Development of a Low Cost Extrusion Based 3D Printer for High Performance Engineering Polymers

Abstract:

The development of a low cost 3D printer is presented for high performance polymers by example of a PEI type material. The development steps and technical alternatives opted for during the design process are outlined in two cycles targeting first printing of non-demanding thermoplastics, such as ABS, PLA etc., followed by an upgrade to printing PEI and similar high performance polymers. Subsystems discussed pertain to the frame, CNC axes including feed motors and motion control, the extruder, hot end and nozzle. Of particular interest are modifications concerning the temperature setting and regulation subsystems of the printer work volume and the printing table. Calibration procedures with pitfalls and solutions is discussed and a documented series of finally successful tests for Ultem1010^TM is presented.

• Periodical: Key Engineering Materials (Volume 960)
• Pages: 37-45
• DOI: https://doi.org/10.4028/p-qO8OUM
• Online since: October 2023
• Authors: Adamos Ioannidis, Maria Boufali, George Christopher Vosniakos*, Theologos Anagnostakis
• Keywords: Additive Manufacturing, Extrusion, High Performance Polymers, Mechatronics

References

[1] Z. Jiang, B. Diggle, M.L. Tan, J. Viktorova, C.W. Bennett, L.A. Connal, Extrusion 3D Printing of Polymeric Materials with Advanced Properties, Advanced Science. 7 (2020).

DOI: 10.1002/advs.202001379

[2] T.D. Ngo, A. Kashani, G. Imbalzano, K.T.Q. Nguyen, D. Hui, Additive manufacturing (3D printing): A review of materials, methods, applications and challenges, Compos B Eng. 143 (2018) 172–196.

DOI: 10.1016/j.compositesb.2018.02.012

[3] A. Das, C.A. Chatham, J.J. Fallon, C.E. Zawaski, E.L. Gilmer, C.B. Williams, M.J. Bortner, Current understanding and challenges in high temperature additive manufacturing of engineering thermoplastic polymers, Addit Manuf. 34 (2020).

DOI: 10.1016/j.addma.2020.101218

[4] J. Huang, Q. Chen, H. Jiang, B. Zou, L. Li, J. Liu, H. Yu, A survey of design methods for material extrusion polymer 3D printing, Virtual Phys Prototyp. 15 (2020) 148–162.

DOI: 10.1080/17452759.2019.1708027

[5] E. Petersen, J. Pearce, Emergence of Home Manufacturing in the Developed World: Return on Investment for Open-Source 3-D Printers, Technologies (Basel). 5 (2017) 7.

DOI: 10.3390/technologies5010007

[6] A. Laplume, G.C. Anzalone, J.M. Pearce, Open-source, self-replicating 3-D printer factory for small-business manufacturing, International Journal of Advanced Manufacturing Technology. 85 (2016) 633–642.

DOI: 10.1007/s00170-015-7970-9

[7] Krishnanand, M. Taufik, Fused Filament Fabrication (FFF) Based 3D Printer and Its Design: A Review, in: Lecture Notes in Mechanical Engineering, Springer Science and Business Media Deutschland GmbH, 2021: p.497–505.

DOI: 10.1007/978-981-15-9853-1_41

[8] M. Boulaala, D. Elmessaoudi, I. Buj-Corral, & Jihad, E. Mesbahi, O. Ezbakhe, A. Astito, & Mhamed, E. Mrabet, A. el Mesbahi, Towards design of mechanical part and electronic control of multi-material/multicolor fused deposition modeling 3D printing, The International Journal of Advanced Manufacturing Technology. 110 (2020) 45–55.

DOI: 10.1007/s00170-020-05847-0

[9] Krishnanand, S. Soni, M. Taufik, Design and assembly of fused filament fabrication (FFF) 3D printers, in: Mater Today Proc, Elsevier Ltd, 2021: p.5233–5241. https://doi.org/.

DOI: 10.1016/j.matpr.2020.08.627

[10] H. Liu, Z. Liu, S. Hao, Design of a throat-extended FDM extruder for multi-axis 3D printing, Strojniski Vestnik/Journal of Mechanical Engineering. 67 (2021) 180–190.

DOI: 10.5545/sv-jme.2021.7124

[11] K.-P. Yang, P. McDowell, R. Demourelle, T. Parker, E. Langstonirst, 3D Printing: A Custom-Built 3D Printer with Wireless Connectivity, International Journal of Computer Science and Engineering. 7 (2020) 1–5.

DOI: 10.14445/23488387/ijcse-v7i10p101

[12] K. Kun, Reconstruction and development of a 3D printer using FDM technology, in: Procedia Eng, Elsevier Ltd, 2016: p.203–211.

DOI: 10.1016/j.proeng.2016.06.657

[13] M. Hoque, M.H. Jony, M. Hasan, H. Kabir, Design and Implementation of an FDM Based 3D Printer, in: 5th International Conference on Computer, Communication, Chemical, Materials and Electronic Engineering : IC4ME2, IEEE, Rajshahi, Bangladesh, 2019: p.1–5.

DOI: 10.1109/ic4me247184.2019.9036538

[14] A. Dine, G.C. Vosniakos, On the development of a robot-operated 3D-printer, in: Procedia Manuf, Elsevier B.V., 2018: p.6–13.

DOI: 10.1016/j.promfg.2018.10.004

[15] V.N.T. Hai, S.N. Phu, T. Essomba, J.Y. Lai, Development of a Multicolor 3D Printer Using a Novel Filament Shifting Mechanism, Inventions. 7 (2022).

DOI: 10.3390/inventions7020034

[16] L. Jaksa, D. Pahr, G. Kronreif, A. Lorenz, Development of a Multi-Material 3D Printer for Functional Anatomic Models, Int J Bioprint. 7 (2021) 145–155. https://doi.org/10.18063/ IJB.V7I4.420.

DOI: 10.18063/ijb.v7i4.420

[17] 3D4Makers, PEI Ultem 1010 filament, (2023). https://www.3d4makers.com/products/pei-filament (accessed February 26, 2023).