Summer Internship

at
Adroitech Information System Pvt Ltd (AISPL), Noida

on
Exploring Additive Manufacturing Technology and
Optimizing FDM Printer Parameters for Polymer Composite.
Duration: June 01, 2023 – July 15, 2023

Submitted by: Industry Mentor:

Yash Gajanan Salve Mr. Shane Alam,
2020UME1218 Application Manager, AISPL

in partial fulfilment for the award of the degree

of
BACHELOR OF TECHNOLOGY

in
MECHANICAL ENGINEERING DEPARTMENT

Malaviya National Institute of Technology, Jaipur

JLN Marg, Jaipur – 302017, Rajasthan
October, 2023

i
CERTIFICATE

ii
 Malaviya National Institute of Technology, Jaipur

Department of Mechanical Engineering

DECLARATION

I hereby declare that the training report entitled “Exploring Additive Manufacturing:
Production of FDM printed parts and Troubleshooting the FDM printing Problem” is an
authentic record of my own work as per the requirements of internship for the award of the
degree of B. Tech in Mechanical Engineering, Malaviya National Institute of Technology,
Jaipur under the guidance of Mr. Shane Alam, Application Manager, Adroitech Information
system Pvt. Ltd., Noida. Certified that the above statement made is correct to the best of my
knowledge and belief.

Date: 03/10/2023 Salve Yash Gajanan

2020ume1212
B. Tech, 4th Year,
Department of Mechanical Engineering,
MNIT Jaipur

iii
 ACKNOWLEDGEMENT
I would like to express my sincere thanks and appreciation to the people who played a crucial
role in making my internship at Adroitech Information System Pvt. Ltd. a valuable and
enriching experience. Their support and guidance have been instrumental in my growth and
learning throughout this internship.

I want to start by extending my heartfelt gratitude to Mr. Sanjeev Sir, Technical Manager,
AISPL for providing me this opportunity. Mr Vikas Mudgal Sir, Senior Application Manager,
4D Simulation Unit. Mr. Shane Alam Sir, Senior Application Manager, 4D Simulation Unit
and entire team at Adroitech Information system Pvt. Ltd. They have been incredibly helpful
and supportive during my training, providing me with their expertise and patiently answering
my questions.

I would also like to express my deep appreciation to Dr. Anup Malik Sir, Associate Professor,
MNIT Jaipur for providing me this opportunity and mentoring me throughout my internship. I
am also thankful to Mr. Shamsher Singh, PHD Scholar, MNIT Jaipur. Their guidance, support,
feedback have been invaluable for completing this internship.

I am also thankful to Prof. G.D. Agarwal, Mechanical Engineering, MNIT Jaipur and Mr.
Amit Pancharya, Associate Professor, Mechanical Engineering, MNIT Jaipur, Mr. Vineet
Kumar Saxena, Adjunct Faculty, MNIT Jaipur to motivate me and enlighten the path to take
an effective Summer Internship.

The knowledge and experiences I gained during this internship will undoubtedly contribute
significantly to my professional growth and future objectives.

Salve Yash Gajanan

2020UME1218,
B. Tech, 4th Year,
Mechanical Engineering Department,
MNIT Jaipur

iv
 ABSTRACT
Summer internships are a crucial requirement for B. Tech students, and I successfully
completed my summer internship focused on Exploring Additive Manufacturing Technology
at Adroitech Information System Pvt. Ltd. I was stationed at their 4D Simulation unit in Noida,
Uttar Pradesh from June 1, 2023, to July 15, 2023.

This internship has been an incredibly enriching experience for me. It provided me with a
practical understanding of real-world applications and exposed me to innovative problem-
solving approaches within the industry. My interactions with Seniors and managers at AISPL
have been instrumental in honing not only my technical skills but also my leadership abilities.
Learning from their experiences and work methodologies, I gained insights into the
responsibilities, strategies, and collaborative efforts required to successfully accomplish
assigned tasks.

Adroitech Information System Pvt. Ltd. is a prominent private sector Global Consultancy and
Services Company, founded in 1988 by Mr. Saroop Chand. The company's headquarters is
situated in Noida, with seven additional branches in major cities across the country. It has four
subsidiary Hope Technologies, Adroitech Engg. Solutions PVT. Ltd, Adroitech Mechanical
Services, 4D Simulation Unit. These subsidiaries provide a range of services including
Mechanical Computer Aided Engineering Design, Geomatics Solutions, Product Distribution
and Services, as well as 3D Printer Distribution and Manufacturing.

4D Simulation is a unit of Adroitech at their Noida Branch. This unit produce Fused deposition
Modelling (FDM) 3d printer. It also provides services related to 3d Printers like Prototyping,
Manufacturing of 3d printed parts.

Additive Manufacturing is a very important technology of Industry 4.0 and 4D Simulation

promoting Industry 4.0 by continuously doing research on Additive manufacturing related
technologies and 3d printer Materials. Additive manufacturing is an efficient technology to
build the parts since it produces less waste, Decreases prototyping cost and time.

This report summarizes the Additive manufacturing Technologies and outcomes of my project
“Optimizing the Enhancing FDM Printer Parameters for High Tensile Strength Printing of
PETG CF and PLA CF Polymer Composites.”

v
 Table of Contents
PROJECT TITLE ........................................................................................................................ i
CERTIFICATE...........................................................................................................................ii
DECLARATION...................................................................................................................... iii
ABSTRACT............................................................................................................................... v
Table of Contents ...................................................................................................................... vi
List of Figures ........................................................................................................................ viii
List of Tables .............................................................................................................................. x
List of Abbreviation .................................................................................................................. xi

1 Company Introduction ......................................................................................................... 1

1.1 About the Company: Adroitech Information System Private Ltd. ................................... 1
1.1.1 Subsidiaries ................................................................................................................ 2
1.1.2 4D Simulation Unit (4DS) ......................................................................................... 3
1.2 About My Internship ........................................................................................................ 3
2 Additive Manufacturing - Redefining Production ............................................................. 4
2.1 History of Additive Manufacturing .................................................................................. 4
2.2 Additive Manufacturing Technologies ............................................................................. 5
2.2.1 VAT Polymerization ................................................................................................... 5
2.2.2 Powder Bed Fusion .................................................................................................... 5
2.2.3 Material Extrusion ..................................................................................................... 7
2.2.4 Binder Jetting ............................................................................................................. 7
2.2.5 Material Jetting .......................................................................................................... 9
2.2.6 Direct Energy Deposition ........................................................................................ 10
2.2.7 Sheet Lamination ..................................................................................................... 11
3 Fused Deposition Modelling ............................................................................................... 13
3.1 Principle of Material Extrusion ...................................................................................... 13
3.2 Parameters for FDM Printer ........................................................................................... 14
3.3 Defects in FDM .............................................................................................................. 17
4 Production of Polymer Printed Part at AISPL ................................................................ 21
4.1 FDM for Polymer Printing: ............................................................................................ 21
4.2 Polymer Printing with Powder Bed Fusion (PBF) process ............................................ 23
4.2 Polymer Printing with Material Jetting process ............................................................. 25
5 Production of Metal and Ceramic Printed Parts ............................................................. 28
5.1 Metal and Ceramic Filaments for FDM ......................................................................... 28

vi
 5.2 Debinding Process .......................................................................................................... 29
5.3 Sintering Process ............................................................................................................ 32
6 Production of FDM Printer at AISPL ............................................................................... 33
6.1 4DS smart one ................................................................................................................ 33
6.2 Components of FDM Printer .......................................................................................... 34
6.3 Component Specification ............................................................................................... 35
6.4 Assembly of 4DS smart one ........................................................................................... 36
6.5 Firmware Installation ..................................................................................................... 39
6.6 Quality Control and checks ............................................................................................ 40
6.7 Troubleshooting: ............................................................................................................ 44
7 Optimization of FDM Printer Parameters ....................................................................... 48
7.1 Objectives ....................................................................................................................... 48
7.2 Materials and Methodology ........................................................................................... 48
7.3 Fabrication of PETG-CF and PLA-CF Specimen .......................................................... 51
7.4 Testing: ........................................................................................................................... 54
7.5 Result:............................................................................................................................. 55
8 Conclusion ........................................................................................................................... 58
References ............................................................................................................................... 59

vii
 List of Figures

Figure 1.1: AISPL office, Noida Branch .................................................................................... 2

Figure 2.1: Schematic of SLA ................................................................................................... 5
Figure 2.2: Schematic of PBF .................................................................................................... 6
Figure 2.3: Layer Deposition by Material Extrusion ................................................................. 7
Figure 2.4: Schematic of Binder Jetting .................................................................................... 8
Figure 2.5: Illustration of Material Jetting Process .................................................................... 9
Figure 2.6: Illustration of powder nozzle configurations......................................................... 11
Figure 2.7: Schematic of LOM Process ................................................................................... 12
Figure 3.1: Schematic of FDM. ............................................................................................... 14
Figure 3.2: Illustration of support structure ............................................................................. 16
Figure 3.3: Infill Density. ......................................................................................................... 16
Figure 3.4: Infill Pattern. .......................................................................................................... 17
Figure 3.5: Delamination of Layers. ........................................................................................ 18
Figure 3.6: Illustration of warping in 3d printed parts ............................................................. 18
Figure 3.7: Raft ........................................................................................................................ 19
Figure 3.8: Staircase effect on FDM printed part .................................................................... 20
Figure 3.9: FDM Printing Process. .......................................................................................... 21
Figure 4.1: .STL file of Gear.................................................................................................... 21
Figure 4.2: a) Selective Absorption Fusion (SAF); b) Multi Jet Fusion (MJF) Printer ........... 24
Figure 4.3: Depowdering Machine based compressed air ....................................................... 25
Figure 4.4: Polyjet Printer: a) J55; b) J35 ................................................................................ 26
Figure 5.1: Process for Metal and Ceramics 3D Printing ........................................................ 28
Figure 5.2: Ultrasonic Solvent Debinder ................................................................................. 30
Figure 5.3: Thermal Debinder .................................................................................................. 30
Figure 5.4: a) High Temperature Furnace; b) Part inside the Refractory Powder bed ............ 32
Figure 6.1: 4DS Smart One FDM Printer ................................................................................ 38
Figure 6.2: a) Stepper Motor; and b) Pulley………………………………………………………………………..38
Figure 6.3: Guide Rail.............................................................................................................. 37
Figure 6.4: a) Lead Screw; and b) Coupler .............................................................................. 38
Figure 6.4: Hot End Assembly ................................................................................................. 38
Figure 6.5: Oozing in Printed Parts.......................................................................................... 45

viii
Figure 6.6: Starting Layer are not printed ............................................................................... 47
Figure 6.7: Under Extrusion Printing....................................................................................... 48
Figure 7.1: CAD Model of Specimen ...................................................................................... 51
Figure 7.2: Gap Generated between Adjacent Layers ............................................................ 53
Figure 7.3: Gap Generated between Outline Perimeter and Infill Layer ................................. 38
Figure 7.4: Printed Skirt and Raft ............................................................................................ 38
Figure 7.5: PETG-CF Specimen Printed using FDM .............................................................. 54
Figure 7.6: PLA-CF Specimen Printed using FDM................................................................. 54
Figure 7.7: Universal Testing Machine .................................................................................... 55

ix
 List of Tables

Table 4.1: Polymer Materials with their characteristics and Applications. ............................. 22
Table 5.1: Metal Filaments Technical Specifications.............................................................. 28
Table 5.2: Ceramic Filaments Technical Specifications. ........................................................ 29
Table 5.3: Thermal Debinding Procedure for Zirconia ........................................................... 31
Table 6.1: Specifications of 4DS smart one printer................................................................. 34
Table 6.2: Components of FDM printer with Name/Specification. ........................................ 36
Table 6.3: Controller Connection and Wiring Quality Checklist. ........................................... 41
Table 6.4: XY Gantry Quality Assurance Checklist. .............................................................. 42
Table 6.5: Printing Quality Checklist ...................................................................................... 43
Table 7.1: PETG-CF and PLA-CF Technical Specifications .................................................. 49
Table 7.2: Factors and Levels for Design of Experiment........................................................ 51
Table 7.3: Universal Testing Machine Specification .............................................................. 51
Table 7.4: Design of Experiment with Evaluated Tensile Strength ........................................ 51
Table 7.5: Notation of Extrusion Temperature in DOE .......................................................... 51

x
 List of Abbreviation
Abbreviation Full Form
AISPL Adroitech Information System Pvt. Ltd.

4DS 4D Simulation

FDM Fused Deposition Modelling

MCAE Mechanical Computer Aided Engineering

GIS Geographic information System

DIP Digital Image Processing

AEC Architecture, Engineering, Construction

AM/FM Automated Mapping/ Facilities Management

SLA Stereolithography

PBF Powder Bed Fusion

FDM Fused Deposition Modelling

MJF Multi Jet Fusion

EBAM Electron Beam Additive Manufacturing

LOM Laminated Objected Manufacturing

ABS Acrylonitrile Butadiene Styrene

SAF Selective Absorption Fusion

SMPS Switching Mode Power Supply

STL Stereolithography/ Standard Tessellation Language

RSM Response Surface Methodology

DOE Design of Experiment

PETG Polyethylene Terephthalate Glycol

PLA Polylactic Acid

CF Carbon Fiber

xi
EM Extrusion Multiplier

CAD Computer Aided Manufacturing

UTM Universal Testing Machine

xii
 1 Company Introduction
India has a mixed economy comprising both private and public sector enterprises. Public
enterprises are government-owned and controlled, while private enterprises are owned by
individuals or private groups. Global Consultancy Firms is a multinational company offering
expert advice across industries, specialize in management, strategy, technology, and finance.
AISPL is such a private sector firm in the global consultancy and services domain.

1.1 About the Company: Adroitech Information System Private Ltd.

Adroitech Information System Private Ltd (AISPL) is a prominent private sector Global
Consultancy and Services Company, founded in 1988 by Mr. Saroop Chand. AISPL is engaged
in providing expert advice to industries related to IT sector, engineering, management,
Construction. AISPL Provides Mechanical Computer Aided Solutions (MCAE), Geomatic
Solutions, AEC Solution 3D printers Services, Product distribution and maintenance of some
of its alliances in India.

• MCAE solutions: which includes Manufacturing Detailing, 3D Parametric Modelling,

CNC, FEA.
• Geomatic Solutions: which includes GIS, DIP, AM/FM.
• AEC Solutions, which includes concept scheme, detail engineering, 3d model, Plant
layout etc.
• Product distribution and maintenance in India for some of the best companies in
AEC/CAD/CAM/GIS arena
• 3D Printer related Services: Producing FDM Printers, Prototyping, 3D printer
distribution across India of leading companies like Stratasys, HP etc

AISPL's headquarters is situated in Noida, with additional domestic offices located in

Hyderabad, Bengaluru, Chennai, Pune, Mumbai, and Kolkata. Company has four subsidiaries
Hope Technology, Adroitech Engg. Solutions PVT. Ltd, Adroitech Mechanical Services, 4D
simulation Unit. The company boasts a workforce of approximately 500-600 employees. In the
fiscal year 2022, the company achieved a turnover of 100 crores. AISPL effectively use their
extensive experience and knowledge with cutting-edge technologies to develop and provide
unique solutions that cater to both intra and Internet deployment for their clients.

1
1.1.1 Subsidiaries

• Hope Technologies: It is US based 100% owned subsidiary of AISPL. It has

headquartered in Bengaluru. Its leading provider of software for professionals working.
It provides CAD/CAM software’s, GIS Solutions. Its products are Sketchup, Bentley,
ZWCAD, ZW3D, Cubi cost.
• Adroitech Engineering Solution Pvt. Ltd.: This subsidiary of AISPL provides AEC
solution to the clients which includes concept scheme, detail engineering, 3d model,
Plant layout etc.
• Adroitech Mechanical Services: Adroitech delivers services which are closely aligned
with the design-through-manufacturing strategies of its global manufacturing
customers, crashing cycle times and reducing costs. It provides Mechanical Computer
Aided Solution which includes Manufacturing Detailing, 3D Parametric Modelling,
CNC, FEA.
• 4D Simulation Unit: It is a unit dedicated for the 3d Printers. It Produces FDM 3D
printers. This unit is also distributor of 3D printers and services of leading 3d printer
manufacturers like Stratasys, HP etc.

Fig 1.1: AISPL office, Noida

Branch
Figure 1: AISPL office, Noida Branch

2
1.1.2 4D Simulation Unit (4DS)

In today’s rapid changing world, firms are looking for advance technology, sustainable and fast
process for production. 4DS is a new subsidiary of AISPL dedicated to the 3D printing. It is
located at Noida Branch of AISPL. It produces FDM 3D printers for education, Research and
DIY things. It is also engaged in providing services related to 3D printers like Prototyping,
Manufacturing of 3D printed parts.

4DS unit produces affordable and quality Desktop printers. There clients are IIT’s, NIT’s,
CSIR, IISC Bangalore, DRDO, SAIL, other private Engg colleges. 3D printing is emerging
technology of Industry 4.0. 4DS unit promoting Industry 4.0 by continuously doing research
on Additive manufacturing related technologies and 3d printer Materials. They have provided
their FDM 3D printer to many Institutes like IIT’s, NIT’s, CSIR, IISC, Private Institute. Since
its establishment, 4DS unit have successfully completed various projects from DRDO, CSIR,
SAIL etc.

1.2 About My Internship

I am very fortunate to acquire this internship opportunity at Adroitech Information System Pvt.
Ltd. at 4D Simulation Unit at Noida, Uttar Pradesh. During my Internship I have explored
about Additive Manufacturing Technologies. I have been assigned a project under the valuable
mentorship of Mr. Vikas Kumar to Optimize the FDM 3D printer parameters for high tensile
strength printing of PETG CF and PLA CF polymer composites. I have completed my project
successfully and got the optimal result. My internship commenced on June 1st, 2023 and lasted
till 15th July 2023.

3
 2 Additive Manufacturing - Redefining Production
Additive Manufacturing (AM) is a revolutionizing manufacturing technology that constructs
three-dimensional objects layer by layer from according to Computer Aided Design (CAD)
models, unlike traditional subtractive manufacturing methods that involve cutting away
material, AM adds material incrementally, resulting in reduced waste and the ability to create
complex, customized, and intricate structures with precision.

AM is redefining production by shifting from traditional mass production models to a highly

customizable, on-demand manufacturing. It allows manufacturer to create customized,
complex parts without need for costly tooling and moulds, significantly reducing lead times
and production costs. Moreover, AM enables distributed and localized manufacturing, reducing
the reliance on centralized production facilities and minimizing supply chain vulnerabilities. In
essence, AM is revolutionizing production by offering flexibility, sustainability, and cost-
efficiency in the creation of everything from aerospace components to medical implants.

This chapter encompasses diverse range of AM technologies, AM materials, and applications.

Since Industries are more focusing on lean manufacturing and fast production. Additionally,
nowadays market is very dynamic in nature, customer demands, competitors are changing
rapidly, thus Industries have to change their product design accordingly and looking for a
technology for rapid production. AM would be revolutionizing technology for the industries.
Thus, it is very crucial to understand the AM Technology.

2.1 History of Additive Manufacturing

Additive Manufacturing (AM), traces its roots back to the 1980s when the technology was first
conceptualized. In 1983, Chuck Hull, engineer at 3D systems, developed Stereolithography
(SLA), one of the earliest AM techniques, which utilized photopolymerization to create 3D
objects layer by layer.

Throughout the 1990s, other AM technologies like SLS and FDM emerged. In the 2000s, AM
gained traction in aerospace and healthcare, and the commercialization of AM technologies led
to wide spread adoption of Additive Manufacturing.

In recent years, AM has become a game-changer in manufacturing, with applications from

healthcare to aerospace. Advances in metal 3D printing, bioprinting, and large-scale
construction have expanded its reach. Today, AM continues to evolve, driving innovation in
materials, speed, and scalability, shaping the future of production.
4
2.2 Additive Manufacturing Technologies
Additive Manufacturing has been classified into seven different categories by ASTM.

2.2.1 VAT Polymerization

In this technique photo-sensitive materials are exposed to radiation/light in a controlled manner
to obtain polymerized material layers. Vat photopolymerization produces parts by selectively
curing liquid photopolymer resins with a radiation/light source. This process application is
limited to the materials that polymerize on exposed to light. VAT Polymerization has three
major Technology

• Stereolithography (SLA)
• Digital Light Processing
• Continuous Direct Light Processing (CDLP)
Stereolithography (SLA): SLA is one of the most widely used vat photopolymerization
technologies. It produces objects by layer-by-layer selectively curing polymer resin with an
ultraviolet (UV) laser beam. As shown in Fig. 2., A building platform is submerged in tank
filled with liquid resin at a distance of one layer height for the surface of the liquid. UV laser
beam is selectively directed on the platform using set of mirrors to cure and solidify
photopolymer resin. After printing, the part is in a not-fully-cured state. It requires further post-
processing under UV light if very high mechanical and thermal properties are required.

Figure 2.1: Schematic of SLA.

2.2.2 Powder Bed Fusion

In Powder Bed Fusion Process, a layer wise fusion of a Powder materials takes place using
thermal energy sources like laser, Electron beam. PBF process has wide range of materials
including polymers, metals, ceramics and composites which can be utilized.

The powder material is spread across platform in a very thin layer. Material is preheated below
its melting temperature. A laser or electron beam is then directed across the powder’s surface,

5
fusing particles together. After each layer, the build platform is lowered and the process repeats.
Each new layer is fused to the previous. This process continues until a product is form. As
layers are built on top of one another, the unfused particles act as a support structure for the
print. PBF has following major technology

• Selective laser Sintering (SLS)

• Electron Beam Additive Melting (EBAM)
• Multi Jet Fusion (MJF)

Selective Laser Sintering (SLS): SLS printers produce solid plastic parts using a laser to sinter
particles together. In SLS layers of powder (typically ~0.1 mm thick) is selectively fused with
laser. This process is generally utilized for Polymers. Powder material is spread across the build
area using a counter-rotating powder levelling roller. The part building process takes place
inside an enclosed chamber filled with nitrogen gas to minimize oxidation and degradation of
the powdered material. Once an appropriate powder layer has been formed and preheated, a
focused laser beam is directed onto the powder bed using galvanometer to selectively fuse the
powder material. After completing a layer, the build platform is lowered by one layer thickness
and a new layer of powder is laid and levelled using the rotating roller. This process repeats
until the complete part is built. Fig. 3. Shows the schematic process of PBF.

Figure 2.2: Schematic of PBF.

Figure 2: Schematic of PBF
Multi Jet Fusion (MJF): MJF produces solid plastic parts through a combination of SLS and
material jetting technologies. After a layer of plastic powder is spread over the build platform,
a printhead with inkjet nozzles selectively deposits agents which cause fusion of particles. A

6
high-power infrared beam then passes over the layer, fusing only areas where the fusing agent
was dispensed.

Electron Beam Additive Manufacturing (EBAM): EBM uses a high-energy electron beam to
induce fusion between metal powder particles in a vacuum chamber. in the EBM process, a
focused electron beam scans across a thin layer of pre-laid powder, causing localized melting
and solidification. EBM can used to process conductive materials only (like Metals)

2.2.3 Material Extrusion

Material Extrusion is most popular Additive manufacturing technology. It is commonly known
as Fused Deposition modelling (FDM). This technique was produced and developed by
Stratasys. In this technology Thermoplastic filament is being fed into heated nozzle, where it
melts and deposited layer by layer to create a part. Layer deposition by Material Extrusion is
shown in Fig. 4. FDM/Fused Filament Fabrication is widely employed in various industries,
from rapid prototyping and product development to producing functional parts. Its ability to
produce robust, lightweight, and complex geometries has made it a popular choice for both
professional and DIY users. However, it's essential to understand the material properties, layer
adhesion, and print parameters to optimize the process for desired outcomes. In the coming
chapter optimization of the process is explained.

Figure 2.3: Layer Deposition by Material Extrusion.

Figure 3: Layer Deposition by Material Extrusion
2.2.4 Binder Jetting
Binder Jetting is a process in which a liquid bonding agent is selectively deposited to join
powder materials. Binder Jetting is also referred as a “Inkjet Printing”. A layer of powder is
spread across the build platform and binders are selectively deposited from printhead
(containing many nozzles) based on computer-aided drafting (CAD) model information in each
layer. This process is repeated until the final geometry is achieved. PBF uses a laser or Electron
Beam to bond successive layers of powder, binder jetting instead uses an industrial printhead
that selectively deposits a liquid binding agent onto the powder. Binder jetting uses an industrial

7
printhead that selectively deposits a liquid binding agent onto the powder. Binder jetting is one
of the more flexible technologies because the process is independent of power source or other
temperature-related constraint within the AM build envelope. The Binder Jetting process is
shown in Fig. 5.

Figure 2.4: Schematic of Binder Jetting

Figure 4: Schematic of Binder Jetting
Process of Binder Jetting:

1. Powder Material: Binder jetting typically uses powdered materials, such as metals,
ceramics, polymers, and even sand. The material powder is spread in a thin layer across
the build platform.
2. Binder Material: A liquid binding agent is precisely deposited onto the powder bed by
a print head. This binder serves to bond the powder particles together in the shape of
the intended 3D object for the current layer.
3. Layer-by-Layer Deposition: The print head moves over the powder bed and the
binding agent is deposited in a way that selectively binds the powder particles in the
desired areas while leaving other areas untouched.
4. Powder Compaction: After each layer is printed, the powder bed is lowered to make
room for the next layer, and a new layer of fresh powder is spread. A roller or wiper
may be used to evenly distribute and compact the powder layer before the next binder
deposition.
5. Repeating the Process: The layering and binding process continues until the entire 3D
object is created, one layer at a time. Excess, unbonded powder remains around the
printed object.

8
 6. Post-Processing: Once printing is complete, the printed object, still encased in loose
powder, is carefully removed from the build chamber. Excess powder is typically
brushed or blown away from the printed part. The printed object may undergo
additional post-processing steps, such as sintering (for metals and ceramics) or
infiltration (for some materials), to enhance its structural integrity.

Applications:

• Binder jetting is used in various industries, including aerospace (for producing metal
components), automotive, healthcare (for creating medical implants), and
architectural modelling (for creating sand Molds).

2.2.5 Material Jetting

In Material jetting, a printhead dispenses droplets of a photosensitive material that solidifies
under ultraviolet (UV) light, building a part layer-by-layer. Material jetting dispenses a
photopolymer from hundreds of tiny nozzles in a printhead to build a part layer-by-layer.
Material jetting dispenses a photopolymer from hundreds of tiny nozzles in a printhead.
Material jetting processes require support, which is often 3D printed simultaneously during the
build from a dissolvable material. With Material jetting multicolour parts can be easily printed.
Material Jetting is widely used for design validation and concept Modelling because of its
excellent surface finish. The Material Jetting process is schematically shown in Fig. 6.

Figure 2.5: Illustration of Material Jetting Process

Figure 5: Illustration of Material Jetting Process
Polyjet: Polyjet is based on material Jetting technology. It is widely used technology for
prototyping because its multicolor part printing feature and high dimensional accuracy. Parts
can be print with Multi Material and different stiffness and color.

Application:

• Design validation of Packaging Bottles

• Biomedical Sample Printing

9
 • Drone Parts
• Concept Modeling
• Rapid Prototyping

2.2.6 Direct Energy Deposition

Direct Energy Deposition process is Additive Manufacturing Process which create parts by
direct melting the materials from wire feedstock or powder and deposited on the workpiece
layer by layer. This process is generally used for metals or alloys. DED processes use a focused
heat source (such as a laser, electron beam or plasma arc) to melt the feedstock material. This
Process build up 3-dimensional objects in a manner similar to the extrusion-based processes.
In addition to the capability to build parts from scratch, DED is also capable of fixing complex
damaged parts, such as turbine blades or propellers. Material is delivered in the form of powder
or Wire Feedstock into the melt pool.

Laser Based Powder Deposition: Laser based powder Deposition is a common type of DED
technology. In LBPD Powder metal deposited on the substrate is melted by laser to create a
new layer. as shown in Fig. 7. Deposition head is utilized to deposit powder metal onto the
substrate Deposition head is integrated with Laser Optics, powder Nozzles, inert gas tubing,
sensors. The substrate can be either a flat plate or an existing part onto which additional
geometry will be fabricated. Deposition is controlled by relative differential motion between
the substrate and deposition head. As the Powder enters the melt pool, Laser Melts the powder
and welded on the layer below. In LBMD, the laser generates a small molten pool (typically
0.25–1 mm in diameter and 0.1–0.5 mm in depth) on the substrate as powder is injected into
the pool. This technology is also available in 4 or 5 axis system using the robotic arm or rotating
Substrate.

10
 Figure 2.6: Illustration of powder nozzle configurations:
(a) co-axial nozzle feeding; and (b) single nozzle feeding.

Application: Figure 6: Illustration of powder nozzle configurations

• Industries that need for larger parts without the need for fine details.
• Fixing Complex damaged parts such as turbine or propeller.
• DED Process can be used to deposit thin layers of dense, corrosion resistant and wear
resistant metals on components to improve their performance and lifetime.
• It can be used for adding new features to an existing component

2.2.7 Sheet Lamination

The Sheet Lamination (SL) is also known as Laminated Object Manufacturing (LOM). LOM
involved layer-by-layer lamination of paper material sheets, and then cut using a Laser or
mechanical Cutter as shown in figure 8, each sheet representing one cross-sectional layer of
the CAD model of the part. In this process only the outer contours of the parts are cut, and the
sheets can be either cut and then stacked or stacked and then cut. These processes can be further
categorized based on the mechanism employed to achieve bonding between layers: (a) gluing
or adhesive bonding, (b) thermal bonding processes, (c) clamping, and (d) ultrasonic welding.

11
Figure 2.7: Schematic of LOM Process.
Figure 7: Schematic of LOM Process

12
 3 Fused Deposition Modelling
FDM process is an additive manufacturing technique based on material extrusion. FDM is
widely used technique because of its cost, easy to use and wide range of materials including
polymer, Metals can be used on it. This technology has made democratized product
development, empowering individuals, educators, researchers, and industries to turn concepts
into reality. Nowadays, the technology of FDM is widely applied in many industries, such as
the biomedical, manufacturing, aerospace, automobile, industrial, and building industries. In
this chapter we will look in detail about the FDM principle, parameters, Process of FDM
Printing.

3.1 Principle of Material Extrusion

FDM uses a heating chamber to liquefy polymer that is fed into the system as a filament. The
filament is pushed into the hot end by Pinch roller system arrangement, and it is this pushing
that generates the extrusion pressure. The stepper motor is responsible for pushing the filament
forward through the extruder assembly. It rotates the drive gear, which grips the filament and
feeds it into the hot end.

There are a number of key features that are common to any extrusion-based system:

• Loading of material (Filament)

• Liquification of the material
• Application of pressure to move the material through the nozzle
• Extrusion
• Plotting according to a predefined path and in a controlled manner
• Bonding of the material to itself or secondary build materials to form a coherent solid
structure
• Inclusion of support structures to create complex geometrical features.

13
 Figure 3.1: Schematic of FDM.

As shown in figure 9, The filament material is fed from the spool into hot end. Pinch roller feed
system is used for the continuous retrieval of filament wire from spool. Hot End has resistive
heaters which controls the temperature and melts the filament wire at temperature just over its
melting point, causing to flow and subsequently form the layer. The melted material is then
flow through nozzle and construct a layer on build platform. The nozzle is a small, precision-
engineered component at the tip of the hot end. It has a tiny hole through which the molten
filament is extruded onto the print bed or previous layers of the print. The diameter of the
nozzle determines the width of the extruded filament. As the nozzle moves over the print bed
or previous layers of the print, it deposits the molten filament in precise patterns based on the
3D model's instructions. This layer-by-layer process gradually builds up the 3D object. After
completion of each layer build platform moves down by a certain layer height. This process
continue until the product is form.

3.2 Parameters for FDM Printer

Fused Deposition Modelling (FDM) 3D printers rely on a parameter to print the part. These
parameters define the printing process, allowing users to fine-tune their prints to meet specific
requirements. From layer height to extrusion temperature, each parameter plays a vital role in
determining the final print's quality, strength, and appearance. In this section, we delve into the
essential FDM printer parameters, unveiling how their careful adjustment empowers creators
to achieve outstanding results.

Layer Height (Resolution): Layer height determines the thickness of each printed layer.
Lower layer height produces finer details in the printing but increase the printing time.

14
Print Speed: The speed at which printhead moves during printing. It can affect print quality
and is often adjustable.

Infill Density: The percentage of interior infill materials used to fill the 3D object. Higher infill
percentages make a print more solid but can increase material usage and print time.

Extrusion Temperature: The temperature at which the filament material is melted and
extruded through the nozzle It varies depending on the type of filament.

Bed Temperature: The temperature of the heated bed. It helps with adhesion and prevents
warping, particularly for materials like Acrylonitrile Butadiene Styrene (ABS).

Flow Rate/Extrusion Multiplier: Adjusts the amount of filament extruded during printing. It
is adjusted by changing the speed at which the stepper motor turns and, consequently, how
much filament is pushed into the hot end. Increasing the flow rate causes the stepper motor to
turn faster, pushing more filament through the nozzle. Decreasing the flow rate slows down the
motor, reducing the amount of filament extruded.

Nozzle Diameter: The size of the nozzle through which filament is extruded. Different nozzle
sizes can impact layer resolution and print speed.

Retraction: The retraction settings controls how much filament is pulled back when the print
head moves between different parts of the print. It helps prevent stringing/oozing.

Cooling Fan Speed: The speed of the cooling fan used to cool the printed material. Cooling is
essential for materials like PLA to improve print quality.

Print Bed Levelling: The process of ensuring that the print bed is perfectly level to maintain
consistent layer adhesion and print quality.

Support Generation:

Support Structure are generated when a feature is printed with an overhang beyond 45 degrees
or intricate design to support printed layers. Support allows us to produce very complex
geometry. After the part is printed Supports needs to be removed. When a feature is printed
with an overhang beyond 45 degrees, it can sag enough to potentially ruin the print. This is
when you need support structures.

15
 a b
Figure 3.2: Illustration of support structure:
a) Parts print with support structure; b) Parts print without support structure.

Infill Density:

Infill density is the “fullness” of the inside of a part. In slicers, this is usually defined as a
percentage between 0 and 100, with 0% making a part hollow and 100%, completely solid.

Figure 3.3: Infill Density.

As shown in figure 11, Part is print with different infill density and corresponding density can
be observed. Infill pattern plays a huge role in a part’s strength, weight, structure, buoyancy,
and print time. Infill patterns are one of the parameters you can control when preparing a 3D
print using slicing software. Common infill patterns include:

Infill Pattern:

In 3D printing, the "infill pattern" refers to the internal structure or lattice-like pattern that fills
the interior of a 3D printed object. This structure is used to provide support to the object and
reduce material usage and print time. In Fig. 12. Different Infill pattern has been shown.

16
Grid: A grid pattern consists of evenly spaced horizontal and vertical lines forming a
checkerboard-like structure. It strikes a balance between strength and print speed

Honeycomb: The honeycomb pattern features hexagonal cells that provide good structural
support. It's known for its strength and efficient use of material.

Triangular: Triangular infill comprises a network of interconnected triangles. It offers robust

support and is often used for mechanical parts.

Rectilinear: Rectilinear is the simplest and fastest pattern, consisting of straight lines crossing
at right angles.

Gyroid: It is a complex and curved pattern that provides good airflow and heat dissipation,
making it useful for cooling or ventilation applications.

Figure 3.4: Infill Pattern.

3.3 Defects in FDM

In FDM printing defects might be present. Defects generally arise from either the print material
characteristics or by selecting the improper FDM parameters for the printing. Common defects
include layer adhesion issues, visible seams where layers meet also termed as staircase effect
on surface, slicer conversion effect (which produces polygonal finite elements),
stringing/oozing (thin strands of excess material), and warping (distortion or curling of printed
parts).

1) Layer Adhesion Issue/Delamination:

In FDM, individual layer stick together to create solid part. Thus, the Layer adhesion is
important factor of FDM printing. However, Layer adhesion defects can occur while printing.

17
In this defect layers don’t stick to each other properly. Thus, gap is created between the layers.
Delamination of layers is shown in Fig. 13. It’ s common causes can be inadequate extrusion
temperature, high printing speed insufficient material flow, higher layer height, high cooling
fan speed or Infill pattern. This defect can lead to surface defect and structural weakness in
printed parts.

Figure 3.5: Delamination of Layers.

2) Warping in FDM:

Warping is a common defect in FDM printers. As newly deposited layers cool, they shrink and
pull the underlying layer upward resulting in warping. Differential cooling causes the buildup
of internal stresses that pull the underlying layer upward, causing it to warp. Warping is
generally observed at the bottom layers due to temperature difference in printed layers and
platform. As shown in Fig. 12. Warping is seen in bottom layers.

Figure 3.6: Illustration of warping in 3d printed parts.

Figure 9: Illustration of warping in 3d printed parts

Prevention of Warpage:

• Increase the adhesion between the part and the build platform by using glue/adhesive
solution.

18
 • Raft - Raft is used to prevent the
warping. Raft is a based layer platform
on which part will be print. Raft can be
easily removable after printing of part.
• Every material has its own susceptibility
to warping. For instance, ABS is
generally more sensitive to warping than
Figure 3.7: Raft.
PLA or PETG, for instance.
• Maintaining the platform at some elevated temperature.

3) Staircase Effect:
This effect is most common in FDM printing. Visible seams are formed where layers of
printed part meet. These lines occur because the object is built up layer by layer, resulting
in a stepped appearance rather than a smooth, continuous surface. It’s mainly due to high
layer height, nozzle size, and the geometry of the printed object. The staircase effect is
shown in Fig. 16.

Prevention of Staircase Effect:

• Reduce Layer Height: Decreasing the layer height in your print settings can make the
steps smaller and less noticeable, leading to a smoother surface finish.
• Print Orientation: Adjusting the orientation of the object on the build platform can
impact how the staircase effect appears. Experimenting with different orientations can
help minimize its visibility on specific surfaces.
• Optimize Print Speed and Temperature: Printing the part at optimum printing speed
and temperature settings can influence the quality of layer bonding and reduce the
staircase effect.

19
 Figure 3.8: Staircase effect on FDM printed part

4) Slicer Conversion effect:

If you're observing variations in print quality after using different slicing software or settings,
this could be referred to as a "slicer conversion effect." Different slicers and settings can impact
how a model is printed, leading to variations in layer adhesion, surface finish, and overall
quality.

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 4 Production of Polymer Printed Part at AISPL
The production of polymer 3D printed parts marks a transformative leap in manufacturing
technology. In this chapter, we will explore AM technology use at AISPL for polymer printing.
With a focus on the printing process, post-processing techniques, and real-world applications.
this chapter unveils the key steps of creating functional and visually stunning polymer 3D
printed parts.

4.1 FDM for Polymer Printing:

FDM printer is used for polymer material. As discussed in previous chapter it is an extrusion-
based technology. Polymer filament is fed into Nozzle of FDM printer, Extruder melts the
filament and extrude layer by layer to create a part. Fig. 17. Shows the FDM process for printing
polymer.

Figure 4.1: FDM Printing Process.

In design step, Part is virtually created in 3D CAD software like Fusion 360, SolidWorks etc.
After creating 3D CAD model .STL file is generated. STL stands for Standard Tessellation
Language or Stereolithography. It encodes this information using the process called
“Tessellation”. Tessellation is the process of tiling a surface with one or more geometric shapes
such that there are overlaps or gaps. Tile floor is a perfect example. Fig. 17. Shows the STL
file of Gear generated after tessellation process.

Figure 4.2: .STL file of Gear

21
Once STL file is generated. Some Preheating Setup are required to be done before printing. In
Preheating step, Filament is installed into the nozzle. Bed is preheated before printing. It is
done to increase the adhesion of layer and bed platform and thus it helps in prevention of
warping.

After Preheating step is done, file is imported in printer for printing. In AISPL 4DS smart one
FDM printer is used for printing. Printer has bed size of 300*300*500mm and has two
extruders for printing. Once the part is printed, then in post processing step Supports created
during printing are removed.

Various Polymer material like PETG (Poly Ethylene Terephthalate Glycol), ABS (Acrylonitrile
Butadiene Styrene), Polylactic Acid (PLA) Nylon, TPU (Thermoplastic Polyurethane), HIPS
(High Impact Poly Styrene), Polycarbonate (PC) and Polypropylene (PP) can be printed.
Materials are selected by according to the use of product working condition. Table 1. shows
Polymer materials and their characteristics and applications.

Table 4.1: Polymer Materials with their characteristics and Applications.

Materials Characteristics Applications

ABS is a low-cost material, great • Cases Enclosure

Acrylonitrile
for printing tough and durable parts • Toys – Lego Brick
Butadiene Styrene
that can withstand high • Automotive
(ABS)
temperatures hardware
It is Flexible filament, known for • RC car tire
Thermoplastic
their elasticity allowing the material • Grip Sleeves
Elastomers (TPE)
to easily stretch and bend. • Phone cases
It is easy to print, very inexpensive, • Test and
calibration items
and provide high Stiffness and good
• Dimensionally
Polylactic Acid (PLA) strength and has high shelf life accurate
assemblies
• Decorative Parts
It is commonly used to manufacture • Water proof
Polyethylene applications
water bottles. Glossy and smooth
Terephthalate Glycol • Planter pot
surface finish, Adheres well to the • Snap fit
(PETG)
bed with negligible warping components

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 Nylon is a tough and semi-flexible
material that offers high impact and • Plastic Gears
Nylon • Screws, nuts, bolts
abrasion resistance. It is an ideal
• Cable ties
choice for printing durable parts
Carbon fibre filaments contain short • RC Vehicles
fibres that are infused into a base • Functional
Carbon Fiber Filled
material to help increase strength prototypes
and stiffness. • Decorative pieces
HIPS is a lightweight material most • Dissolvable
Support Material
commonly used as a dissolvable
HIPS for ABS
support structure for ABS models. • Protective Cases

4.2 Polymer Printing with Powder Bed Fusion (PBF) process

Powder Bed Fusion process is used to print the polymer material. It uses a layer wise fusion of
a Powder materials takes place using thermal energy sources like laser, Electron beam. Material
is in Powder Form and it is spread across bed using bed levelling roller. Then laser selectively
fuse powder material. This process continues until the part is created.

At AISPL Selective Absorption Fusion (SAF) and Multi Jet Fusion PBF 3d printer are used for
polymer printing. SAF is developed by Stratasys. It has an effective print size of 315 x 208 x
293 mm. Minimum layer thickness which can be print is 100μ and energy consumption of
3.25KW. It uses Polymer powder material like Nylon Polyamide (PA12, PA11). In SAF laser
is used to fuse the powder material. After each layer bed platform move downward by given
layer thickness. Fig. 18. (a) shows the image of SAF printer

Multi Jet Fusion (MJF) is combination of Binder jetting and PBF Technology. Printhead is
present which selectively deposits binding agent into powder bed, then UV light fuse the
particle. It has Effective Print size of 380 x 284 x 380 mm. Minimum layer thickness which
can be print is 90μ. It has a print resolution of 1200 dpi and energy consumption of 8KW.
Operation Temperature range – up to 250℃. Fig. 18. (b) shows the image of MJF printer.

23
 (a) (b)
Figure 4.3: a) Selective Absorption Fusion (SAF) Printer; b) Multi Jet Fusion (MJF) Printer

Post Processing in Powder Bed Fusion (PBF)

In PBF process like SAF, MJF, post-processing steps are crucial to remove printed parts from
the surrounding powder bed while ensuring the parts' integrity. Here's an overview of the post-
processing process for removing parts from the powder bed in PBF

1. Cooling: After the PBF machine completes the printing process, the build chamber, which
contains the printed parts and surrounding unsintered powder, is gradually cooled down. This
helps to solidify the printed parts and make them easier to handle.

2. Depowdering: The first step in removing parts from the powder bed is depowdering. In this
process:

• Manual Removal: Operators use brushes, scrapers, and handheld tools to carefully
remove excess powder from the printed parts. This step can be labour-intensive and
requires precision to avoid damaging the parts.
• Air or Inert Gas Blowing: Compressed air or inert gas (such as nitrogen) can be used
to blow away loose powder from the parts. This is often done within a controlled
environment or glovebox to minimize powder exposure. Fig. 19. Shows the
Depowdering machine based on compressed air.
• Vibrating Tables or Sieving: In some cases, vibrating tables or sieving machines are
employed to sift and separate printed parts from the loose powder. This method helps
ensure thorough powder removal.

24
 Figure 4.4: Depowdering Machine based compressed air

3. Part Inspection: After depowdering, the printed parts are inspected for quality and
adherence to design specifications. Any defects, incomplete sintering, or abnormalities are
identified at this stage.

4. Additional Post-Processing (Optional): Depending on the application and desired

finish, additional post-processing steps may be applied:

• Support Removal: If the parts were printed with support structures, these supports
are removed manually or using tools.
• Surface Finish: Abrasive blasting, tumbling, or other surface finishing processes
may be employed to improve the appearance and texture of the parts.

5. Powder Recovery: The unsintered powder that was removed during depowdering is
typically collected, sieved, and recycled for use in future prints. This helps reduce material
waste and costs.

The post-processing process for removing parts from the powder bed in PBF is critical for
achieving high-quality, functional components and to ensure that the printed parts are free from
defects and ready for use in various industries, including aerospace, automotive, and medical
applications.

4.2 Polymer Printing with Material Jetting process

Material Jetting is a 3D printing technology commonly used for polymer printing. It works by
jetting tiny droplets of photopolymer resin onto a build platform and then solidifying them
using UV light. At Production Department of AISPL Polyjet printers are available for printing.
In Fig. 20, Two Polyjet Printers with model J35 and J55 developed by Stratasys are available

25
for polymer printing. These printers have rotating circular build platform with printing are of
1174 cm^2 and build part up to height of 15.5cm. Energy consumption of J35 and J55 printers
is 1KW and 2KW respectively.

(a) (b)
Figure 4.5: Polyjet Printer: a) J55; b) J35

Printing Process of Polyjet Printer:

1. Material: Photopolymer resin is present in a liquid form, often stored in cartridges, which
are loaded into the 3D printer.

2. Layer Deposition: The printer's print head or multiple print heads move over the build
platform. Each print head contains hundreds of tiny nozzles that precisely jet small droplets of
liquid photopolymer resin onto the build platform.

3. UV Light Curing: As soon as the material is deposited, UV light sources (typically LEDs
or lasers) positioned near the print heads quickly cure, or solidify, the resin. This process is
layer-specific, meaning it happens only on the current layer being printed.

4. Layer-by-Layer Building: Steps 2 and 3 are repeated layer by layer. The build platform
gradually moves down (or the print heads move up), and each new layer is deposited and cured
on top of the previous one. This layering continues until the entire 3D object is formed.

5. Support Material: In many Material Jetting systems, a secondary material is used as a

support structure for overhanging or intricate features of the object.

6. Post Processing: Once the printing is complete, the printed object is removed from the build
platform. If support material was used, it is dissolved or mechanically removed. The object

26
may undergo additional post-processing steps like washing, curing under UV light, and surface
finishing.

Key Advantages of Material Jetting for Polymer Printing:

• High Resolution: Material Jetting can achieve very high levels of detail and precision,
making it suitable for applications requiring intricate and accurate parts.
• Diverse Materials: It can print with a wide range of photopolymer materials, allowing
for various colours, textures, and material properties in a single print.
• Multi-Material and Full-Colour Printing: Some Material Jetting systems can print
in full colour and even combine multiple materials within the same object.
• Smooth Surface Finish: Objects printed with Material Jetting typically have smooth
and visually appealing surface finishes.

Polyjet is commonly used in industries like dental and medical, where high precision and
complex geometries are essential. It's also utilized for producing prototypes, architectural
models, and other applications requiring fine detail and aesthetics

27
 5 Production of Metal and Ceramic Printed Parts
Metal and ceramic printing using Fused Deposition Modelling (FDM) is a specialized and
advanced application of this 3D printing technology. FDM is traditionally associated with
thermoplastic polymers, but with advancements in materials and technology, it's now possible
to use metal and ceramic materials as well. it's now possible to use metal and ceramic materials
as well. In this section, an overview of how metal and ceramic printing with FDM is given.

Figure 5.1: Process for Metal and Ceramics 3D Printing

5.1 Metal and Ceramic Filaments for FDM

To print metal objects with FDM, metal composite filaments are used. These filaments consist
of a mixture of metal powder (e.g., stainless steel, bronze, copper) and a thermoplastic binder
material (e.g., PLA, ABS). The metal content can range from 70% to 90% by weight and rest
is binder. Metal Filaments and their technical specifications are given in Table 2.

Table 5.1: Metal Filaments Technical Specifications.

Metal Specification (% weight) Printing Sintering Cost per

Filament & Density (g/cc) Temperature Temperature 1kg
Stainless 85% Stainless steel; 15% 205-235°C 1200-1400°C Rs. 30,000
Steel 17-4 PLA; Density - 3.0g/cc
filament
Stainless 92% Stainless Steel; 8% 120-130°C 1350℃ under Rs. 45,000
Steel 316L Binder; Density – 5.2g/cc Ar/Hydrogen
H13 Steel 90% Stainless Steel; 10% 180-190℃ 1350℃ under Rs. 45,000
Binder; Density – 4.5g/cc Ar/Hydrogen
(Source – Zetamix)

Ceramic Filaments: Ceramic printing using FDM employs specialized ceramic filaments.
These filaments consist of ceramic powders (e.g., Zirconia alumina) mixed with a
thermoplastic binder. Similar to metal composites, the ceramic content can vary. Ceramic
Filaments and their technical specifications are given in Table 3.

28
Table 5.2: Ceramic Filaments Technical Specifications.

Ceramic Specification (% weight) Printing Sintering Cost per

Filament & Density (g/cc) Temperature Temperature 1kg
Zirconia 86% Zirconia; 14% Binder; 180°C 1475°C Rs. 54,000
Density - 3.5g/cc
Alumina 83% Alumina; 17% Binder; 120℃ 1550℃ under Rs. 53,000
Density – 2.5g/cc Ar/Hydrogen
(Source – Zetamix)

5.2 Debinding Process

The Debinding process is a crucial step that involves the removal of the binder material from
the green part (the 3D printed metal object) after it has been printed using a metal filament.
After 3D printing with a metal/ceramic filament that contains metal/ceramic powder and a
binder material, the green part is carefully removed from the 3D printer. The green part is
fragile at this stage and needs to be handled with care. The debinding process prepares the
green part for the subsequent sintering step, where the metal particles are fused together to
create a solid metal object. There are two steps for Debinding, one is Solvent Debinding
followed by Thermal Debinding.

1. Solvent Debinding: In this process acetone is used as solvent to remove the binding agent
from the green part. For this process Solvent Debinding machine is used shown in Fig.22. There
are two steps in this process.

Step 1: Solvent Bath

• Green part is dipped into the Acetone solution to debind the printed part.
• The duration is depending on wall thickness and part geometry but takes at least 2
hours.

Step 2: Drying

• Part is then kept in ambient air to dry.

• The duration is depending on wall thickness and part geometry but takes at least 2
hours.
• This step is essential to measure the mass removed by the solvent debinding step.

29
 Figure 5.2: Ultrasonic Solvent Debinder

Specification of Solvent Debinder:

• Manufacturer – Zetamix
• Model – Zetabinder
• Volume – 300*155*150 mm
• Capacity – 6.5 L
• Temperature Control – 20-80℃
• Energy consumption – 450 W

2. Thermal Debinding:

• After Solvent Debinding, In Thermal debinding the part is placed in furnace where the
binder material begins to break down and vaporize. Fig. 23 shows Thermal Debinder.
• Parts are place in a crucible on a refractory powder bed to accommodate shrinkage and
support the part during debinding.
• The most reliable process consists of a heating rate of 8°C per hour from 20°C to 500°C.
It takes 2 and half days to complete the debinding.

Figure 5.3: Thermal Debinder

30
Specification of Thermal Debinder:

• Manufacturer – Zetamix
• Model – Zetasinter: Tubular Furnace
• Tube diameter – 10 cm
• Tube Length - 120cm
• Max temperature – 1600 ℃
• Heating Power - 3500W
• Energy Consumption - 7 KW
• Dimension - 860*605*1120mm

In Below Table 4. Thermal cycle for Zirconia with temperature and duration is given. The
temperature is gradually increased to a level where the binder material begins to break down
and vaporize. The rate of temperature increase is carefully controlled to prevent cracking or
distortion of the green part. As the temperature continues to rise, the binder material vaporizes
and is removed from the green part in the form of gas. This process can take several hours or
even days, depending on the size and complexity of the part. Once the binder material has been
effectively removed, the green part is now considered debinded. It consists of the metal powder
particles held together by weak forces and is still somewhat fragile.

Table 5.3: Thermal Debinding Procedure for Zirconia

Segment From To (℃) Heating Dwell time Segment Duration

(℃) rate (h) duration in total
(℃/h) (min) (h)
0 20 0 0
1 20 125 35 180 3h
2 125 200 50 90 4h30
3 200 215 22 40 5h10
4 215 250 11 180 8h10
5 250 280 20 90 9h40
6 280 320 8 300 14h40
7 320 510 24 480 22h40

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5.3 Sintering Process
The debinded green part is then subjected to a sintering process. During sintering, the
temperature is raised to a level that causes the metal particles to fuse together, creating a solid
and dense metal object. The sintering process may take place in a controlled atmosphere
furnace or under vacuum conditions, depending on the specific material being used. Sintering
is carried out it in a high temperature furnace. Temperature is increased in a control manner to
avoid the cracking or distortion. Parts are place in a crucible on a refractory powder bed to
accommodate shrinkage and support the part during as shown in Fig. 24 (b).

Thermal Cycle for Zirconia for Sintering:

1) Heating: 20 ℃ to 1475 ℃ with 50℃/h ramp, in 29h. Holding time is 2h

2) Cooling: 1475℃ to 20℃ with 100℃/h in 15h

(a) (b)

Figure 5.4: a) High Temperature Furnace; b) Crucible with part inside the Refractory Powder
bed

32
 6 Production of FDM Printer at AISPL
In the rapidly evolving landscape of additive manufacturing, 3D printing has emerged as a
groundbreaking technology with diverse applications spanning from education and research to
DIY enthusiasts. The 4DS unit of AISPL (Adroitech Information System Private Limited), is a
subsidiary committed to the world of 3D printing. this unit spearheads the design, assembly,
and distribution of FDM 3D printers, empowering individuals and industries to bring their
creative visions to life.

In previous chapter we have discussed various types of Additive manufacturing technologies.

In this chapter, we delve into the fascinating world of FDM printer production at the 4DS unit.
We explore the intricate process of assembling the vital components that make these FDM
printers.

6.1 4DS smart one

4DS Smart One is a Fused Deposition Modeling (FDM) 3D printer produced at the 4DS unit,
AISPL as shown in Fig 6.1. This innovative machine combines precision engineering with user-
friendly features, making it an ideal choice for both beginners and experienced makers. With a
robust frame, versatile heated bed, and intuitive control panel, the 4DS Smart One empowers
creators to bring their ideas to life with accuracy and reliability, while offering the flexibility
to explore a wide range of printing materials and applications. The specifications of 4DS smart
one printer are shown in Table 6.1.

Figure 6.1: 4DS Smart One FDM Printer

33
Table 6.1: Specifications of 4DS smart one printer.

Parameters Value
Technology FDM
Build Volume (XYZ) 300*300*500mm
Extrusion type Direct Extrusion type
No. of Extruder 2
Extruder Diameter 1.75mm
Layer Resolution 100 µm
Max. extrusion temperature 350℃
Build platform Heated type
Maximum Bed Temperature 100℃

6.2 Components of FDM Printer

• Stepper motor – It is used to control the movement of print head in X, Y, and Z
direction. Stepper motor is used because it provides precise motion to print head.
➢ Specification – Model – Nema 17
➢ Step Angle – 1.8⁰
➢ Torque – up to 3000 RPM
• Guide rails – Guide Rails are linear tracks that ensure smooth and accurate movement
of the 3D printers print head along different axes, such as X, Y, and Z.
➢ Model – MGNR - 12
• Belts – Belts are often toothed belts. They transfer motion from the stepper motors to
various component like print head. They play pivotal role in controlling the movement
of the print head and bed, ensuring precise and synchronized operation.
➢ 1140 2GT – 200mm
• Build Platform/ Bed – The bed is the flat surface on which the 3D prints are created.
It is typically made from aluminum or glass. The bed’s surface quality and temperature
control are essential for successful adhesion and print quality.
• Heater Bed – Heated bed is an integral part of bed in many printers. It heat the bed
platform to help prevent warping and improve adhesion of the first print layers.
Temperature control is essential for different filament types

34
 • Hot End and Extruder Assembly – The hot end and extruder assembly is responsible
for melting and extruding filament material. It comprises a Nozzle (hot end) and a
feeding mechanism (extruder) that ensures a consistent flow of filament during printing.
• Controller – The controller is the brain of the 3D printer, managing all the hardware
components and executing the instructions from the slicing software. Slicing software
generates the G code for the printing of part. Controller interprets G-code commands
and coordinates the printer’s movements.
• Power Supply: The power supply unit provides the necessary electrical power to
operate the 3D printer’s components, including the motors, heaters, and electronics.
• Cooling Fans: Cooling fans are placed regulate the temperature of various components
such as hot end and printed parts.
• Sink Fans: Sink fans are used to dissipate heat generated by electronic components
like stepper motor or the controller board. They control the overall temperature of the
printer
• Sensors: Sensors, such as temperature sensors and filament presence sensors, provide
real – time data to the printer’s controller.
• Lead Screw: Lead screw are commonly used in Z-axis movements to control the
vertical position of the print bed or hot end precisely. They offer stability and accuracy
in layer height adjustment.
• Endstop: Endstop are switches or sensors places at the printer’s physical limits (end
position) to prevent mechanical collision. They serve as safety measures and ensure
proper printer calibration. It is also used to position printhead at its home position.
• BL Touch Sensor: A BL touch is an auto-leveling probe that assists in calibrating the
printer’s bed. It measures variation in the bed’s surface and adjust the print head’s height
accordingly for even layer printing.
• Relay: It is used to resume the discontinued print
• Control Panel: The control panel is an interface that allows users to control 3D printer.
It often includes a display screen and buttons for navigating menus and initiating prints.
• Spool Holder: The spool holder is a support structure for the filament spool. It ensures
the filament unwinds smoothly and is delivered to the extruder without tangling.

6.3 Component Specification

4DS smart one is FDM printer model which is produce in 4DS simulation unit at AISPL. FDM
printer performance depends on the component specification. Each component plays a pivotal
35
role in shaping the printer's performance, precision, and reliability. In this section of the report,
we delve into the detailed specifications of the key components that make up our FDM printers.

Table 2.2: Components of FDM printer with Name/Specification.

Parts Name/ Specifications

Stepper Motor Nema 17 – Step angle – 1.8⁰, Torque – upto 3000rpm
Pulley Diameter – 5mm; 32 teeth
Guide Rails MGNR – 12 (Y axis), MGNR – 12H 20C (X-axis)
Belts 1140 2GT – 200mm
Bed Aluminum
Heated Bed 35W
Hot End and Extruder E3D Hemera
Assembly
Power Supply SMPS - 24v
Cooling Fans 2
Sink Fan 2
Sensors Thermistors
Lead Screw Diameter – 10mm
Endstop Optical Sensor
Control Panel 7 inch led Screen

6.4 Assembly of 4DS smart one

Assembly is crucial part of production of FDM printer. Each component, from guide rails to
hot ends, finds its purpose and place in the 3D printer frame. This stage is where the vision of
a functional, reliable, and accurate 3D printer comes to fruition.

1 Frame Assembly:
• Frame of 4DS smart one is made of Aluminum sheet. All the components of
printer will be mounted in the frame, so frame should have high quality and
strength, ensuring stability and level.
• L shape Mountings for motors is attached to the frame with the help of grub
screws.

36
2 Stepper Motor Installation:
• Stepper motor is installed on the mounting attached to frame with the help of
grub screws.
• 3 Motors are installed for motion in X, Y and Z direction.
• Install Pulley on motor.
• Stepper drivers are installed which controls the stepper motor.

(a) (b)

Figure 6.2: a) Stepper Motor; and b) Pulley

3 Guide rail Installation:
• Attach linear guide rails to the frame along
the X and Y axes. In 4DS smart one printer 3
guide rails are installed.
• In 4DS smart one printer, horizontal plane
represents XY plane. On Y axis Guide Rail
printhead is install
• Guide rails ensure precise alignment and
Figure 6.3: Guide Rail
secure attachment to facilitate smooth motion.

4 Belt and Pulley Installation:

• Install timing belts on the x and y axes. Tension the belts appropriately to
prevent slack while allowing smooth movement.

5 Lead Screw Installation:

• Lead screw is installed to control the vertical movement of the printer’s bed.
• Lead Screw is attached to the motors with the help of Coupler. Coupler enable
motor to turn a lead screw.

37
 (a) (b)

Figure 6.4: a) Lead Screw; and b) Coupler

6 Heated Bed Installation:

• Heated Bed is attached to the lead screw. Lead screw controls the vertical
motion of Heater bed
• Heater bed is integrated with heating element which heats the bed.
• Connect the heated bed to the printer’s electronics for temperature control.

7 Hot End and Extruder Assembly:

• Assemble the hot end including nozzle to the Gantry. Gantry is attached to the
guiderail.
• Install Cooling fan to the assembly to cool extruder and printed layers. Its
primary function is to rapidly cool down the melted filament as it exits the
nozzle, ensuring that it solidifies quickly.
• 4DS smart one printer is installed with Two Hot End and Extruder Assembly.
So, printing of part with two materials can be possible

Figure 6.5: Hot End Assembly

38
 8 Cooling Fan and Heat Chamber Fan:
• Install cooling fans for stepper motor drivers
• Install Heat Chamber fans, which heat the chamber upto 60℃.

9 Sensors and Endstop Placements:

• Install Endstop at the printer’s physical limits to prevent collisions. In 4DS
smart one Optical Endstop is used.
• Temperature sensor are installed at Hot end & extruder assembly and heater bed.
It gives Extruder temperature and Bed Temperature
• BL touch sensor is installed at Hot end and Extruder assembly.

10 Controller Installation:
• It’s the most crucial part of the assembly. Doing proper connection of all
components to the controller is very essential. Mount the controller board and
connect it to printer’s component, including motors, heaters, and sensors.
• It involves connection of Main Switch, power supply controller, Relay, sensors,
heat chamber fan, stepper motor driver etc.
• Carefully route and secure wiring to prevent interface with moving parts.

11 Power Supply Management:

• 24v SMPS is installed for supply power to the components of printer
• SMPS is choose according the hot end configuration.

12 LED Screen Integration

• Install LED screen to the controller, it is a control panel for the printer.
• It can control the printer operation using it and also it shows printing parameters
like temperature, time and progress.

6.5 Firmware Installation

Firmware is the link between software and hardware: It converts inputs from software to an
output that computer hardware can understand. In 3D printing, that process happens whenever
you send a G-code file from your slicing software to the 3D printer: The firmware “works out”
the code and accordingly gives an output to the stepper motors, heaters, display, and so on.
39
For example, let’s consider the G-code command “G1 X10 Y20”. The firmware understands
this command and then determines the output to be given to the stepper motor so that the
extruder reaches X=10 and Y=20. Without firmware, the 3D printer wouldn’t understand the
G-code input.

In 4DS Smart one printer Marlin Firmware is used. Marlin is one of the most widely known
and commonly used 3D printer firmware options. Many 3D printer manufacturers include
Marlin firmware as is or adapt it to run on their 3D printers. 4DS smart one has 32-it controller
for fast performance and It is compatible with the marlin firmware

Major Steps required to customize the Firmware for the 3D printer:

• Connect 3D printer to the computer

• Open your firmware (in this case, Marlin) in Arduino IDE.
• Enter the Printer-specific information in the machine-specific configurations. These
might include:
➢ Steps (mm) for your extruder and X-, Y-, and Z-axis motors
➢ Maximum travel distances of your three axes
➢ Maximum feed rates (or speed) and acceleration for your axes and extruder
motors
➢ Any other custom settings in your original firmware
• In the “Tools” section, select your 3D printer controller board processor, and make
sure that the COM port is correctly configured.
• Once you’re done, click on the “Tick” icon in the top left corner. This will initiate the
compiling process. After the firmware is compiled, you’ll get a message that says
“Done Compiling”.
• Upload the firmware to your 3D printer.
• Initialize EEPROM in your 3D printer.

6.6 Quality Control and checks

Once Assembly of parts is done, We Perform comprehensive quality control checks, verifying
the proper assembly of components. We check that all the pieces are in the correct place and
that they work properly. Precise alignment, secure connections, and comprehensive
functionality tests are conducted to ensure the printer's readiness for optimal performance.

Various Quality checks are performed to verify the assembly properly.

40
 A. Controller Connection and Wiring Quality Check
B. X-Y Gantry Quality Assurance Checklist.
C. Printing Quality Check.

A) Controller Connection and Wiring Quality Check:

This Quality check ensures the proper operation and safety of the printer. Table 6.3. shows the
checklist which have been follow while assuring quality Controller Connection and Wiring
Quality Check.

Table 6.3: Controller Connection and Wiring Quality Checklist.

Checkpoint Inspection Yes No

Visual Inspection of Cables Inspect for damage, fraying, loose

and Connections connections.

Power Off and Unplugged Ensure the 3D printer is safely

disconnected from power.

Electrical Connections Inspect the connections on the

controller board, stepper motor
drivers, and power supply

Proper Cable Routing Check that cables are neatly

organized and routed correctly.

Wire Integrity Examine wires for wear, kinks, or

damage to insulation.

Electrical Connections Inspect the connections on the

controller board, stepper motor
drivers, and power supply

B) X-Y Gantry Quality Assurance Checklist:

This Quality check ensures the quality of Gantry. Gantry has assembly of Extruder, Hot End,
Cooling and heat sink fan, End Stops, Belts. So, checking the proper fitting of all the parts,
alignment of pulleys, belts, Endstop is done in this quality check procedure. Table 7. shows the
checklist which have been follow while assuring quality of X-Y gantry.

41
Table 6.4: XY Gantry Quality Assurance Checklist.

S. No Quality Description Yes No

All nuts and bolts of both extruders are tight

1
properly

Both part cooling fans and heat sink fans are

2
working
Both filament sensors are working independently.
3 All nuts and bolts of XY gantry guide rails are
tight
All nuts and bolts of XY gantry guide rails are
4
tight

Bolts of holding block of smooth rod are tight

5
properly

BL-Touch sensor fixed properly and all its wires

6
arranged properly

Both extruder filament tensioning thumb screw

7
are tight

All belts of xy gantry tension are maintained

8
properly.

Grub screws of all teeth pulleys are tight

9
properly.

10 Closed belts are aligned with both side pulley.

11 X and Y motors small close belt is tight properly.

All 4 L Bracket of Gantry Holding that fixed with

12
gantry and aluminum extrusion are tight properly.

All screws of aluminum extrusion that holding

13
the filament spool holder are tight properly.

Y axis Guide Rails holding bracket grub screw &

14
other screws are tight properly

Y axis Guide Rails holding bracket grub screw &

15
other screws are tight properly

42
 16 Check extruder motor is in correct direction.

17 Grub screws of part cooling fan are tight property

Endstop of X and Y gantry are aligned and fixed

18
properly

Screws of X & Y gantry stepper motors are tight

19
properly

Heat block and nozzle of both extruders are tight

20
properly

Check Extruder moving in XY axis

21
300mm*300mm without any obstruction

C) Printing Quality Checklist:

This Quality check is done to ensure the proper working of 3D printer. It ensures stepper motor,
Gantry assembly, Extruder, Sensors are working properly. In this Quality check test specimen
is printed and quality check list is performed.

Table 6.5: Printing Quality Checklist

S. No Quality Description Remarks

1 Check adhesion of the first layer to the bed.

2 Measure key dimensions to verify against specifications.

Inspect for surface defects like blobs or stringing.

3
Confirm correct Extrusion temperature and Bed
4
temperature during printing.
5 Inspect for surface defects like blobs or stringing.

6 Inspect for stringing or oozing

7 Evaluate quality of supports and ease of removal.

43
These are some of the major Quality checks which is done to ensure the Quality and
performance of FDM 3D printer. These tests are performed before sending the printer to the
customer. Thus, printer can offer a high printing performance.

6.7 Troubleshooting:
Troubleshooting common issues in Fused Deposition Modeling (FDM) 3D printers is done for
achieving reliable and high-quality prints. In this section we will look into common problems
and their possible solutions.
1. Poor Adhesion to the build plate:
• Ensure the build plate is clean and proper levelling should be done.
• Apply an appropriate bed adhesive e.g., glue stick, painter’s tape, adhesive solution.
• Check the first layer height to ensure proper adhesion.

2. Warping:

• Use a heated bed and ensure it’s at the correct temperature for the filament material.
• Apply raft to increase adhesion to the bed.
• When printing larger parts, consider adding an enclosure around your printer to
maintain a higher temperature around your print. The enclosure can also prevent wind
drafts that could rapidly cool the part during printing.

3. Stringing and Oozing:

• Stringing and oozing are hair like feature which are created while printing when the
nozzle moves from one point to another. Oozing is shown in Fig. 29.

Figure 6.7: Oozing in printed part [6.1]

44
 • Adjust Retraction Distance: This determines how much plastic is pulled out of the
nozzle. Try increasing the retraction distance by 1mm and test again to see if the
performance improves.
• Adjust Retraction Speed: This determines how fast the filament is retracted from the
nozzle. If you retract too slowly, extruder may start leaking before the extruder is
done moving to its new destination. If you retract too quickly, the filament may
separate from the hot plastic inside the nozzle, or the quick movement of the drive
gear may even grind away pieces of your filament. Between 1200-6000 mm/min (20-
100 mm/s) where retraction performs best.
• Temperature is too high: If the temperature is too high, the plastic inside the nozzle
will become less viscous and will leak out of the nozzle much more easily. To resolve
this issue try decreasing your extruder temperature by 5-10 degrees.

4. Layer Misalignment and Shifting:

• Inspect and tighten belts and pulleys to prevent slipping.

• Check that the stepper motor drivers and wiring are functioning correctly.

5. Not Extruding at start:

• Extruder was not primed before beginning the print:

• Most extruders start leaking plastic when they are sitting idle at a high
temperature. If extruder has lost some plastic due to oozing, when it starts
extruding, which creates a void inside the nozzle where the plastic has drained
out.
• Due to this it is likely that it will take a few seconds before plastic starts to come
out of the nozzle this caused delayed in extrusion. Thus, Extruder didn’t print
starting layers as shown in Fig. 30.
• To solve this issue, include a Skirt in printing. The skirt will draw an outline
offset to the part and in the process, it will prime the extruder with plastic.

45
 Figure 6.8: Starting Layers are not printed [6.1]

• Nozzle start too close to the bed:

• If the nozzle starts too close to the build table surface, there will not be enough
room for plastic to come out of the extruder. An easy way to recognize this issue
is if the print does not extrude plastic for the first layer or two, but begins to
extrude normally around the 3rd or 4th layers as the bed continues to lower
along the Z-axis.
• To solve this problem, Increase G-Code offsets which can be found on the G-
Code tab of Simplify3D’s process settings. This allows you to make very fine
adjustments to the Z-axis position. For example, if you enter a value of 0.05mm
for the Z-axis G-Code offset, this will move the nozzle 0.05mm further away
from the print bed.
• The extruder is clogged:
• Extruder clogged when the foreign debris are trapped inside the nozzle.
• To solve this issue, Increase the Extruder temperature and use purge option
given in 4DS smart one printer. With purge option filament comes out of the
nozzle with the filament debris which are clogged inside will also come out.
• If the filament didn’t come even after purging, then manually you need to purge
the clogged debris. Increase the extruder temperature, use small rod (e.g., Allen
key backside) and put it inside the nozzle and push downward so that debris
come out of the nozzle to clear the nozzle.
• In extreme case, it may require disassembling of the extruder to clean the nozzle.

46
6. Under-Extrusion:

• In under Extrusion less plastic extrude out of the nozzle and you may start to
notice gaps between adjacent extrusions of each layer. As shown in Fig. 31.

Figure 6.9: Under Extrusion Printing [6.1]

• To solve this issue, First verify that filament diameter in software that is added.
Check to make sure that this value matches the filament that you purchased. You
may even want to measure your filament yourself using a pair of calipers to
make sure that you truly have the correct diameter specified in the software.
• Increase the extrusion multiplier: Extrusion multiplier allows you to easily
modify the amount of plastic that is extruded. So, increasing it can solve the
issue of under extrusion.

This is how an effective troubleshooting is an indispensable skill for any FDM 3D printing
enthusiast or professional. By systematically identifying and addressing common issues such
as adhesion problems, warping, extrusion issues, and nozzle clogs, we can significantly
improve the reliability and quality of our prints.

47
 7 Optimization of FDM Printer Parameters
In previous chapters we have discussed about various Additive manufacturing technology.
Understand the FDM Printer Working and its troubleshooting. To apply the gathered
knowledge during internship I am doing project entitled “Optimization of FDM Printer
Parameters for High Tensile Strength Printing of Polyethylene terephthalate Glycol (PETG)-
Carbon Fiber (CF) and Polylactic Acid (PLA)-Carbon Fiber (CF) Polymer Composites”. With
an increasing demand for robust and durable components across various industries, the need
for achieving superior mechanical properties in 3D-printed objects is crucial. This research not
only improves the strength of what we create but also adds to the growing possibilities of 3D
printing.

7.1 Objectives
The objective of this research is to systematically investigate and optimize the parameters and
techniques involved in Fused Deposition Modeling (FDM) 3D printing. Specifically, our focus
was on enhancing tensile strength of PETG-CF and PLA-CF polymer composite. we aim to
achieve this by fine-tuning variables such as Layer height, Extrusion Multiplier, Infill Density,
Extrusion Temperature, Printing Speed, Orientation. Through rigorous experimentation and
analysis, we seek to identify the ideal combination of these parameters to produce 3D-printed
parts.

7.2 Materials and Methodology

In this research we have use Polyethylene terephthalate Glycol (PETG)-Carbon Fiber (CF)
and Polylactic Acid (PLA)-Carbon Fiber (CF) Polymer Composites. Material is manufactured
by Tesseract company. This polymer composite is in the form of wire Filament. This
composite has 80% base material and 20% Carbon Fiber.

Materials:

PLA is a biodegradable and environmentally friendly thermoplastic filament commonly used

in 3D printing. It's derived from renewable resources like cornstarch or sugarcane. PLA is
known for its ease of use, low warping, and minimal odor during printing. PETG is a durable
and versatile 3D printing filament known for its excellent layer adhesion and impact resistance.
PETG is transparent and can be used for clear prints. PETG is commonly used for making of
plastic bottles.

48
In PETG-CF and PLA-CF filament, Carbon fiber is incorporated into PLA and PETG filaments
to bolster their mechanical properties, enhancing their strength, rigidity, and durability. The
addition of carbon fiber reinforcement significantly increases the tensile strength of these
filaments, making them well-suited for applications requiring robust and load-bearing
components. Technical Specification of PETG-CF and PLA-CF is given in Table 10.

Table 7.1: PETG-CF and PLA-CF Technical Specifications

Parameter PETG-CF PLA-CF

Specification (% weight) 80% PETG, 20% Carbon Fiber 80% PLA, 20% Carbon Fiber
Material type Wire Filament Wire Filament
Recommended Extrusion 210 – 240 ℃ 190-230℃
Temperature
Filament Diameter 1.75 ± 0.03mm 1.75 ± 0.03mm
Color Black Black
Filament Spool 1Kg 1Kg
Bed Temperature 80 ℃ 60 ℃

Methodology:
In this study, the experimentation included the following steps: computer-aided design (CAD),
design of experiments, parts fabrication using FDM and measurement of responses.

Computer Aided Design:

As shown in Fig. 32, Specimen has dog bone shaped structure and It is designed according to
the ASTM standard D638 (Type 1). This Tensile method is designed to produce tensile property
data for the control and specification of plastic Material. Each of the measurement like gauge
length, Width, Overall length Thickness is taken according to the standard. The SolidWorks
Software is used to model the specimen and generating a .STL file.

49
 Figure 7.1: CAD Model of Specimen

Design of Experiment (DOE):

The Box–Behnken design of response surface methodology is used to examine the effect of
process parameters on the printing High Tensile strength PETG-CF and PLA-CF.

RSM is widely used in various industries, including manufacturing, engineering, and research,
to systematically improve processes, reduce costs, and optimize product performance. RSM
helps plan a series of experiments by varying input factors (variables) within certain levels.
These experiments are designed to explore how changes in variables affect the response.

In our experiments Six Variable i.e., FDM parameter Extrusion Multiplier, Layer Height,
Extrusion Temperature, Printing Speed, Infill Density, Orientation was included in this study.
and three levels as shown in Table.11. All the Variables which are taken for these experiments
are continuous. The levels of these process parameters are set based on the Material Properties,
machine capacity and literature and are shown in Table 11.

50
Table 7.2: Factors and Levels for Design of Experiment

S. No Factors Level 1 Level 2 Level 3

1 Extrusion Multiplier (EM) 0.85 0.9 0.95
2 Layer Height (mm) 0.2 0.25 0.3
Extrude Temperature PETG – CF 220 230 240
3 (℃)
PLA – CF 190 200 210
4 Printing Speed (mm/sec) 30 45 60
5 Infill Density (%) 33 50 66

6 Orientation (⁰) 15 30 45

A comprehensive experimental design is prepared using the Box–Behnken design of response

surface methodology using the Minitab 21 software (developed by Minitab LLC). The
experimental design suggested a total of 54 experiments.

7.3 Fabrication of PETG-CF and PLA-CF Specimen

As shown in Figure 33, a FDM 3D printer (Model: 4DS Smart One, 4D Simulation) is used
in the present work. Printer can print in 300*300*500mm Volume. The manufacturer
recommends to use Simplify3d software for Slicing. PETG-CF and PLA-CF material is used
to print the specimen. After importing the STL file into Simplify3D software, the GCODE
files were created per the experiment’s design and then transferred to the machine for printing
the specimens.

In Pre-Printing process, Bed temperature is required to be set at 80℃ and 60℃ for PETG-CF
and PLA-CF Material. Applying Glue stick on PI sheets for adhesion is required for PLA-CF
and Adhesive solution was made of ABS and Acetone to apply on PI sheet for PETG-CF. After
Starting the printer, Nozzle take some time to start printing until the extrusion temperature
reach to the set input value in Slicing. During this Nozzle starts leaking material. This material
is required to clean to avoid the void inside the nozzle. Tong is used to clean the Leaked material
from Nozzle.

Challenges Faced During Printing:

• Under Extrusion Printing:
First, we have started printing the specimen with Extrusion Multiplier (EM) levels as
0.8, 0.85, and 0.9. But we notice that while printing specimen with EM 0.8, gaps
between adjacent layers are generated as shown in Fig. 33. The problem is due to Under

51
 Extrusion of material. So, to solve this issue we have change the levels of Extrusion
Multiplier as 0.85, 0.9, 0.95.

Figure 7.2: Gap generated between Adjacent Layers due to low EM

• Gap between Infill layers and Outside layers:

At starting Specimen were printed at 2 Outline perimeters. But due to this Gap
between Infill layers and Outside layers were produced as shown in Fig. 34. To solve
this issue, we had increase outline perimeter to 4. This issue is also reduced when
Extrusion Multiplier is increased.

Figure 7.311: Gap Generated between Outline Perimeter and Infill Layers

• Bottom Layer Adhesion Problem:

When we are printing Bottom layer were not sticking to the PI Sheets. To solve this
issue, we made adhesive solution of Acetone and ABS to apply on PI Sheets for
PETG-CF sample and for PLA-CF we used glue stick. We also used Raft for better

52
 adhesion while printing bottom layers. Raft solve adhesion problem but including raft
increase the printing time by 45 minutes on average
• Extruder not printing the layer at starting:
As explain in 6.7. Troubleshooting section of chapter 6. Most extruders start leaking
plastic when they are sitting idle at a high temperature. If extruder has lost some
plastic due to oozing, when it starts extruding, which creates a void inside the nozzle
where the plastic has drained out. Thus, when Extruder start printing, they miss some
starting feature, as shown in Fig. 35. At Left Bottom Corner some part is not printed.
To solve this issue Skirt is included in printing at an offset of 5mm as shown in
Fig.35. Skirt is an outline line printed at offset to the part and the raft is printed below
the part.

Figure 7.4: Printed Skirt and Raft

• Nozzle gets clogged between the printing:

Initially we were printing the material with extrusion temperature level for PLA-CF as
180℃, 190℃, 200℃ and PETG-CF with temperature level as 200℃, 210℃ and
220℃. For PLA-CF at 180℃ extrusion temperature level nozzle was getting clogged
due to insufficient temperature required for melting. And similar case for PETG-CF at
200℃. Due to the clogging of Nozzle some features were not printing and the whole
sample was discarded. Then we iterate by changing the Extrusion temperature 190℃,
for PLA-CF and 210℃ for PETG-CF material and the problem gets resolved. So, our
Final Extrusion Temperature Level was 190℃, 200℃, 210℃ and 210℃, 220℃ and
230℃ for PETG-CF.

53
After iterating for several times and changing the levels of parameter we decided the levels for
parameter as mentioned in table 11. And we printed the parts according to the DOE. The total
54 specimens of each PETG-CF and PLA-CF material are printed are shown in Figure 36.

Figure 7.5: PETG-CF Specimens Printed using FDM

Figure 7.5: PETG-CF Specimens Printed using FDM

Figure 7.6: PLA-CF Specimens Printed using FDM

7.4 Testing:
After Specimens of PETG-CF and PLA-CF were fabricated. Specimens were tested on
Universal Testing Machine as shown in Fig. 7.7. Universal Testing Machine Specification are
given in Table 7.3. For Tensile Testing Load Rate was taken as 5mm/min. After Testing was
done for 54 specimens of each material, Tensile Strength was evaluated.

54
 Figure 12: Universal Testing Machine

Table 7.3: Specification of Universal Testing Machine

Parameter Specifications
Manufacturer Tinius Olsen
Model H25KL Aimil
Operation Pneumatic
Maximum Load Capacity 25 KN

7.5 Result:
As shown in Table 7.4. Design of Experiment with Evaluated Tensile Strength is given and for
Experiment No. 24 PETG-CF and PLA-CF has a Maximum Tensile strength i.e., 35.26 MPa
and 30.9375 MPa respectively. Layer height, Extruder Temperature, Printing speed, Infill
Density, Orientation is 0.25mm, 220 ℃ (PETG-CF) and 190 ℃ (PLA-CF), 60mm/sec, 33%,
0.9, 15⁰ respectively for Experiment 25. Range of Tensile strength varies between 14.75 –
35.26Mpa for PETG-CF and 12.93MPa – 30.94 MPa for PLA-CF.

55
Table 7.4: Design of Experiment with Evaluated Tensile Strength.

Tensile Tensile
Layer Extruder Infill
Exp Printing Orientatio Strength Strength
heigh temperatur densit EM
. No speed n (PETG) PLA
t e y
(MPa) (MPa)
1 0.3 2 45 33 0.95 30 18 14.30
2 0.2 2 60 49.5 0.9 15 19.78 15.12
3 0.2 3 45 49.5 0.95 45 28 19.63
4 0.3 2 30 49.5 0.9 15 18.36 16.05
5 0.25 3 45 49.5 0.85 15 14.75 12.93
6 0.25 2 45 49.5 0.9 30 18.01 16.63
7 0.2 3 45 33 0.9 30 26.82 20.91
8 0.3 2 30 49.5 0.9 45 31.34 23.43
9 0.2 1 45 33 0.9 30 25.62 20.21
10 0.25 2 45 49.5 0.9 30 32.0 24.23
11 0.3 2 45 33 0.85 30 28.26 22.59
12 0.2 2 45 33 0.85 30 21.32 16.80
13 0.25 1 60 49.5 0.95 30 34.25 26.65
14 0.3 2 60 49.5 0.9 15 29.95 19.85
15 0.3 2 45 66 0.95 30 32.78 26.94
16 0.25 2 45 49.5 0.9 30 31.56 23.84
17 0.2 2 45 33 0.95 30 28.58 21.41
18 0.25 2 30 33 0.9 15 31.05 22.28
19 0.25 2 60 66 0.9 15 31.12 20.14
20 0.25 1 60 49.5 0.85 30 25.69 24.06
21 0.2 2 30 49.5 0.9 45 24.15 22.51
22 0.3 3 45 33 0.9 30 29.95 24.13
23 0.2 2 45 66 0.95 30 31.05 22.40
24 0.25 1 45 49.5 0.95 45 35.26 30.93
25 0.25 2 60 33 0.9 15 31.73 21.94
26 0.2 1 45 66 0.9 30 25.86 24.59
27 0.25 2 60 66 0.9 45 30.69 23.96
28 0.25 3 30 49.5 0.95 30 34.90 26.63
29 0.25 3 30 49.5 0.85 30 30.72 27.01
30 0.3 1 45 33 0.9 30 26.17 26.58
31 0.25 1 45 49.5 0.85 15 22.98 20.96
32 0.25 3 45 49.5 0.95 15 33.29 27.52
33 0.2 2 30 49.5 0.9 15 18 21.56
34 0.3 1 45 66 0.9 30 31.34 25.14
35 0.25 3 60 49.5 0.95 30 34.83 26.70
36 0.25 2 45 49.5 0.9 30 30.98 24.27
37 0.25 1 45 49.5 0.95 15 32.86 27.47
38 0.25 1 30 49.5 0.85 30 26.17 20.16
39 0.25 2 45 49.5 0.9 30 30.72 25.62
40 0.25 2 45 49.5 0.9 30 30.91 25.57
41 0.25 1 30 49.5 0.95 30 31.44 25.69

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 42 0.25 1 45 49.5 0.85 45 26.22 21.37
43 0.25 2 30 66 0.9 45 30.02 24.49
44 0.25 2 60 33 0.9 45 29.30 26.87
45 0.3 3 45 66 0.9 30 29.15 26.29
46 0.2 2 60 49.5 0.9 45 27.88 21.20
47 0.2 2 45 66 0.85 30 24.78 22.09
48 0.3 2 45 66 0.85 30 28.50 22.88
49 0.25 2 30 66 0.9 15 27.95 27.13
50 0.3 2 60 49.5 0.9 45 26.63 25.21
51 0.25 2 30 33 0.9 45 32.09 23.79
52 0.25 3 60 49.5 0.85 30 30.21 21.17
53 0.25 3 45 49.5 0.85 45 29.32 21.49
54 0.2 3 45 66 0.9 30 31.05 21.82

Notation of Extrusion Temperature:

Table 7.5: Notation of Extrusion Temperature in DOE.

Notation Extrusion Temperature for PLA-CF Extrusion Temperature for PETG-CF

(℃) (℃)
1 190 220
2 210 230
3 220 240

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8 Conclusion
In the culmination of this internship journey, I find myself enriched with invaluable
experiences, knowledge, and a deeper understanding of the dynamic world of 3D printing and
additive manufacturing. Over the course of my internship at AISPL's 4DS unit, I had the
privilege of immersing myself in the realm of cutting-edge technology and innovation.

Throughout this internship, I actively contributed to the assembly of FDM 3D printers,

gaining hands-on expertise in the intricate process of transforming individual components
into fully functional machines. This experience has underscored the critical importance of
precision and quality control checks.

Furthermore, my involvement in the optimization of FDM printer parameters for high tensile
strength polymer composite printing taught me the research procedure. This research
endeavor allowed me to not only fine-tune the intricacies of 3D printing but also witness the
profound impact it can have on printing and mechanical strength.

The opportunity to work with composite filaments like PETG-CF and PLA-CF was
particularly enlightening, as it showcased the transformative potential of materials
engineering in additive manufacturing. These advanced composites, with their exceptional
strength and durability, have expanded the possibilities for creating high-performance
components across various industries.

In addition to technical skills, this internship has honed my problem-solving abilities, time
management, and adaptability in a professional setting. The collaborative environment at
AISPL provided a platform for learning from seasoned experts, and I am immensely grateful
for the mentorship and guidance I received.

I extend my sincere gratitude to the entire team at AISPL's 4DS unit for their unwavering
support, and I am excited about the prospects that lie ahead in my career. This internship has
been a transformative experience, and I am eager to apply the knowledge and skills acquired
here to future endeavors, contributing to the ever-evolving landscape of additive
manufacturing.

58
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Chapter 1:

1. Company Website: http://www.adroitecinfo.com/

Chapter 2:

1. Book: I. Gibson, D.W. Rosen, and B. Stucker, “Additive Manufacturing

Technologies”, Springer
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9. Directed Energy Deposition:
https://www.lboro.ac.uk/research/amrg/about/the7categoriesofadditivemanufacturi
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Chapter 3:

1. Fused Deposition Modelling Process: https://www.hubs.com/

2. Sood, A. K., Ohdar, R. K., & Mahapatra, S. S. (2010). Parametric appraisal of
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Chapter 4:

1. Powder Bed Fusion Process: https://www.hubs.com/

59
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https://www.lboro.ac.uk/research/amrg/about/the7categoriesofadditivemanufacturi
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technology/
4. HP Multi Jet 3D printing Technology:
https://www.hp.com/us-en/printers/3d-printers/products/multi-jet-technology.html

Chapter 5:

1. Abhishek Kumar Singh, Sriram Chauhan: Technique to Enhance FDM 3D Metal

Printing. DOI:10.9756/BIJIEMS.7574
2. Introduction to Metal 3D Printing: https://all3dp.com/1/fdm-metal-3d-printing-
makerbot/
3. Metal and Ceramic Filaments for FDM: https://zetamix.fr/en/category/filaments-
en/
4. High Temperature Muffle Furnance:
https://www.harriergroups.com/programmable-muffle-furnace-1500c/
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Chapter 6:

1. https://www.simplify3d.com/resources/print-quality-troubleshooting/stringing-or-
oozing/

Chapter 7:

1. Tesseract Premium PETG Carbon Fiber PETG CF 1.75mm 3D Printing Filament:

https://www.amazon.in/Tesseract-1-75mm-Printing-Filament-
Spool/dp/B09HXMWLB4?th=1
2. Tesseract Premium PLA Carbon Fiber PLA CF 1.75mm 3D Printing Filament:
https://www.amazon.in/Tesseract-1-75mm-Premium-Printing-
Filament/dp/B09HXMM3H6

60
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Hsin Hsieh 1, Chieh-Yu Pan 3, and Wen-Chen Huang 4, Effect of Printing
Parameters on the Thermal and Mechanical Properties of 3D-Printed PLA and
PETG, Using Fused Deposition Modeling, https://doi.org/10.3390/polym13111758
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Begic-Hajdarevic, Maida Cohodar Husic and Mirko Ficko: Effect of Process
Parameters on Tensile Strength of FDM Printed Carbon Fiber Reinforced
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