International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 05 | May 2025
p-ISSN: 2395-0072
www.irjet.net
Manufacturing of a cost-effective 3D Printer for prototyping and educational purpose. Kaivalya Kulkarni1, Samarth Joshi 2, Akash Jadhav 3, Suraj Bodake 4, Aashish Mali 5, Prof. P. L Firake6 #Dept. of Mechanical Engineering , JSPM's Rajarshi Shahu College of Engineering, Tathawade, Pune, Maharashtra ---------------------------------------------------------------------***--------------------------------------------------------------------Abstract - Additive manufacturing (AM), especially Fused Deposition Modelling (FDM), has become increasingly popular due to its affordability and flexibility. This project aims to design and assemble a custom FDM 3D printer, allowing us to gain practical experience in additive manufacturing while providing a functional printing solution for our institution. The printer is constructed using an Arduino Mega 2560, RAMPS 1.4, NEMA 17 stepper motors, and a Creality Ender 3 V2 hotend. During our initial test prints, we encountered problems like layer misalignment and unstable vertical movement. To find solutions, we researched and found a reference video that demonstrated the addition of structural supports—Lsupports and R- supports—to stabilize the lead screw and minimize vibrations. Motivated by this, we decided to implement similar modifications by 3D printing custom supports on an Ender 5 Pro. We anticipate that these changes will enhance print accuracy, improve dimensional stability, and decrease mechanical inconsistencies. This paper outlines the design, assembly, challenges, and modifications made to our 3D printer. We will conduct final print tests to confirm the improvements, making this project a valuable resource for students and researchers interested in the development of 3D printer
This project focuses on the design and fabrication of a cost-effective FDM 3D printer to gain hands-on experience in additive manufacturing and provide a functional printing solution for our institution. The motivation behind this project stems from the lack of a working 3D printer in our college, which limits students’ ability to explore and experiment with 3D printing technology. To bridge this gap, we aimed to build a 3D printer from scratch, understanding its mechanical structure, electronic control systems, and software configurations. Through this, we sought to develop a deeper knowledge of stepper motor control, firmware tuning, calibration, and material extrusion processes. The 3D printer was developed using Arduino Mega 2560 with RAMPS 1.4, NEMA 17 stepper motors, A4988 motor drivers, a V6 J-head hot end, and a MK2B heated bed, ensuring a balance between affordability and functionality. During initial tests, print quality issues such as layer misalignment and unstable vertical movement were observed. After researching potential solutions, we found that lead screw vibrations contributed to these errors. Inspired by a reference study, we integrated Lsupport and R-support structural modifications to stabilize the lead screws and improve print accuracy. These supports were 3D-printed using an Ender 5 Pro and are currently being integrated into our system.
Key Words: Fused Deposition Modelling, Additive Manufacturing, 3D Printer Development, Lead Screw Stability, RAMPS 14, Arduino Mega 2560, Print Quality Optimization
This paper documents the design, fabrication, assembly, and testing of our custom 3D printer, highlighting the challenges faced, modifications made, and expected improvements.
1.INTRODUCTION Additive Manufacturing (AM), commonly known as 3D printing, has revolutionized the way objects are designed and fabricated. The concept of AM dates back to the 1980s, with the development of stereolithography (SLA) by Charles Hull in 1986, which laid the foundation for modern 3D printing. Over the years, various AM techniques such as Selective Laser Sintering (SLS), Fused Deposition Modelling (FDM), and Digital Light Processing (DLP) have been developed, each catering to different industrial and consumer needs. Among these, FDM technology, introduced in the late 1980s and patented by Stratasys in 1992, has become the most widely used due to its affordability, ease of operation, and material versatility.
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