Delta ceramic 3 d printer

3D RAPID PROTYPING MACHINE
CAPSTONE PROJECT Submitted
in partial fulfillment of the
Requirement for the award of the
Degree of
BACHELOR OF TECHNOLOGY
IN
Mechanical Engineering
By
Ramireddy Venkata Siva Sandeep (11307010)
Karumuri Mohan Krishna (11306405)
Thota Roja Babu (11304020)
Under the Guidance of
Mr. Patel C.H
(Assistant Professor)
Lovely School Of Technology And Sciences
Lovely Professional University Punjab
April-2017

TOPIC APPROVAL PERFORMA
School of Mechanical Engineering
Program : 1208::B.Tech. - ME
COURSE CODE : MEC494 REGULAR/BACKLOG : Regular GROUP NUMBER : MERGC0105
Supervisor Name : Patel C.H. UID : 15755 Designation : Assistant Professor
Qualification : Research Experience :
SR.NO. NAME OF STUDENT REGISTRATION NO BATCH SECTION CONTACT NUMBER
1 Ramireddy Venkata Siva Sandeep 11307010 2013 M1306 09963049717
2 Karumuri Mohankrishna Rao 11306405 2013 M1306 8427305596
3 Thota Roja Babu 11304020 2013 M1306 9501894464
SPECIALIZATION AREA : CAD/CAM & Mechatronics
PROPOSED TOPIC : Design and fabrication of Delta 3D printer.
Supervisor Signature:
Qualitative Assessment of Proposed Topic by PAC
Sr.No. Parameter Rating (out of 10)
1 Project Novelty: Potential of the project to create new knowledge 6.33
2 Project Feasibility: Project can be timely carried out in-house with low-cost and available resources in
the University by the students.
6.67
3 Project Academic Inputs: Project topic is relevant and makes extensive use of academic inputs in UG
program and serves as a culminating effort for core study area of the degree program.
7.00
4 Project Supervision: Project supervisor’s is technically competent to guide students, resolve any issues,
and impart necessary skills.
6.67
5 Social Applicability: Project work intends to solve a practical problem. 6.33
6 Future Scope: Project has potential to become basis of future research work, publication or patent. 6.67
PAC Committee Members
PAC Member 1 Name: Jaiinder Preet Singh UID: 14740 Recommended (Y/N): NA
PAC Member 2 Name: Piyush Gulati UID: 14775 Recommended (Y/N): NA
PAC Member 3 Name: Dr. Manpreet Singh UID: 20360 Recommended (Y/N): Yes
DRD Nominee Name: Dr. Amit Bansal UID: 18697 Recommended (Y/N): Yes
DAA Nominee Name: Kamal Hassan UID: 17469 Recommended (Y/N): Yes
Final Topic Approved by PAC: Design and fabrication of Delta 3D printer.
Overall Remarks: Approved
PAC CHAIRPERSON Name: 12174::Gurpreet Singh Phull Approval Date: 07 Mar 2017
4/28/2017 1:07:55 PM

I
CERTIFICATE
This is to certify that the Capstone project titled “3D RAPID PROTYPING MACHINE”
that is being submitted by “Ramireddy Venkata Siva Sandeep (11307010), Thota Roja
Babu(11304020), Karumuri Mohan Krishna Rao (11306405) is in partial fulfillment of the
requirements for the award of BACHELOR OF TECHNOLOGY DEGREE, is a record of
Bonafide work done under my guidance .The contents of this Capstone project, in full or in
parts, have neither been taken from any other source nor have been submitted to any other
Institute or University for award of any degree or diploma and the same is certified.
The Capstone project is fit for submission and the partial fulfillment of the conditions
for the award of B. tech in Mechanical Engineering.
Mr. Patel C.H
Assistant Professor
Lovely School of Technology and Science
Lovely Professional University
Phagwara, Punjab.
Date:

II
ACKNOWLEDGEMENT
We have taken efforts in this project. However, it would not have been possible
without the kind support and help of teachers and the organizations. We would like to extend
our sincere thanks to all of them. We are highly indebted to Lovely Professional University
for their guidance and constant supervision as well as for providing necessary information
regarding the capstone project and also for their support in completing this report. We would
like to express our gratitude towards our parents, group mates, Mentor Mr. Patel C.H and
members of the University Kind Co-operation and encouragement, which helped us in
completion of this project report. We would like to express our special gratitude and thanks
to the university persons for giving us such attention and time.
We would like to thank to everyone who helped in the completion of the project either
directly or indirectly.
Our thanks and appreciation also goes to our HOS “Dr.Gurpreet Singh Phull”who
gave us the opportunity for experiencing such knowledge and people who have willingly
helped us out with their abilities.
Karumuri Mohan Krishna Rao (11306405)

III
DECLARATION
We students of B. Tech under Department of ME (Mechanical Engineering) of Lovely
Professional University, Punjab, hereby declare that all the information furnished in this
capstone project report is based on our own intensive research and is genuine.
This capstone does not, to the best of my knowledge, contain part of my work, which
has been submitted for the award of my degree either of this university or any other university
without proper citation.
Date:
Signature and Name of the student
Karumuri Mohan Krishna Rao (11306405)

ABSTRACT
3d printing is a thriving technology trending today among science community. Lots of research is
being done to use the technology to its full potential. 3D printing will continue to provide low-
cost effective solutions in various sectors.
In this project our aim is to design and fabrication of Delta 3D printer, it mainly aims to
manufacturing 3D ceramic objects by successively placing layer on layer. For creating 3D Printer
prototype model we used CREO and Unigraphics design software’s.
To print 3D component G-codes and M-codes are automatically generated with the help of “CURA
Software”. These G-codes and M-codes will be copied to the SD Card Module for the movement
of the extruder. The Arduino code has been Written in order to control the movement of the
extruder with the help of Stepper Motors.
We wish to construct a universal 3D printer. In this printer, many techniques are employing to
print 3D objects like CAD Model Designing, Stereo lithography (STL), Ceramic Extruding,
Stepper motor controlling etc.
By universal we mean that most of the techniques to print 3D objects can be integrated in one
Machine so that a standard is established.
We also wish to make the machine Cost effective and most reliable so it will provide benefits for
the Society.
Process: Clay deposition modeling
Key Words: SD card module, 3D printer, Aurdino, STL, 3D CAD Models.
APPLICATION: Tea cup, Pots, constructing of houses, Prototype models etc..;
V

1. Contents
CHAPTER-1 .............................................................................................................................. 1
INTRODUCTION TO 3D PRINTER............................................................................................ 1
CHAPTER -2 ............................................................................................................................. 3
HISTORY OF 3D PRINTER....................................................................................................... 3
CHAPTER -3 ............................................................................................................................. 5
SCOPE OF 3D PRINTER .......................................................................................................... 5
CHAPTER-4 .............................................................................................................................. 6
LITERATURE REVIEW............................................................................................................. 6
4.1 RESEARCH: Delta analysis and Kinematics of delta printers ........................................... 6
4.2 RESEARCH: REPRAP project ......................................................................................... 6
4.3 PROJECT: Self build 3d printer ........................................................................................ 6
4.4 MARLIN Firmware............................................................................................................ 7
CHAPTER -5 ............................................................................................................................. 8
COMPONENTS OF 3D PRINTER ............................................................................................. 8
5.1 ELECTRONICS:................................................................................................................... 8
5.1.1 Arduino: ............................................................................................................................ 8
5.1.2 Ramps 1.4:................................................................................................................11
5.1.3 STEPPER MOTOR: ..................................................................................................12
5.1.4 Limit switch: ..............................................................................................................14
5.1.5 SD card module: .......................................................................................................15
5.1.6 Power Supply:...........................................................................................................16
5.2 Mechanical Components .................................................................................................17
5.2.1 MDF Board:...............................................................................................................17
5.2.2 Steel Rods: ...............................................................................................................17
5.2.3 Linear and Circular Ball Bearings: .............................................................................18
5.2.4 Cylinder:....................................................................................................................19
Figure-5.18 Plumbling pipe ................................................................................................19
5.2.4 Hose: ........................................................................................................................19
5.2.5 Rack and pinion : ......................................................................................................20
5.2.6 Hopper : ....................................................................................................................21
5.2.7 Syringe:.....................................................................................................................21

VII
5.3 Ceramic material .............................................................................................................22
Figure -5.23 Ceramic pot ..........................................................................................................22
5.3.1Green field Bentonite powder:....................................................................................23
CHAPTER -6 ............................................................................................................................24
PRINCIPLE OF 3D PRINTER...................................................................................................24
6.1 Design in CAD:................................................................................................................24
6.2 Slicing:.............................................................................................................................25
6.3 Gcode:.............................................................................................................................26
6.3.1 Syntax of Gcode:.......................................................................................................26
6.3.2 Sample Gcode: .........................................................................................................26
6.4 CAD to Gcode visualization: ............................................................................................27
Chapter-7..................................................................................................................................28
WHY DELTA?...........................................................................................................................28
7.1 Introduction to Delta Printer: ............................................................................................29
CHAPTER-8 .............................................................................................................................30
DELTA PRINTER KINEMATICS ...............................................................................................30
CHAPTER-9 .............................................................................................................................32
PROCEDURE FOR DELTA 3D PRINTER ................................................................................32
9.1 Conversion of xyz to delta: ..............................................................................................32
9.2 Motor conversion:............................................................................................................32
9.2.1 Implementation: ........................................................................................................32
9.2.2 Algorithm For Motion Trajectory ................................................................................32
9.2.3. Implementation:........................................................................................................33
9.3 Calibration: ......................................................................................................................34
9.3.1 Implementation: ........................................................................................................34
CHAPTER-10 ...........................................................................................................................35
SOFTWARE USED FOR GENERATING G-CODES.................................................................35
10.1 CURA 2.3.1: ..................................................................................................................35
10.2 Arduino IDE: ..................................................................................................................38
CHAPTER-11 ...........................................................................................................................41
WORKING OF 3D PRINTER ....................................................................................................41
CHAPTER-12 ...........................................................................................................................42
DESIGN of 3D CAD Models & ASSEMBLY ..............................................................................42

VIII
VIII
VIII
VIII
12.1 Designs: ........................................................................................................................42
12.2 Assembly of the printer: .................................................................................................43
CHAPTER-13 ...........................................................................................................................45
CONCLUSION AND FUTURE SCOPE.....................................................................................45
REFERENCES AND BIBLIOGRAPHY......................................................................................46
• 3D Printing: Build Your Own 3D Printer and Print Your Own 3D Objects(book) .................46

IX
LIST OF FIGURES :
Figure 1.1 Cartesian 3D Printer…………………………………………………………………………….1
Figure 1.2 Different techniques in 3D Printer……………………………………………………………....2
Figure 2.1 First 3D printer made by Makerbot industries.............................................................................3
Figure 5.1 Pin Configuration of Arduino MEGA 2560................................................................................9
Figure 5.2 Ramps Stepper Motor Driver Shield .........................................................................................11
Figure 5.3 Pin Configuration of Ramps Stepper motor driver shield .........................................................11
Figure 5.4 RepRap 3D Printer outline ........................................................................................................12
Figure 5.5 Polarity of Stepper Motors ........................................................................................................13
Figure 5.6 NEMA standard 17 Stepper Motor............................................................................................13
Figure 5.7 Limit Switch..............................................................................................................................14
Figure 5.8 modes of limit switch ................................................................................................................14
Figure 5.9 Master Slave Connection in SPI protocol..................................................................................15
Figure 5.10 Regulated Power Supply .........................................................................................................16
Figure 5.11 Switch Mode Power Supply (SMPS)Mechanical Components...............................................16
Figure 5.12 MDF board ..............................................................................................................................17
Figure 5.13 Hard Chrome plated Steel rods................................................................................................17
Figure 5.14 Linear and Circular Bearings...................................................................................................18
Figure 5.15 Cross-sectional diagram of Circular and Linear Bearings.......................................................18
Figure 6.1 CREO CAD user interface ........................................................................................................24
Figure 6.2 Slicing of a 3D model................................................................................................................25
Figure 6.3 Preview of a 3D model and its single layer for slicing..............................................................25
Figure 6.4Gcode Visualization ...................................................................................................................27
Figure 7.1 Working of Cartesian and Delta Printers...................................................................................28
Figure 7.2 Delta 3D printer.........................................................................................................................29
Figure 8.1 Axis of Delta printer..................................................................................................................30
Figure 8.2 Axial rod alignment in delta printers.........................................................................................31
Figure 10.1 User Interface of CURA 2.3.1.................................................................................................35
Figure 10.2 Loading .stl file to the software...............................................................................................36
Figure 12.1 Design of Base and Top of printer...........................................................................................42
Figure 12.2 Design of Linear and Circular Bearing holder ........................................................................42
Figure 12.3 Assembly of the printer ...........................................................................................................43

1
CHAPTER-1
INTRODUCTION TO 3D PRINTER
Making our homes to manufacturing hubs, 3D printing has made lot of changes in making
our ideas to real. The word Rapid Prototyping is mostly known by the industry people, this is a
concept used by the designers to make prototypes in design labs. Rapid Prototyping machines have
capability to print any object in the world, this capability of replicating things made them to be on
our desktop .Once they were only used by prototype makers in industry, but today it’s a pie of
every DIY hobbyist and spread over every industry from making food to building homes and cars.
Almost every educational institute have one of it. Need for rapid implementation of ideas made to
enter them into our workspaces.
Traditional Manufacturing and production processes uses conventional molding or casting
process and subtracting manufacturing process.Making of molds is expensive and, these molds
need to be replaced with the new ones if there is any change in the previous designs. In contrast,
3d printers use additive manufacturing technique which can be suitable for any kind design
changes. Moreover, subtractive manufacturing processes results in wastage of 90% of material
used. Whereas additive process uses only required amount of material to print, this make it most
efficient way to prototype a design.
The Additive Manufacturing (AM) process, the name itself conveys the process what it does.
Process goes by slicing 3d model designed by a designer, then printing the slices and the property
of material used to combine it form a 3d model. It’s just a 2d printer adding layer upon layer coined
the name additive manufacturing and also a printing in 3D. 3D printers are customized prototyping
machines suitable to work at any place.
Figure 1.1 3D Printer

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3d printing
Stereo
lithography
Electronic
Beam Melting
Selective Laser
Melting
Fused Deposition
Method
Digital Light Processing
Figure 1.2 Different Techinques of 3D printer
• Stereo lithography is the oldest method developed by 3D system Inc. which uses lasers to harden
the resin, laser is moved according to the input. This results in 3d object.
• Digital Light Processing(DLP) is the process which uses DLP projectors to project light on the
resin, then layer of the 3d image is produced with each projected image.
• Selective laser melting technique uses high power laser beams and metallic powder. When
metallic powder is exposed to laser it starts melting and forms a solidified 3D structure.
• Electronic Beam Melting technique uses electron beam instead of laser beam used in SLM, rest
process remains same as SLM,
• Fused Deposition Method(FDM) used production grade thermoplastics to build parts. This the
one of the most widely used technique because it is less expensive compared to the other
techniques. It simply heats the thermoplastic material and extrudes according to the input CAD
model provided. FDM is the prime example for usage of additive manufacturing technique.

3
CHAPTER -2
HISTORY OF 3D PRINTER
In late 1980, the first 3d printing technology (additive manufacturing) was evolved which
was known as rapid proto-typing. This is first invented by CHARLES HULL. This is developed
because for any usage of the product as prototype it is very cost effective to develop in industry.
So, the idea of inventing this was the major reason .The 3d systems rapid prototyping was
introduced in 1987, which was tested and sold which was made by SLA (stereo lithography
apparatus).Within the same year there was another rapid prototyping machine which used the other
technique of printing the object that is SLS (SELECTIVE LASER SINTERING).This was
invented by the scientist named CARL DECKARD who was professor at the university of Texas
in USA. In the year 1989, there was another prototyping machine which was developed by the
SCOOT CRUMP .This is the other technique of making the 3d object that is FDM (fused
deposition modeling).
Additive manufacturing processes for metal sintering such as selective laser, laser melting.in early
1990’s the metal working was done by fabric ion and welding which uses automation was the
welding purpose andall .but the idea of making the 3d objects was started by many people by
making use of the raw material and making the required shapes instead of using the metal as the
material.
Figure 2.1 First 3D printer made by Makerbot industries

4
Other 3d printing technologies was also evolving this now a days like ballistic particle
manufacturing, laminated object manufacturing and solid ground curing and three dimensional
printing. Many of the competitors was growing day by day but the three main companies which
was remain until today was EOS, Stratasys and 3d Systems Inc. Europe, 1989 the EOS formed in
Germany which was founded by HANS LANGER. After the invention of laser sintering the EOS
R&D department was focused on the laser sintering .Today they were one of the company
recognized for the quality output of the production of 3d printing objects. Stratasys is one of the
company which developed the FDM (fused deposition modeling).This is used by many people
now a days by an open source software RepRap.3d systems was the one invented the SLA machine
which is one of the most largest 3d printing organization .

5
CHAPTER -3
SCOPE OF 3D PRINTER
In recent years, 3D printing has truly begun to capture the imagination of the masses, as
low cost printers for personal use begin to make it possible for hobbyists and aspiring designers to
create objects designed in CAD software right on their desks.
The Additive Manufacturing, or 3 Dimensional printing, goes beyond the capability of printing
in the conventional sense of ink on paper, allowing for objects to be physically printed before your
very eyes. 3D printers allow you to create models,prototypes and products out of materials such
as plastics and metals. 3D printing allows individuals and companies to rapidly prototype ideas for
new products and also promises to cut down costs on the creation of products through savings in
supply-chains, product waste and storage.
The benefits of 3D printing are likely to revolutionize many industries. The automotive
and aerospace industries benefit from much shorter lead times than with associated traditional
engineering methods such as casting or machining, allowing for much faster development and
testing of components. In the future, it may even be possible for large components or even entire
cars to be entirely 3D printed, as recently demonstrated by Local Motors at the 2014 International
Manufacturing Technology Show in Chicago, USA.
The 3D printers has ability to print electronic circuitry which adds a feature for consumers
to 3D print electronic products like mobile phones, or the possibility of producing highly
customized products based on individual consumer preferences. Google has recently partnered
with 3D Systems Inc. to develop Project ARA, a modular phone which will allow customized 3D
printed personalized features, which could point to a future of consumer electronics mainly shaped
by 3D printing.
The food industry is also set for a revolution, thanks to 3D printing. NASA has invested
in this technology in the hope that one day its astronauts will be able to print their food whilst in
space. Whilst printers currently exist that allow for 3D creations of foodstuff such as chocolate
and pasta, 3D printing may in the future be able to allow fine control of the nutritional content of
many types of food, which in turn could help tackle several health problems such as obesity and
diabetes or even world hunger.

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CHAPTER-4
LITERATURE REVIEW
4.1 RESEARCH: Delta analysis and Kinematics of delta printers Steve graves
had completely described about the inverse and forward kinematics of especially delta 3d
printers, he is one who had given a clear cut visualization on working of deltabot. Paper also
focuses on stabilization of structure for each input and ends with the error calculation. This
helped us in understanding the kinematics of printers and give us a way think intuitively about the
movement on them.
4.2 RESEARCH: REPRAP project
Open source hardware project accelerated 3d printers use by everyone, as we know open source
projects grow rapidly because of number of developers. This project created worlds 1st open
source hard and software for 3d printers. They integrate all their electronics onto a board and
named it as RAMPS motor shield which compatible for Arduino MEGA. Dev group made it as
successful, that they today compete with commercial printers. They added each new printer
developed by devsto their inventory and call them as RepRap printers, they are almost of 40-50
printer designs available with a little span of time. This helped us a lot to understand about
electronics and gave us clear idea of making a printer from scratch.
4.3 PROJECT: Self build 3d printer
Jonathan kept is an Artist and designer. He designed printer with commonly available components,
this helped us to make the printer from components which are easily available. We replicated his
design to make our project successful. He is also a creator of ceramic 3d printers, he make many
sculptures they stood best in UK art exhibition of art. Design of printer is easy and this is a delta
printer.

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4.4 MARLIN Firmware
One of the industry standard Firmware, Which is used by almost every commercial 3d printers
today. This is complete firmware which has support for Cartesian, delta, SCARA Kinematic
motions. It even support for 49 Extruders which is a full-fledged color 3d printing. It also support
on board LCD and Bluetooth support for your printers. We inherited our code flow and
implemented our own logics to make our boot work according to code.

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CHAPTER -5
COMPONENTS OF 3D PRINTER
5.1 ELECTRONICS:
5.1.1 Arduino:
Arduino is the open source platform used for the building electronic projects. This is of both
hardware which is a microcontroller and a software. Which runs on the computer to write and burn
the code in the hardware. Like the other controllers it does not need the code burner it has the USB
cable to get contact with the computer. we can directly burn the code in to the hardware.
We can say Arduino on mini system on a single printed circuit board (PCB) which consists of
basic required circuitry and components to use a microcontroller in extreme usage. Where the
hardware is embedded with the unseemly easy software, where the targeted users are from any
departments and even easily used by a school kid.
The Arduino consists of microcontroller, required circuitry, on board Analog to Digital
converters,testing LEDs, USB connect port, and regulator for different onboard voltages like 3.3
and 5 volts.
They are many Arduino boards available according to their special features. They were made
for different users to meet their requirements such as some need more number of General-
purpose input/output (GPIO’s) and some need small and compact designs. Here are some
Arduino boards ArduinoUno, Arduino due, Arduino MEGA, ArduinoLeonardo and Lilypad. We
added Arduino MEGA 2560 in our project for its extended GPIO ports.
We need almost 20 GPIOs to interface all our components.
The Arduino shields was also provided to get the extra features to the Arduino boards like wireless
network access,cell access and any prototype circuits
● Wireless shield
● GSM shield
● Ethernet shield
● Proto shield

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Arduino MEGA 2560
Figure 5.1 Pin Configuration of Arduino MEGA 2560

10
Arduino MEGA Pin description:
Serial pins:Use for serial communication mega has 4 serial com ports their pins are
described below
● Serial 0 : (Tx) pin 0 (Rx) pin 1
● Pins 0 and 1 is connected to USB to Transistor-transistor logic(TTL) Serial chip to
communicate with Arduino software, they are used by pc when they are connected to
software.
● PWM(Pulse Width Modulation) pins: Pin 2 - 13 and Pin 44 - 46 can write PWM output
when AnalogWrite function is used. PWM, is a technique for getting analog results
with digital means. Digital control is used to create a square wave, a signal
switched between on and off.
● SPI pins (Serial Peripheral Interface ) : Pins for SPI protocol , we used this for SD card
● Pin 13 Led
● Pin 50 Master input slave output
● Pin 51 Master output slave input
● Pin 52 Serial clock
● Pin 53 Chip select
● I2C (Inter integrated circuit )
● Pin 20 (SDA) Serial data line
● Pin 21 (SCl) Serial clock line
● Analog inputs : 16 Analog read pins are available on mega , which can be accessed by
AnalogRead function Pin A0 - A15 (54-69)
● Every pin onboard can be used as a digital pin , so it has 69 digital pins call by functions
Digital Read and Digital Write

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5.1.2 Ramps 1.4:
Ramps is RepRap Arduino MEGA Pololu shield. It is used for the purpose of steeper driven
board.it can only work when it is connected to the Arduino board mega 2560 .Board is specially
designed for decrease the connection complexity of bringing all the connections onto a single
board. This is made especially made for pololu stepper drivers.
Figure 5.2 Ramps Stepper Motor Driver Shield
This make connections between stepper drivers, extruders and control electronics with Arduino,
part replacement and upgrade ability and expansion of inputs and output ports. Ramps should be
mounted on an Arduino board for the usage.
This shield is of the pin headed socket .It can be easily removed for the future use.For the safety
and protection of the board additional 5A is fused.
Figure 5.3 Pin Configuration of Ramps Stepper motor driver shield

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Ramps features:
● Can install up to 5 stepper motor drivers. .
● Pins of I2C and SPI are reserved for expanding.
● Use the interface for servos for level printing platform.
● Can run 2 motors for Z axis in parallel.
● Support for Hotend and Hotbed.
● Slot for 2 thermistors one for Hotend bed.
● Support for 3 stopends.
● Smart adapter adds the both LCD and SD card adapter.
● Fuse for 11A input.
Figure 5.4 RepRap 3D Printer outline
5.1.3 STEPPER MOTOR:
Stepper motor is a dc motor with toothed shaft or step motor which was used for the precisely
defined increment in the position of shaft. They have toothed electromagnets which are responsible
for presided step motion.It divides the full rotation into equal number of steps. Steppers are divided
into categories on the basis of their winding arrangement, Unipolar and Bipolar.
Unipolar are easy to operate as they need easy transistor circuitry to operate them. As they have
separate windings for each side and the common side is grounded, motion is caused by energizing

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each coil. It uses only one polarity no change in direction of current, it's named as unipolar.
In Case of bipolar it just have half of windings available in unipolar, it uses two poles of winding
to the energizing them as same pattern as unipolar. Driver part become more complex in case of
bipolar, it uses 2 h-bridge circuits to change the direction of flow of current.We have an advantage
of high torque in bipolar because total coil is energized every time.
Figure 5.5 Polarity of Stepper Motors
NEMA 17 Stepper Motor
Figure 5.6 NEMA standard 17 Stepper Motor
It is National electrical Manufacturers association (NEMA) standard 1.7 inch motor, Torque of
motor depends on winding inside it.

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Specifications
● 1.5 to 1.8 torque for each phase.
● 1-4 volts.
● Holding torque 4.5 kg.
● 200 steps per revolution.
● 1.8 degree per step.
5.1.4 Limit switch:
A limit switch is operated by the motion of any machinery object to count the particles passing
through it or as safety interlocks. This is the electromechanical device which consists of actuator
connected by the set of contacts in which any object touching the actuator makes the device to
connect or break the electric connection. Because of their easy installation and reliability they
were used in many ways.
● Common
● Normally closed
● Normally open
Figure 5.7 Limit Switch
Common:It is the pin from which the input pulse is send,that is 1 or 0.this pin will be in contact
with the actuator of the switch. When the actuator is touched to any object the pulse is generated
sent from this pin.
Figure 5.8 modes of limit switch

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5.1.5 SD card module:
This module helps data on SD card to Arduino. This module comes with 6 pins, requires 4 control
pins to communicate and other two are Vcc and ground. SD card module uses SPI protocol to
communicate with peripheral devices.
SPI is serial to peripheral interface protocol is developed by Motorola, for on board PCB
peripherals communication. This is made for short distance communication like controller to
peripheral slaves in a circuit. Four control pins MISO, MOSI, serial clock, chip select. MISO pin
is master input and slave output, this function helps to read data from slave. MOSI master output
and slave input, this send out data to peripherals .chip select is to select a peripheral device a time.
Many device can be connected to a single master. They are two modes of connecting them daisy
chained SPI and independent slave configuration. It has high throughput than I2C.
Figure 5.9 Master Slave Connection in SPI protocol

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5.1.6 Power Supply:
Figure 5.10 Regulated Power Supply
Regulated power supply converts ac to dc and dc is also regulated according to load requirements.
It starts with transformer ac is converted to dc by rectifier circuitry helps to convert full wave to
positive side , then comes the role of capacitor removing the ripples from rectifier . You get the
dc as output from the capacitor. Regulation circuitry is used to help voltage regulation
Output, mostly this is done by 7805 for 5v and 7812 for 12v.
Surface Mounted Power Supplies (SMPS) are considered to be more efficient than normal linear
relation circuitry, because there is no current flow in case of cuttoffmode .It uses an oscillator
circuit and an inductor element than a normal linear power supply, Oscillator circuitry helps to
reduce the response time at transistor. Inductor element helps in storing the current .By varying
the duty cycle of the switching we can change the energy stored in inductor. They are also called
non dissipative regulators because only required power is pumped into the inductor.
Input voltage: 230v ac
Output voltage: regulated according to sense resistors.
Output current: 5A-10A
Efficiency: 65-75%
Figure 5.11 Switch Mode Power Supply (SMPS)Mechanical Components

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5.2 Mechanical Components
5.2.1 MDF Board:
Medium-Density Fiberboard is an engineered wood product made by breaking down
hardwood or softwood residuals into wood fibers, often in a defibrator, combining it with wax and
resin binder, and forming panels by applying high temperature pressure. MDF is generally denser
than plywood.
Figure 5.12 MDF board
Physical properties of MDF are it is made up of 82% of wood fiber, 9% of urea formaldehyde
resin glue 8% of water and 1% of paraffin wax and the density is typically between 500 Kg/m3
and 1000 Kg/m 3
. These MDF boards are available in market with different dimensions and with
different thicknesses which varies the density of each board.
5.2.2 Steel Rods:
We have used hard chrome plated steel rods for making the structure of the printer. Six
rods with sizes 700mm long and 12mm diameter are used.
Figure 5.13 Hard Chrome plated Steel rods

18
5.2.3 Linear and Circular Ball Bearings:
A ball bearing is a type of rolling element bearing that uses balls to maintain separation between
the moving parts of bearing i.e., the inner and outer part of the bearing. The purpose of ball bearing
is to reduce rotational friction and support radial and axial rods.
Figure 5.14 Linear and Circular Bearings
Figure 5.15 Cross-sectional diagram of Circular and Linear Bearings

19
5.2.4 Cylinder:
Cylinder is basically used to store the ceramic material
Figure 5.16 Plumbling pipe
5.2.4 Hose:
It’s one extreme end is connected to cylinder and other extreme end is connected to
extruder with the help of this ceramic can be transferred from cylinder to extruder ie;syringe
Figure 5.17 Hose

20
5.2.5 Rack and pinion:
A rack and pinion is a type of linear actuator that comprises a pair of gears which convert
rotational motion into linear motion. A circular gear called "the pinion" engages teeth on a linear
"gear" bar called "the rack"; rotational motion applied to the pinion causes the rack to move
relative to the pinion, thereby translating the rotational motion of the pinion into linear motion.
This mechanisms is connected to the cylinder which is used to push the ceramic material
inside the hose
Figure 5.18 Rack Pinion
5.2.6 Hopper :
Hopper is placed one extreme end of the cylinder which is used to fill the ceramic material
inside the cylinder
Figure 5.19 Hopper

21
5.2.7 Syringe:
The clay extruder is simply parts adapted from the injection syringe of 50ml. The soft clay
is extruded out of the cartridge with the help of Rack and Pinion Mechanisms. The pinion which
is connected to the stepper motor which controllers the movement of rack and which further
controller the flow of ceramic material to print the 3D object.
Figure 5.20 Syringe
5.3 Ceramic material
A ceramic material is an inorganic, non-metallic, often crystalline oxide, nitride or
carbide material. Some elements, such as carbon or silicon may be considered ceramics. Ceramic
materials are brittle, hard, strong in compression, weak in shearing and tension. They withstand
chemical erosion that occurs in other materials subjected to acidic or caustic environments.
Ceramics generally can withstand very high temperatures, such as temperatures that range from
1,000 °C to 1,600 °C (1,800 °F to 3,000 °F). Glass is often not considered a ceramic because of
its amorphous (noncrystalline) character. However, glassmaking involves several steps of the
ceramic process and its mechanical properties are similar to ceramic materials.
Figure 5.21 Ceramic pot

22
5.3.1Green field Bentonite powder:
Bentonite Clay is a unique clay due to its ability to produce an “electrical charge” when
hydrated. Upon contact with fluid, its electrical components change, giving it the ability to
absorb toxins. Bentonite is known for its ability to absorb and remove toxins, heavy metals,
impurities, and chemicals.
Bentonite is a swelling clay. When it becomes mixed with water it rapidly
swells open like a highly porous sponge. From here the toxins are drawn into the
sponge through electrical attraction and once there, they are bound.
Figure 5.22 Green Field bentonite Powder

23
CHAPTER -6
PRINCIPLE OF 3D PRINTER
Below flowchart gives an idea about the workflow in process of 3d printing. It starts with
a designing of 3d model in CAD software ends with printing of model.
Design
in CAD
SLICING GCODE PRINTING
6.1 Design in CAD:
One can implement their ideas by designing them in Computer Aided Design softwares. When
we save them they form a STL (stereo lithography) file format, which has information of your 3d
design as points, which is helpful for reproduction or any other purposes.
We use this generated .stl file for further step known as slicing. Used online CAD stl generator
called CREO. Easy for beginners to design things in 3d, it is very useful for new users, GUI
based interface help in making the cad files in minutes
Figure 6.1 CREO CAD user interface

24
6.2 Slicing:
Figure 6.2 Slicing of a 3D model
We were focused on fused deposition kind of printers , where slicing is the most important
task to make 3 plane then to a 2d plane and at last to usable Gcode .The slicing technique helps in
determining the part to be filled with material also where it should be ideal. This is more helpful
for making the trajectory of the extruder end of the printer.
This reduces your complex 3d image to a layers of 2d image, this is helpful in determining
in extrusion speed, head speed,temperature and fan off and on.We also have the power to decide
size of wall, pattern of movement, thickness and is area where is make you 3d file to meet your
printer settings. Such as work area, length of axial rods, max stepping angle. We used Slic3r for
our project. We also adder our own printer adding new setting some of them delta bot printer has
radial work area, we had fixed the axial rod length, constant extruder speed.
Figure 6.3 Preview of a 3D model and its single layer for slicing

25
6.3 G-code:
The type of code designed by MIT SERVO MECHANISM laboratories, mostly used for CNC
machining and industrial applications. This answers the machine to question like, which and how
it should move. This follow its own easy kind of Syntax mostly industrial use this code their robots
in the assembly line.
Some of the Syntax of G code that we used, we normally used G0,G1 motions which have their
own function.
● G - Information of motion.
● M- Miscellaneous functions of machine.
● G0 - Rapid move
Moves rapidly to the prescribed position in Gcode. Where the components such as drill or
Extruder in our case is in off position. As there is no such part to drill in that
trajectory.Moves may not be straight path.
● G1 - Controlled move
Move is slow as compared with G0, it should move in a straight line. Which follows
linear interpolation to map all the points in plane.
● Words after the specified motion are axis and motion in each axis. E,F gives the details
about feed rate and Extrusion. X, Y and Z gives the value beside them is motion in that
axis.
6.3.1 Syntax of G-code:
G0/G1 [X{X position}] [Y{Y position}] [Z{Z position}] [E{Extruder position} [F{Feedrate}]
6.3.2 Sample G-code:
G1 F2220 X9.259 Y7.845 E103.21
The stated example gives the information of about it is a controlled move, having feed rate of
2220 and motion 9.256, 7.8445 mm in X, Y axis respectively. Last part give the temp
ofextrusion head. E plays a vital role in printers it decides the print exit or not at that place.

26
6.4 CAD to G-code visualization:
This example would clarify doubts about how g-code is linked to a CAD file, Code below is used
to create a rectangular box having its coordinate points (-13.6, 13.6), (-13.6, 13.6), (13.6,-13.6)
and (13.6, 13.6). This is rectangle designed in cad and the coordinate are very helpful in generation
of Gcode.
Figure 6.4Gcode Visualization

27
CHAPTER-7
WHY DELTA…?
` It very easy to work with Cartesian coordinates, we fell easy to imagine in with them
because we were trained to do that from long time. Every cad software also store same format to
store them to a file.
They are many types of 3d printers available according to coordinate system they use. We
usually see Cartesian, polar and Delta coordinate system with these printers .Cartesian printers are
almost the most used among all of them , as they are easily conceptualize for makers, easy to
calibrate and each axis can calibrate independently.
Now let's talk about what it lags, it is comparatively slow as compared with delta. Here are
some points which are the reason behind to choose delta printer.
● EASY to build than Cartesian.
● FAST than Cartesian, moving from point to point.
● 3 Steppers are enough for complete movement, even same load on each stepper.
● NO need of moving bed, many printers do it this which makes print to deform to
another shape.
● REDUCED parts which results in low maintenance.
● TALL built volume.
Figure 7.1 Working of Cartesian and Delta Printers

28
7.1 Introduction to Delta Printer:
The delta is a type of configuration normally used by pick and place robots in industries,
this results in a fast and accurate positioning .It has three legged mechanism to reach a circular
workspace in a plane . Total work space look as a Cylinder.They came around 2005 having
principles adopted from industry level delta bots, first delta printer is developed by Kossel. Which
is a good move towards large volume and easy build printers. It’s also same concept of tri
linearization as all three moving axial rods concentrate to reach a point. Best part about delta is
that it just needs very small movement when compared with others. This uses three linear axis,
where a joining end results in reaching each point of the work space. Three linear axis are kept at
each vertex of triangle. Usually for motion in z, we need to move all the axis. Motion in X, Y are
done by different motion rate in each axis. Different rate can by Pythagorastheorem.
Figure 7.2 Delta 3D printer

29
CHAPTER-8
DELTA PRINTER KINEMATICS
We used reverse kinematics to derive the equations to the printer, our goal is map each
Cartesian point to the motion of three motors. We then making the motion onto center extruder
portion.
To find the relation between Cartesian and rod movements, we had taken some constants
to figure out the location of the required points. Firstly we get values from G-code, which we
print using a delta printer.
Our main objective to find the motion of steppers started by making a coordinate system
on the printer base and we assumed that each pair of rods parallel to each other. All three set of
rods are arranged with a phase difference of 120 degrees. Rods are at 90˚,210˚ and 330˚.
Figure 8.1 Axis of Delta printer
In the above picture blue line gives the position of rods to be placed, which is at the end of
it. Now we are done with the arrangement of rods. We calculated them in our code by following
lines of code.

30
///////////////////////////////////////////////////////////////////////////
const float R = 135 ;
const float one_rodx = R * cos (90*0.0174532);
const float one_rody =R * sin (90*0.0174532);
const float two_rodx=R * cos (225*0.0174532) ;
const float two_rody =R * sin (225*0.0174532);
const float three_rodx =R * cos (315*0.0174532);
const float three_rody =R * sin (315*0.0174532);
/////////////////////////////////////////////////////////////////////////////
Above line of code for initialization of your printer work area radius then, finding the
values of each center of pair of rods. Then we need to find the distance between every point to the
three points that we calculated. We can easily solve this by using Pythagoras theorem below
diagram is helpful in visualizing that known length of axial rod, distance between the point and
the rod then finding the other side.
Figure 8.2 Axial rod alignment in delta printers
Above logic is to apply for all three xyz coordinates to get new coordinates points , which are
helpful in finding the distance from linear bearings to the ground of printer, Then we find the
required amount of motion from subtraction the total length.

31
CHAPTER-9
PROCEDURE FOR DELTA 3D PRINTER
9.1 Conversion of xyz to delta:
● Finding distance from point to center of pair of rods.
● Calculating distance from bottom to extruder.
● Subtracting from total height to get the delta coordinates.
9.2 Motor conversion:
We have done a quite good effort to run all the motors simultaneously. We converted all values
acquired from Gcode, We normalize all the values to the scale of 0-1.where all the values are
divided by maximum value of the three coordinate. Below steps could help to get make the
pattern of energizing the coils of steppers.We will get the values from G Code, information of
required movement in each axis.Then converted by xyz to delta function which are the required
movement for the each motor to move.
9.2.1 Implementation:
Distance
(pow(pow(a-c,2)+pow(b-d,2),0.5));
Pythagoras theorem
xmov=pow((pow(axial_rods, 2)-pow(d1, 2)), 0.5);
9.2.2 Algorithm For Motion Trajectory
Input as values Xout, Yout,and Zout which are values generated from xyz2delta function.
Aim that, we need to start all our motors to run at single point of time and end their motion at
same time. Some steps should be missed in middle with equal gap for each missing step. We
have a constraint that only a motor can run at a time.

32
1. Finding Maximumof all three values
2. Normalization Dividing max value with all,scale reduced to (0-1).This give us value
having 1 is going to run all the time and less the value need to move for less amount of
time.
3. Finding Off time the value for non-motioni.e., just subtract the one from the previous value.
4. Dividing that with one gives the number of steps for each missing step is found. i.e., if the
value says that motor should next miss step for each 7 steps. This makes our motor to on
at same time and off, covers required distance.
Importance is it that it creates same rate of change motion in each axis as almost equal to
a derivative function.
9.2.3. Implementation:
Finding of delta value to next miss step.
x_=1/ (1-(x/maxvalue))
Check code for is this step is your miss step.
for (float i=0;i<=maxvalue;i++)
{ if(i!=x_1)
motorx(direction_x);
else
x_1=x_1+x_ ;
}

33
9.3 Calibration:
This part is most important in case of calibration of printing. It helps printer to move its end
effector to home location. This helps to make us to estimate the trajectory from home location.
This helps us know the location of the end effector.
We used limit switches to find the end of each axis .It is polled every time, when limit switch is
set then we get to know that it reached the end of axis.
>> Start of motor.
>>Polling of limit switch.
>>When it is set then stop the motors.
9.3.1 Implementation:
while(stopendx==1)
{stopendx= digitalRead(limitx);}

34
CHAPTER-10
SOFTWARE USED FOR GENERATING G-CODES
10.1 CURA 2.3.1:
Step 1: open Stl File which is at the left of the window
Figure 10.1 User Interface of CURA 2.3.1

35
Step2: load the .stl file, you get a preview at left corner of window. You can select your slicer
engine according to your requirement weather it may be solid or light or hollow. Automatically it
will generate G-code according to the parameters.
Figure 10.2 Loading .stl file to the software
Step 3: After completion of slicing ready to save option will be highlighted in the desktop just by
clicking ready to save G-codes and M-codes will be saved In notepad
Figure 10.3 Ready to G-codes and M-codes files

36
10.2 Arduino IDE:
Figure 10.4 Arduino IDE user interface
Code written in Arduino is named as sketch
1. Verify is nothing but compiling of code its gives error in the (10) space on the two
bottom of the window.
2. Upload function is used to transfer or burn your code onto your board using pin 0, 1 i.e.
Serial 0 port.
3. New opens a new Sketch.
4. Open opens your Sketches saves.
5. Save button saves your code.
6. Serial monitor is used to show the values that you grab from sensors uses serial 0 port
and Serial commands such as Serialprint, Serialprintln.
7. Name of Sketch.

37
8. Work Area for your Code.
9. Message display about compilation, errors and all that what it need to speaks to you.
10. Text console errors present in line numbers are displayed, debugging is done easily by
the information provided.
11. Information of Board and Serial port.
Just 2 steps to connect your board starts with choosing of board and then the port number
and it's ready to write a sketch.
Step 1
Select your Board
Step 2
Select Serial port
Figure 10.5 Selection of respective board in Arduino IDE
Figure-10.6 Selection of serial port

38
Sample code:
// Sketch written in Setup function is Executed once and the loop function runs over and over
again forever
Voidsetup() { //////////////////////////
// initialize digital pin 13 as an output . /////setup function//////////
pinMode (13, OUTPUT); //////////////////////////
}
//loop_function
/////////////////////////////////////////////////////////////////////////
Voidloop() {
digitalWrite(13, HIGH); // turn the LED on (HIGH is the voltage level)
delay(1000); // wait for a second
digitalWrite(13, LOW); // turn the LED off by making the voltage LOW
delay(1000); // wait for a second
}
///////////////////////////////////////////////////////////////////////

39
CHAPTER-11
WORKING OF 3D PRINTER
11.1Flow Chart Diagram:
Figure 11.1

40
CHAPTER-12
DESIGN of 3D CAD Models and ASSEMBLY
12.1 Designs:
We have used the following designs in making the structure of the printer.
Figure 12.1 Design of Base and Top of printer
Figure 12.2 Design of Linear and Circular Bearing holder

41
12.2 Assembly of the printer:
Figure 12.3 Assembly of the printer

Figure 12.4 Assembly of 3D CAD Model
44

45
CHAPTER-13
CONCLUSION AND FUTURE SCOPE
In our project we tried to mimic the functionality of full-fledged commercial 3d printers. Our
main goal is to cut down the cost of printer .Our research in finding best of structures gave us good
knowledge about them. We then end up our things by choosing delta structure. We get know about
complexity of its kinematics , our hard work results in converting the concepts to code and then to
a working model .We added features like calibration that makes our printer to calibrate in seconds.
We had succeeded in making a low cost printer using delta configurations that, our printer cost
only around Rs.10000. We also moved down our precision slave to micrometers.
Future scope:
Today we see plastic and clay are used widely for making the products. We expect the
teleportation of object is achieved by recognizing molecules in an object breaking down into
atomic size and reshaping them back they appear.
Many doctors are using printers to make organs, making them from cell level. This make
humans to replace their damaged organs with the new one. They also moved to consumer user
products like dresses, shoes and even jewelry.
We also heard the news about building homes with giant mega cement extrusion printers.
This would lead to interesting stuff like sending printers to space, printing colonies at moon and
mars. It is best example of bringing your dreams to real word, if you can make an objects in cad
they bring them to real word.

46
REFERENCES AND BIBLIOGRAPHY
Books Referred:
1. 3D Printing: Build Your Own 3D Printer and Print Your Own 3D Objects.
2. Rapid Prototyping by Dr.Amitabha Ghosh
3. Johann C. Rocholl (Rostock) Style Delta Robot Kinematics by Steve Graves
4. The Delta Parallel Robot: Kinematics Solutions Robert L. Williams II, Ph.D.,
williar4@ohio.edu
5. Sirinterlikci, A., Sirinterlikci, S., Utilizing Rep-Rap Machines in the Engineering
Curriculum,
6. Johann C. Rocholl (Rostock) Style Delta Robot
Kinematics.
https://www.google.co.in/url?sa=t&rct=j&q=&esrc=s&source=web&cd=1&cad=rja&uact
=8
k_Delta_Kinematics_3.pdf&usg=AFQjCNHwvrkIcPOUZZKTdb7h4kaZnBJd9Q&sig2=Z
a5
7. _lXG19m5JOU08I32x8Q&bvm=bv.120551593,d.c2E
8. MAKE YOUR OWN 3D DELTA PRINTER FOR CERAMIC by Jonathan
kept http://www.keep-art.co.uk/Self_build.html
9. 3d printer for dummies by Kalani
kirk
https://www.google.co.in/url?sa=t&rct=j&q=&esrc=s&source=web&cd=1&cad=rja&uact
=8
10. &ved=0ahUKEwjiy%2520Printing%2520for%2520Dummies1.pdf&usg=AFQjCNG8On
ZU C-UyfomXJLoOpBybbwGN2Q&sig2=Mc4VU6i2rJhNXUIWMcupkA
11. The Rep-Rap project http://reprap.org/
12. marlin firmware by Erik van der Zalm https://github.com/MarlinFirmware/Marlin

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