Scanning Electronic Microscope (SEM). The maximum
compressive strength of the cubic specimens for cementitious 3DP was 8.26 MPa at the
saturation level of 170% for both the shell and core.
The minimum porosity obtained was 49.28% at the saturation level of 170% and 340% for
the shell and the core, respectively.

[7] Elizabeth Matias, Bharat Rao, “3d printing on its historical evolution and the implications
for business”, 2015 Proceedings of PICMET: Management of the Technology Age.Quite
simply, the term “additive manufacturing” refers to the process of building products by
adding many very thin layers of material, layer on top of layer. Historically speaking,
additive manufacturing can trace its roots back to the 19th century, particularly the fields of
topography and photo sculpture. However, in a “Brief History of Additive Manufacturing and
the 2009 Roadmap…” by Beaman et al, they cite that in 1972 Ciraud released the first
technology that truly represented today’s definition of additive manufacturing

[3]. Ciraud’s process is described as taking meltable materials and using a beam of energy to melt the
material, thereby building a product by melting layer on top of layer. Unfortunately, while there are
drawings and sketches regarding Ciraud’s invention, there is no proof that the technology was actually
produced and executed. In a final report published by the Japanese and World Technology Evaluation
Centers in 1997, Beaman again is a contributor on the historical perspective of additive
manufacturing. Here, he references Hideo Kodama as the first scientist known to have produced a
functioning additive manufacturing system in 1981. Alan Herbert of 3M in 1982 then closely
followed him.
This time, there was proof that the technologies were developed and tested. Both Kodama and Herbert
developed technologies where a prototype part was actually built, layer by layer [15]. After a few
years, Chuck Hull invented the stereolithography machine (SLA) in 1986. This machine is considered
to be the first 3D printer [10] [15].
The stereolithography machine slowly poured liquid plastic to build plastic outputs. Not surprisingly,
this technology was very expensive and therefore only utilized by large research universities, large
companies, and government research labs. Flash forward to present day, there are three major additive
manufacturing/3D printing methods: 1) Fused Deposition Modeling (FDM), 2) Laser Sintering

5
Platform, 3) and the ZPrinters Platform. Hull makes an excellent analogy regarding FDM technology;
he likens it to a very sophisticated glue gun. This is currently the most commonly used 3D printer.
Laser Sintering Platforms can print other materials aside from plastic – metals, ceramics, etc. These
printers are more sophisticated; however they are also more expensive. ZPrinters, the third major
technology, are also more sophisticated and again more expensive. It utilizes a powder substance that
solidifies with a sprayed binding chemical [10]. B. Common Applications 1. Rapid Prototyping
“Rapid Prototyping” is perhaps the most mature application of additive manufacturing/3D printing
technologies in the business space.
In fact in some research, rapid prototyping refers to the different additive 551 2015 Proceedings of
PICMET '15: Management of the Technology Age manufacturing/3D printing methods patented by
the key players in the field – Stratasys, 3D Systems, Objet, Z Corp, and Solidscape [17] [8]. However,
throughout this paper, rapid prototyping will refer to the process of designing a 3D model with
computer aided design software (CAD), and producing a prototype, typically out of plastic, via 3D
printing technology.
This prototype then becomes the basis for the design of the final product [14]. Rapid prototyping
reduces manufacturing costs by enabling the multiple iterations of the design process. This means
engineers and designers can design a more precise model in 3D and review a scaled, physical object.
Users are then able to evaluate a concept and provide several rounds of design feedback or
modifications [8].
This is quite different than former prototyping methods in 2D. In 2D, designers and engineers would
sketch, with measurements, a prototype from many different perspectives on paper or in 2D software.
With 3D design and rapid prototyping, companies are less likely to send incorrect measurements or
faulty specifications into full-fledged production

Figure 3.1(CAD design)

6
 2.2 PROBLEM DEFINITION

Faster Production
3D printing is quicker than conventional manufacturing including injection molds and
subtractive production.

Easily Accessible
3D printing has been around for decades but it really did not take off until 2010. The
explosion of 3D printing interests has brought easier to use software and hardware to
consumers as more competition has entered the space

Better Quality
Traditional manufacturing methods can easily result in poor designs, and therefore poor
quality prototypes.

.Tangible Design and Product Testing

There’s no way seeing a product on the screen or virtually can compare to the actual feel of a
prototype. 3D printing offers that benefit. It is possible to experience the touch and feel of the
product prototype to physically test it and find flaws in the design. If a problem is found, you
can modify the CAD file and print out a new version by the next day.

.Cost-effectiveness
Traditional prototyping methodologies including production runs and injection mold are
costly as they require a lot of human labor. Labor costs are also very high with conventional
subtractive manufacturing. With 3D printing, however, labor can be as little as one person
issuing a print command

Creative Designs and Customization Freedom

Traditional manufacturing techniques are good at creating millions of copies of the same
thing. It results in same dull and boring designs without the capacity to be improved much.3D
printing allows for endless personalization

Unlimited Shapes and Geometry

Old methods of manufacturing rely on molds and cutting technologies to generate the desired
shapes. Designing geometrically complex shapes can be hard and expensive with this
technology. 3D printing takes on this challenge with ease and there’s not much the
technology can’t do with the proper support material.

.Less Waste Production

CNC cutting and injection is molding result in a lot of wasted resources. Both involve the
removal of materials from solid blocks. Unlike these two, 3D printing only uses material that
is needed to create a prototype part
.

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 CHAPTER 3
3.1 DESIGN/FABRICATION/ANALYSIS DETAILS
3.1.1 WHAT IS FDM?

Figure 3.2(types of 3d printing)

.Fused Deposition Modeling (FDM), or Fused Filament Fabrication (FFF), is an additive

manufacturing process that belongs to the material extrusion family. In FDM, an object is built by
selectively depositing melted material in a pre-determined path layer-by-layer. The materials used are
thermoplastic polymers and come in a filament form.
FDM is the most widely used 3D Printing technology: it represents the largest installed base of 3D
printers globally and is often the first technology people are exposed to. In this article, the basic
principles and the key aspects of the technology are presented.
A designer should keep in mind the capabilities and limitations of the technology when fabricating a
part with FDM, as this will help him achieve the best result.

Figure: 3.3(layer by layer FDM PROCESS)

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 3.1.2 HOW DOES FDM WORK?
Here is how the FDM fabrication process works:

 A spool of thermoplastic filament is first loaded into the printer. Once the nozzle has
reached the desired temperature, the filament is fed to the extrusion head and in the
nozzle where it melts.
 The extrusion head is attached to a 3-axis system that allows it to move in the X, Y
and Z directions. The melted material is extruded in thin strands and is deposited
layer-by-layer in predetermined locations, where it cools and solidifies. Sometimes
the cooling of the material is accelerated through the use of cooling fans attached on
the extrusion head.
 To fill an area, multiple passes are required (similar to coloring a rectangle with a
marker). When a layer is finished, the build platform moves down (or in other
machine setups, the extrusion head moves up) and a new layer is deposited. This
process is repeated until the part is complete.

3.1.3 CHARACTERISTIC OF FDM

3.1.3.1 PRINTER PARAMETERS:

Most FDM systems allow the adjustment of several process parameters, including the temperature of
the nozzle and the build platform, the build speed, the layer height and the speed of the cooling fan.
These are generally set by the operator, so they should be of little concern to the designer.
What is important from a designer's perspective is build size and layer height:
The available build size of a desktop 3D printer is commonly 220 x 220 x 230 mm, while for
industrial machines this can be as big as 1000 x 1000 x 1000 mm. If a desktop machine is preferred
(for example for reducing the cost) a big model can be broken into smaller parts and then assembled.
The typical layer height used in FDM varies between 50 and 400 microns and can be determined
upon placing an order. A smaller layer height produces smoother parts and captures curved
geometries more accurately, while a larger height produces parts faster and at a lower cost. A layer
height of 200 microns is most commonly used

WRAPING:
Warping is one of the most common defects in FDM. When the extruded material cools
during solidification, its dimensions decrease. As different sections of the print cool at
different rates, their dimensions also change at different speeds. Differential cooling causes
the buildup of internal stresses that pull the underlying layer upwards, causing it to warp, as
seen in figure 3. From a technology standpoint, warping can be prevented by closer
monitoring of the temperature of the FDM system (e.g. of the build platform and the
chamber) and by increasing the adhesion between the part and the build platform.

The choices of the designer can also reduce the probability of warping:

 Large flat areas (think of a rectangular box) are more prone to warping and should be
avoided when possible.
 Thin protruding features (think of the prongs of a fork) are also prone to warping. In this
case, warping can be avoided by adding some sacrificial material at the edge of the thin

9
 feature (for example a 200 microns thick rectangle) to increase the area that touches the build
platform.
 Sharp corners are warping more often than rounded shapes, so adding fillets to your design
is a good practice.
 Different materials are more susceptible to warping: ABS is generally more sensitive to
warping compared to PLA or PETG, due to its higher glass transition temperature and
relatively high coefficient of thermal expansion.

LAYER ADHENSION:
Good adhesion between the deposited layers is very important for an FDM part. When the
molten thermoplastic is extruded through the nozzle, it is pressed against the previous layer.
The high temperature and the pressure re-melt the surface of the previous layer and enables
the bonding of the new layer with the previously printed part.

The bond strength between the different layers is always lower than the base strength of the material.
This means that FDM parts are inherently anisotropic: their strength in the Z-axis is always smaller
than their strength in the XY-plane. For this reason, it is important to keep part orientation mind when
designing parts for FDM.
For example, tensile test pieces printed horizontally in ABS at 50% infill were compared to
test pieces printed vertically and were found to have almost 4 times greater tensile strength in
the X,Y print direction compared to the Z direction (17.0 MPa compared to 4.4 Mpa) and
elongated almost 10 times more before breaking (4.8% compared to 0.5%).
Moreover, since the molten material is pressed against the previous layer, its shape is
deformed to an oval. This means that FDM parts will always have a wavy surface, even for
low layer height, and that small features, such as small holes or threads may need to be post
processed after printing.

Figure 3.4 (Layer adhension)

10
 Figure 3.5 (3D printer)

SUPPORT STRUCTURE
Support structure is essential for creating geometries with overhangs in FDM. The melted
thermoplastic cannot be deposited on thin air. For this reason, some geometries require support
structure. A detailed article explaining the use of support structure can be found here.
Surfaces printed on support will generally be of lower surface quality than the rest of the part. For this
reason, it is recommended that the part is designed in such a way to minimize the need for support.
Support is usually printed in the same material as the part. Support materials that dissolve in
liquid also exist, but they are used mainly in high-end desktop or industrial FDM 3D printers.
Printing on dissolvable supports improves significantly the surface quality of the part, but
increases the overall cost of a print, as specialist machine (with dual extrusion) are required
and because the cost of the dissolvable material is relatively high.

COMMON FDM MATERIALS

ABS PLA PETG

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  Acrylonitrile Butadiene (ABS)

ABS stands for Acrylonitrile Butadiene Styrene. ABS is an impact-resistant engineering

thermoplastic & amorphous polymer. ABS is made up of three monomers: acrylonitrile, butadiene
and styrene:
 Acrylonitrile: It is a synthetic monomer produced from propylene and ammonia. This
component contributes to ABS chemical resistance & heat stability
 Butadiene: It is produced as a by-product of ethylene production from steam
crackers. This component delivers toughness & impact strength to ABS polymer
 Styrene: It is manufactured by dehydrogenation of ethyl benzene. It provides rigidity
& process ability to ABS plastic

Key Properties of ABS Plastic

ABS is an ideal material of choice for various structural applications, thanks to its several
physical properties such as:

 High rigidity
 Good impact resistance, even at low temperatures
 Good insulating properties
 Good walkability
 Good abrasion and strain resistance
 High dimensional stability (Mechanically strong and stable over time)
 High surface brightness and excellent surface aspect

Mechanical Properties of ABS

TABLE NO-1

Elongation at Break 10 - 50 %

Elongation at Yield 1.7 - 6 %

Flexibility (Flexural Modulus) 1.6 - 2.4 GPa

Hardness Shore D 100

Stiffness (Flexural Modulus) 1.6 - 2.4 GPa

Strength at Break (Tensile) 29.8 - 43 MPa

Strength at Yield (Tensile) 29.6 - 48 MPa

12
 Toughness (Notched Izod Impact at Room
Temperature) 200 - 215 J/m

Toughness at Low Temperature (Notched

Izod Impact at Low Temperature) 20 - 160 J/m

Young Modulus 1.79 - 3.2 GPa

Limitations of ABS
 Poor weathering resistance
 Ordinary grades burn easily and continue to burn once the flame is removed
 Scratches easily
 Poor solvent resistance, particularly aromatic, ketones and esters
 Can suffer from stress cracking in the presence of some greases
 Low dielectric strength
 Low continuous service temperature

FIGURE 3.6 (ABS)

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  Polylactic acid (PLA)

Polylactic acid or polylactide (PLA) is a thermoplastic aliphatic polyester derived

from renewable resources.
In 2010, PLA had the second highest consumption volume of any bio plastic of the world,
although it is still not a commodity polymer. Its widespread application has been hindered by
numerous physical and processing shortcomings.
The name "polylactic acid" does not comply with IUPAC standard nomenclature, and is
potentially ambiguous or confusing, because PLA is not a polyacid (polyelectrolyte), but
rather a polyester

 Polyethylene terephthalate (PETG)

Polyethylene terephthalate is a plastic resin of the polyester family that is used to make
beverage, food and other liquid containers, as well as for some other thermoforming
applications. PETG is a clear amorphous thermoplastic that can be injection molded or sheet
extruded. It can be colored during processing.

PROPERTIES
PETG can be semi-rigid to rigid, depending on its thickness, and it is very lightweight. The
main virtue of PETG is that it is fully recyclable. Unlike other plastics, its polymer chains can
be recovered for additional use It makes a good gas and fair moisture barrier, as well as a
good barrier to alcohol and solvents. It is strong and impact-resistant. It is naturally colorless
with a high transparency.

APPLICATIONS
PETG is used as a Midrange priced product between Acrylic & Polycarbonate. The clearity
of PETG approaches that of Acrylic & Impact Resistance of Polycarbonate. Also is used in
Signing, Glazing, POP Displays, etc.

Figure 3.7(PETG)

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DIFFERENT PARTS TO BE MANUFACTURED BY THE FILAMENT
SCOOP:-

1. GEARS

2. CHESISES

3. WHEELS

4. BEARING

5. SHAFTS

6. ROBO CHAIN

PROCEDURE OF 3D PRINTING
There are some procedures for printing. First you must create a computer model for printing
the object. For creating that, you can use Computer Aided Design Software like AutoCAD,
3DS Max etc.
After the object file is created, the file need to be modified. The object file contains
numerous amount of curves. Curves cannot be printed by the printer directly.
The curves have to be converted to STL (Stereo lithography) file format. The STL file format
conversion removes all the curves and it is replaced with linear shapes.
Then the file need to be sliced into layer by layer. The layer thickness is so chosen to meet
the resolution of the 3D printer we are using.
If you are unable to draw objects in CAD software, there are many websites available which
are hosted by the 3D printing companies to ease the creation of 3D object.
The sliced file is processed and generates the special coordinates. These coordinates can be
processed by a controller to generate required signal to the motor for driving extruder. This
layer by layer process generate a complete object

DESIGNING USING CAD

Computer-aided design (CAD) is the use of computer systems to assist in the creation, modification,
analysis, or optimization of a design. CAD software is used to increase the productivity of the
designer, improve the quality of design, improve communications through documentation, and to
create a database for manufacturing.
CAD output is often in the form of electronic files for print, machining, or other manufacturing
operations. CAD software for mechanical design uses either vector-based graphics to depict objects of

15
traditional drafting, or may also produce raster graphics showing the overall appearance of designed
objects. However, it involves more than just shapes.
 As in the manual drafting of technical and engineering drawings, the output of CAD must
convey information, such as materials, processes, dimensions, and tolerances, according to
application- specific conventions. CAD may be used to design curves and figures in two-
dimensional (2D) space; or curves, surfaces, and solids in three-dimensional (3D) space.
 Today, CAD systems exist for all the major platforms (Windows, Linux, UNIX and
Mac OS X); some packages even support multiple platforms which enhances the
capabilities of 3D printing into a new level

CONVERSION TO STL FILE FORMAT

An STL file is a triangular representation of a 3D surface geometry. The surface is tessellated
logically into a set of oriented triangles (facets). Each facet is described by the unit outward normal
and three points listed in counterclockwise order representing the vertices of the triangle.
While the aspect ratio and orientation of individual facets is governed by the surface curvature, the
size of the facets is driven by the tolerance controlling the quality of the surface representation in
terms of the distance of the facets from the surface.
The choice of the tolerance is strongly dependent on the target application of the produced
STL file. In industrial processing, where stereolithography machines perform a computer
controlled layer by layer laser curing of a photo-sensitive resin, the tolerance may be in order
of 0.1 mm to make the produced 3D part precise with highly worked out details.
However much larger values are typically used in pre-production STL prototypes, for
example for visualization purposes. The native STL format has to fulfill the following
specifications:

(i) The normal and each vertex of every facet are specified by three coordinates
each, so there is a total of 12 numbers stored for each facet.

(ii) Each facet is part of the boundary between the interior and the exterior of the
object. The orientation of the facets (which way is ``out'' and which way is ``in'')
is specified redundantly in two ways which must be consistent. First, the
direction of the normal is outward. Second, the vertices are listed in
counterclockwise order when looking at the object from the outside (right-hand
rule).

(iii) Each triangle must share two vertices with each of its adjacent triangles. This is
known as vertex-to-vertex rule.

(iv) (The object represented must be located in the all-positive octant (all vertex
coordinates must be positive).

3.2 DETAILED PROJECT SECHULED

16
 TABLE NO 2
S.NO MONTH PROGRESS
1. JULY Browsed through various topics for project and
finalized “3D PRINTER “and in 3d printer we are
doing project on FDM filament test print.

2. AUGUST Literature review of various Research papers on 3D

printer and visited various workshop

3. SEPTEMBER Visited various workplaces, where 3D printer is

implanted and various industries where 3D printer
is used.
4. OCTOBER Planned a complete system for workplace.

5. NOVEMBER Research on various components used and the

technology used.
6. DECEMBER Started the making of3 D printer

7. JANUARY Starting making various models on FDM

FILAMENTS.
8. FEBRUARY Submission of the project.

Figure 3.8(nozzle of 3d printer)

3.3 COST ESTIMATION OF PROJECT

17
 TABLE NO 3

S No. Items Approx. Price (Rs.)

1. Frame 12000
2. Bearing 1000-1500
3. Belt 1200-1500
4. Head and extruder 7550
5. Electronics material 3420
6. Motor and bed 16000
7. Raw material 2100
TOTAL COST 42000/-

FAN 1
NOZZLE
FAN 2

Figure 3.9(head of 3D printer)

18
 CHAPTER 4
EXPECTED OUTCOME

1. Traditional manufacturing methods can easily result in poor designs, and

therefore poor quality prototypes. But we the coming of 3D printing technology
better quality of products can be manufactures and good quality prototype.

2. Produce products which involve great level of complexity that simply could not be
produced physically in any other way.
3. Additive manufacturing can eliminate the need for tool production and therefore
reduce the costs, lead time and labor associated with it

4. Additive Manufacturing use up to 90% of standard materials and therefore

creating less waste.

Printing 3D organs can revolutionaries the medical industry. • Rapid prototyping

causes faster product development

5. Increased operating life for the products.

6. Spare parts can be printed on site which will eliminate shipping cost.

7. Wider adoption of 3D printing would likely cause re-invention of a number of

already invented products.

8. NASA engineers are 3-D printing parts, which are structurally stronger and
more reliable than conventionally crafted parts, for its space launch system.

9. NASA's first attempt at using 3D-printed parts for rocket engines has passed its
biggest, and hottest, test yet.

10. bio printing is the process of generating spatially-controlled cell patterns using
3D printing technologies, where cell function and viability are preserved within
the printed construct. Using 3D bio printing for fabricating biological constructs
typically involves dispensing cells onto a biocompatible scaffold using a
successive layer-by-layer approach to generate tissue-like three-dimensional
structures.

19
 REFRENCE

[1] Dongkeon Lee, Takashi Miyoshi, Yasuhiro Takaya and Taeho Ha, “3D Micro fabrication
of Photosensitive Resin Reinforced with Ceramic Nanoparticles Using LCD
Microstreolithography”, Journal of Laser Micro/Nano engineering Vol.1, No.2, 2006.

[2] Ruben Perez Mananes, Jose Rojo-Manaute, Pablo Gil, “3D Surgical printing and pre
contoured plates for acetabular fractures”, Journal of ELSEVIER 2016.

[3] Alexandru Pirjan, Dana-Mihaela Petrosanu, “The Impact of 3D Printing Technology on

the society and economy”, Journal of Information Systems and Operations Management,
Volume 7, Dec 2013.

[4] Gabriel Gaala, Melissa Mendesa, Tiago P. de Almeida, “Simplified fabrication of

integrated microfluidic devices using fused deposition modeling 3D printing” Science Direct.

[5] Pshtiwan Shakor, Jay Sanjayan, Ali Nazari, Shami Nejadi, “Modified 3D printed powder
to cement-based material and mechanical properties of cement scaffold used in 3D printing”,
Science Direct.

[6] Siddharth Bhandari, B Regina, “3D Printing and Its Applications”, International Journal
of Computer Science and Information Technology Research ISSN 2348-120X.

[7] Elizabeth Matias, Bharat Rao, “3d printing on its historical evolution and the implications
for business”, 2015 Proceedings of PICMET: Management of the Technology Age.

[8] Frank van der Klift, Yoichiro Koga, Akira Todoroki, “3D Printing of Continuous Carbon
Fibre Reinforced Thermo-Plastic (CFRTP) Tensile Test Specimens”, Open Journal of
Composite Materials, 2016, 6, 18- 27.

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