The document presents a preliminary presentation on the fabrication of a 3D printer based on Fused Deposition Modeling (FDM) technology. It was submitted by a group of students to their project guides at the Government College of Engineering and Technology in Jammu. The presentation includes sections on how 3D printers work using FDM, the required materials and components, the principles and process of FDM printing, applications of FDM printing, and the current and future scope of the technology.

1. G O V E R N M E N T C O L L E G E O F E N G I N E E R I N G A N D
T E C H N O L O G Y , J A M M U
P R E L I M I N A R Y P R E S E N T A T I O N O N
F A B R I C A T I O N O F 3 D P R I N T E R B A S E D O N F U S E D
D E P O S I T I O N M O D E L I N G ( F D M ] .
SUBMITTED TO:
SANJEEV GUPTA
ASSOCIATE PROF. & HOD MECH. ENGG. DEPT.
PROJECT GUIDES:
SANJEEV GUPTA
ASSOCIATE PROF. & HOD MECH. ENGG. DEPT.
SAHIL PAHDA
ASSISTANT PROF. (AA) MECH. ENGG. DEPT.
PARDEEP SINGH
ASSISTANT PROF. (AA) MECH. ENGG. DEPT.
SUBMITTED BY:
DANISH BANOTRA (GCET/21/18)
VISHAL SINGH SLATHIA (GCET/46/18)
KAMIL JAN (GCET/75/18)
SAHIL SHARMA (GCET/102/18)
SURYA DEV SINGH (GCET/220/18)
STANZIN KHENRAB (GCET/290/18)
VIJAY KUMAR (GCET LES/59/19)

2. LIST OF CONTENTS:
1. Introduction
2. How does 3D Printer work
3. Fused Deposition Modeling
4. Material Requirements
5. Components Required
6. Principle and Working
7. Applications
8. Advantages
9. Disadvantages
10. Future Scope
11. Conclusion
12. Work Distribution
13. Components used and progress
14. References

3. INTRODUCTION:
What is 3D Printing?
3D printing or additive manufacturing is a process of making three dimensional solid
objects from a digital file. The creation of a 3D printed object is achieved using additive
processes. In an additive process an object is created by laying down successive layers
of material until the object is created.
3D printing enables you to produce complex shapes using less material than traditional
manufacturing methods.
A few types of 3D Printing Methods:
1) Stereolithography (SLA)
2) Fused Deposition Modeling (FDM)
3) Selective Laser Sintering (SLS)
4) Laminated Object Manufacturing (LOM)

4. HOW DOES 3D PRINTING WORKS?
Slicing basically means
slicing up a 3D model into
hundreds or thousands of
layers and is done with
slicing software.
After slicing file is
transferred to 3D printer.
Slicing
There are
different software
tools available.
3D software are
used to draw the
3D model of the
object to be
printed.
3D software

5. FUSED DEPOSITION MODELING:
• Fused deposition modeling (FDM) is one of the most widely used additive
manufacturing processes for fabricating prototypes and functional parts in common
engineering plastics.
• FDM 3D printer takes a plastic filament and squeezes it through a hot end, melting it
and then depositing it in layers on the print bed. These layers are fused together,
building up throughout the print, and eventually they will form the finished part.
• Many types of materials can be used with FDM techniques, including the most
common thermoplastics, chocolate, pastes, and even “exotic” materials like metal- or
wood-infused thermoplastic.
• The simplicity, reliability, and affordability of the FDM process have made the additive
manufacturing technology widely recognized and adopted by industry, academia, and
consumers.

6. WHY FDM?
• A recent MakerBot survey found that 77% of respondents use FDM printers to
do their 3D printing. Engineers and designers use them to make concept
models, functional prototypes and do research and development.
• The biggest reason - cost. After the patents for FDM expired in 2009, many
businesses and startups jumped at the chance to have free access to the
technology. Not only that, but free open-source hardware projects like RepRap
gave would-be entrepreneurs a proven path to making 3D printers. So as
these companies competed with each other, they were able to lower the price
of FDM printers.

7. MATERIAL REQUIREMENTS:
1) PLA:
• PLA stands for Polylactic Acid
• PLA is a biodegradable and bioactive thermoplastic polyester
• Suitable applications for PLA include parts, prototypes and products that are not
required to endure extreme stress.
2) ABS:
• ABS stands for Acrylonitrile butadiene styrene.
• ABS is usually produced through the emulsion process from 3 components or recycled
from itself.
• ABS is used when parts require extra strength; however, some improved composites
are slowly starting to displace it.

8. 3) PET:
• PET stands for Polyethylene terephthalate is a thermoplastic polymer resin
• It’s used widely for almost everything – from bottles to clothes.
4) PETG:
• PETG stands for Polyethylene terephthalate Glycol
• It improves PET by making it stronger and more durable
5) TPU:
• TPU stands for Thermoplastic polyurethane
• Itis a rubber-like material used to produce semi-flexible parts.
• Technically, it’s a polyurethane plastic and a block copolymer – its structure is made up
of a chain of hard and soft segments.

9. COMPONENTS REQUIRED:
1. MICRO CONTROLLER
2. EXTRUDER
3. NOZZLE
4. FILAMENT
5. END STOPS
6. STEPPER MOTOR
7. HEATING BED
8. FRAME

10. PRINCIPLE OF FDM (FUSED DEPOSITION
MODELING):
• FDM works on an “additive” principle by laying down material in layers. A plastic
filament or metal wire is unwound from a coil and supplies material to an extrusion
nozzle which can turn the flow on and off.

11. WORKING PROCESS OF FDM:
• Create a 3d model using CAD software and then slice it into hundreds or thousand
layers using slicing software.
• Transfer this sliced model into the 3D printer for the printing.
• Heat the nozzle until it reaches the desired temperature. The filament will be fed to the
extrusion head and then it will be melts in the nozzle.
• The extrusion head can move in the X,Y and Z directions. The extrusion head
extrudes melted material in very thin strands .The material is deposited layer-by-layer
on the platform, and then will be cool and solid.
• When one layer is finished, the build platform will move down (on some machines, the
extrusion head moves up) and a new layer will be deposited. This process repeats
until the part is completed.

12. APPLICATIONS:
1) The Architectural Model:
• The architectural model printed by a 3D printer costs almost half the time shorter than
the one made by any traditional method.
• A roll of filament can be used to print about at least three to four models, while costing
you at a lowest price.
2) The Automotive Industry:
• For the design of the car shape or internal structure.
• You only need to draw the parts you need through the 3D software.

13. 3) Animation Industry:
• With the help of FDM 3D printers you can easily produce any customized evil
headgear or superhero outfit.
• There is almost no limitation of complexity, which can greatly improve the visual effects
and texture of film and television dramas.
4) Smart Home:
• To create conceptual models of various shapes and functions, and accelerate the
formation of the final design plan.
• Change the design thinking of household design.
5) Education:
• To train students in innovative and practical ability.
• It allows students to transform their ideas or creations into reality.

14. ADVANTAGES:
1) Budget-Friendly:
• A nice, pocket-friendly FDM 3D Printer has all the essential requirements could be
easily bought in less than 200 dollars.
• Their filament is also cheap i.e. approximately 18 USD for 1KG of PLA.
2) Filament Reusable:
• FDM printer experiences some error and our printing gets failed. This causes the
filament that was used in printing to be unusable in other printers.
• FDM printers as most of the filaments are plastic-based thus they can be reused.

15. 3) Less Complex:
• The overall complexity of an FDM 3D printer is very low.
• In FDM 3D printers all the steps i.e. designing, slicing, printing, post-curing, etc. are
very simple.
4) Easy Ergonomics:
• Ergonomics means the connection between human and machine.
• FDM printers have most efficient connection between both.
5) Variety of Material Choice:
• There are more than 9 filament options available to be used as fodder in FDM printing.

16. DISADVANTAGES:
1) Rough Surface Finishing:
• Due to height and adhesion technology, the finished product made by FDM 3D printers
is not very good.
• One method of eliminating these rough surfaces is by post-curing processes i.e.
Acetone application, Gap filling, Priming & painting, Epoxy adhesion.
2) Warping is common:
• The layers tend to bend in any direction i.e. upward or downward.
• This can be cured by printing in small parts or by optimum calibration.

17. 3) Nozzle Clogging:
• This happens due to the irregular temperature settings and also when printing is very
fast with respect to the pace of melting of filament.
• So one thing we can do to prevent this is the proper calibration of the printer before
printing.
4) Loner Printing Time:
• As FDM printers print layer by layer the total printing time sometimes reaches in days
for a normal model of average volume.
• The printing time also depends on the selected quality, layer height, etc. of the 3D print
you want.
5) Bed Calibration Needed Frequently:
• After two to three prints the bed calibration of FDM printers gets misaligned.
• If you don’t correct the alignment of the bed after every print, then your next print’s
initial layers will get distorted and may result in print failure.

18. FUTURE SCOPE OF
FDM
The scope of 3D printing
encompasses objects like
aircraft components, musical
keyboards, interactive
posters, human organs, and
much more.
Distributed manufacturing
allows extreme
customization and low-
volume production of
products.

19. IN AEROSPACE AND AIRCRAFT INDUSTRY
Fused Deposition
Modelling (FDM),
commonly used to create
prototypes and tools.
FDM thermoplastics have
enough rigor to live up to
the demands. Between
ULTEM 1010, Nylon 12
and Nylon 6, we can
produce flight-worthy parts
that won't drive up the
cost.

20. • In Future, FDM machines with new materials, material tracking, closed-
loop feedback systems, increasingly cheaper sensors, multi-material
printing, advanced tool paths, automatic bed clearing, and color printing.
• The advancements in the FDM hardware, software, materials and
applications suggest that FDM 3D printing will eventually become yet
another manufacturing technology.
• Dental will adopt FDM 3D printing as a dominant production technology.

21. CONCLUSION
It is generally accepted that 3D printing will be a revolutionary force in
manufacturing. FDM printing has blasted into popularity and doesn’t
look like it’s going anywhere soon. That’s probably just as well,
seeing as how it’s helping bring more people into the world of 3D
printing. Many companies are already using the technology to
repeatedly produce complex components, for example in automotive
and aerospace manufacturing.

22. DISTRIBUTION OF WORK PERTAINING TO THE PROJECT:
• Software team:
a) CAD design: Vijay Kumar
b) Slicing software: Danish Banotra
• Electronics team:
Suryadev Singh.
Kamil Jan.
Sahil Sharma.
• Hardware cum machining team:
Stanzin Khenrab.
Vishal Singh Slathia.
• Post-Processing team:
Sahil Sharma.
Suryadev Singh

23. COMPONENTS USED IN FABRICATION:
• Filament : PLA filament of 1.75 mm diameter is used because:
1.75mm Diameter Pros
a) More popular, easier to buy.
b) Smaller extruder required compared to 3mm.
c) Easier to use with bowden tube.
d) Smaller nozzle diameter (<0.4mm) can be used for precise prints.
e) Better flow rate flexibility due to higher surface to volume ratio, allowing for faster
melting in nozzle and higher volume extrusion rates.
We are using PLA because it is Biodegradable, cheap and provides good surface finish.
• Nozzle size : Generally 0.4mm nozzle is considered a good choice because it is
roughly the mid point of the nozzle ranges. It is often considered a good compromise
as it has a good balance between print speed and resolution.

24. • Extruder: We are going for Bowden extruder because:
The motor on Bowden extruders are located away from the hot end which reduces the weight
of moving parts. This allows for more accurate prints as momentum is greatly reduced,
particularly at higher speeds (less momentum to overcome during instant changes in
direction).
• The extruder itself is made of different parts.
• The Filament Drive Gear: Also known as extruder drive gear is responsible for pushing
the filament into the hot end.
• The Heat Sink: The heat sink along with the heat Sink Fan ensures that the material is still
in solid state until it reaches the nozzle.
• The Heater Cartridge: This is the component that works to heat up the filament.
• The Thermocouple: To maintain the right temperature, the extruder uses a temperature
sensor. This is used for the hot end.
• The Cooling Fan: Once the melted filament is deposited, it must be cooled down for
setting before the next layer gets deposited. The job of the cooling fan is to ensure the
same.
• Nozzle: This forms the tip of the extruder. The filament is melted and it comes out of the
nozzle for deposition. There are different sizes of nozzles that the printers use. 0.4 mm is
the most common one. By keeping the smaller diameter of nozzle, one can achieve finer

25. • End Stops : The end stops help the print head to know where the zero position is. It
also prevents derailing of bed. We have used mechanical limit switches.
• Printing bed : We are using a heating bed so that proper adhesion is provided.
• Linear rails are used instead of linear rods because in rods there is a chance of
rotation which can affect the printing.
• Slicing software used by us is Cura because of:
a) Free to use.
b) Provides 3D printing e-learning courses.
c) Have a big community of active users.

26. MECHANICAL ELECTRONICS
COMPONENTS COMPONENTS

27. CURRENT PROGRESS

28. REFERENCES:
• https://all3dp.com/2/fused-deposition-modeling-fdm-3d-printing-simply-explained/
• https://www.hubs.com/knowledge-base/what-is-fdm-3d-printing/
• https://themechninja.com/07/fdm-printing-advantages-disadvantages-detailed/
• https://qidemy.com
• https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7257444/
• https://www.sciencedirect.com/topics/materials-science/fused-deposition-modeling
• https://www.iitk.ac.in/dordold/index.php?option=com_content&view=category&layout=b
log&id=200&Itemid=219

29. THANK
YOU