INTERNATIONAL JOURNAL OF SCIENTIFIC & TECHNOLOGY RESEARCH VOLUME 9, ISSUE 01 , JANUARY 2020
ISSN 2277-8616
Design And Development Of 3d Printer Filament
Extruder For Material Reuse
P.Ravichandran, C.Anbu, R.Poornachandran, M.Shenbagarajan, K.S.Yaswahnthan
Abstract: 3D printing technology or 3D printer which is one of the branches of fourth industrial revolution is being widely used in various industries such
as manufacturing, medical, automobile etc. The 3D printing process builds a three dimensional object from computer aided desi gn model, usually by
successively adding material layer by layer, unlike conventional machining, casting and forging process, where material is removed from a stock item or
poured into a mold and shaped by means of dies, press and hammers. The material which is successively added layer by layer is called as Acrylonitrile
Butadiene Styrene (ABS). This material at the initial stages will be in the form of granules and later it will be turns into a filament like structure with
various diameters depending on the 3D printer size. The granules undergo a process called extrusion process where these material are turned into
desired filament by heating at about 180 degree Celsius and solidifying it. The existing model or machine for this extrusion process have some
disadvantages like they are not cost effective, need trained labor to operate, high and frequent maintenance is required and as these machine are huge
in size they cannot be installed at every places especially at educational institutions and small scale industries . The main objective of this paper is to
design and develop a table top filament extruder where the materials which had got wasted during the 3D printing process can be collected and
reformed into a filament for reuse. This proposed system also overcomes all the disadvantages that have been mentioned above.
Index terms : 3D printing, Acrylonitrile Butadiene Styrene (ABS), Filament, Die, Extruder, Microcontroller, Relay,
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1
INTRODUCTION
3D printing filament is the thermoplastic feedstock for fused
deposition modelling 3D printers. Many types of filament are
available in the market with different properties with various
temperature ranges for printing the required product. At
present, filaments are available in few different standard
diameters like 1.75 mm, 2.85 mm and 3 mm. The production
of 3D printing filament is generally consisting of processes like
heating, extruding and cooling to transform granules into the
finished product. In this process, the filament is pulled from
outside rather than pushed through the nozzle to produce the
filament. The diameter of the filament is not decided by the
diameter of the nozzle. The size or diameter of the filament is
decided by the process that takes place after the plastic has
been heated. An outside force is applied to the filament as it is
pulled out of the extruder to define the width of the filament.
Most commonly used size of the filament is either 1.75 mm or
3 mm diameter. The plastic granules are always white or clear.
The colour of the filament has been changed by adding the
required additives with granules before the heating process.
Also, these additives will be the deciding parameter of the
special properties of the filament, e.g. increased strength or
magnetic properties. Before the filament is extruded the
granules are heated to 80°C to dry it and reduce water
content. The granules must be dried as many thermoplastics
are hygroscopic and extrusion of damp plastic causes
dimensional flaws (this is also the case when the finished
filament is being printed). From there the granules are fed into
a single screw extruder where it is heated and extruded into a
filament. The size of the filament is measured by the
application of laser as part of quality control equipment to
make sure the correct size of the filament. The filament is then
fed through a warm water tank which cools the filament which
gives the filament its round shape. After, the filament is fed
through a tank containing cold water to cool it to room
temperature.
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Finally, it will be rolled onto a spool to form a finished product.
DIY type filament production systems use the above method
of FDM 3D printers of pushing the filament into the extruder to
get the correct size of the filament. The existing process
consists of some of the disadvantages like increase in
machine cost, as the process is more tedious and contains
more technical equipment these machines require trained
labours. The size of machine is also huge and it cannot be
easily installed in small scale industries and for laboratory
uses in institutions. Also the cost of maintenance is
comparatively high. So in order to overcome all these
disadvantages mentioned above, a new methodology has
proposed in this paper. In the proposed method, the whole
setup of the machine is reduced to a table top portable
extruder which can be carried out to any places. The setup
consists of a hopper where the granules or ABS pellets are
loaded and it is made to flow through a pipe with the help of
wooden drill bit where the material is heated and melted with
the help of heating cartridge. Then, these temperature values
are loaded into Arduino UNO which automatically controls the
temperature between specified ranges.
2
PROBLEM DEFINITION
2.1 Literature Review
Alvaro Goyanes et al (2014), their project is to design and
build an extrusion machine that makes 3D printer filament
from water bottles, these water bottles are usually
polyethylene terephthalate (PET) materials which are taken as
intake for making filament. Mark D Grooms (2016), their
project is to develop a 3d printer filament extruder at low cost
with the help of the materials and components that they got
the scraps and they discussed to use easy available materials
to finish the entire product. Antonim durna (2014), this article
deals with the modification of the nozzle and its entire
assembly with a hot end, so that it was not necessary to use a
Teflon insertion and to reach the maximum temperature of the
nozzle. Rina Abdullah et al (2017), they developed an
automatic temperature control system for smart tudung saji
(sweet) using arduino microcontroller which helped us to know
the design behind interfacing the microcontroller and the
temperature sensor equipment. Kreiger et al (2014), here they
• P.Ravichandran is currently working in Kongu Engineering College,
Erode,
Tamilnadi,
India,
PH-6374304743.
E-mail:
prc.mts@gmail.com
• C.Anbu is currently pursuing master degree program in Mechatronics
Engineering in Kongu Engineering College, Tamilnadu, India.
• R.Poornachandran, M.Shenbagarajan and K.S.Yaswahnthan are
currently pursuing under graduate degree program in Mechatronics
Engineering in Kongu Engineering College, Erode, Tamilnadi, India.
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INTERNATIONAL JOURNAL OF SCIENTIFIC & TECHNOLOGY RESEARCH VOLUME 9, ISSUE 01 , JANUARY 2020
discussed the different types of materials that can be used for
3D printer applications and their properties of the material
based on melting temperature and solidifying temperature.
Meera Mohan et al (2017), in this project they have
researched and studied about the different types of
temperatures sensors that can be used in different
applications to measure the desired temperatures. Seyeon
Hwang et al (2015), in this project he had studied and
analyzed about the different types of materials that can be
used in the filament extrusion process and also their different
mechanical properties that has to be consider while selecting
a filament. Adhiyamaan and S.H.Masood (2014), have
presented a study of dynamic and mechanical properties of
fused deposition Modelling (FDM) on rapid prototyping
processed material such as acrylonitrile butadiene styrene. It
involves the measurement of damping properties of the
material as it is deformed under stress.
Lihan Huang and
Joseph Sites (2007), proposed a paper of automatic control of
microwave heating process for n package pasteurizing of beef
frankfurters which helps used how to control the temperature
for the process.
ISSN 2277-8616
2.3 Proposed Solution
In proposed method, the whole setup of the machine is
reduced to a table top extruder and also it is portable which
can be carried out to any places. The setup consists of a
hopper where the granules or ABS pellets are loaded and it is
made to flow through a pipe with the help of wooden drill bit
where the material is heated and melted with the help of
heating cartridge .Then, these temperature values are loaded
into arduino UNO which automatically controls the
temperature between a specified range. Automating the
process, decreasing the requirement of the labour, Can be
used in small scale industries especially in institutions, The
system contains simple controls which is flexible to the
operator neglecting the need for skilled labour.
3 METHODOLOGY
The methodology and stages in designing of the proposed
model is shown in the Figure 3.1
2.1.1 Summary of the Literature
A detailed literature survey provides information about the
technology used in developing a table top 3D printer and
analysis of ABS and other plastic granule material. Hence it is
decided to use ABS material as a raw material for this work.
The control of temperature during the extrusion process is an
important one in this work, because it has to be maintained
between specified temperatures. The controlling of
temperature is done by using micro controller control system.
2.2 Existing System
The existing machine which is used for extruding the 3D
printer filament is usually huge in size and it is also not
adoptable for every place especially for small scale industries
and also in institutions for laboratory purposes. These types of
machines need high and frequent maintenance and also a
trained labor to operate this and it is also not cost effective
when it is being used by the institutions or small scale
industries. The existing system 3D printer filament extruder is
shown in the Figure 1. The disadvantages of the current
method is increase in machine cost, required trained labor,
only suitable for large scale industries, Cost of maintenance is
high.
FIGURE 2. METHODOLOGY
4
FEASIBILITY STUDY
Feasibility study aims to objectively and rationally uncover the
strengths and weaknesses of the existing business or
proposed venture, opportunities and threats as presented by
the environment, the resources required to carry through, and
ultimately the prospects for success. The purpose of the
feasibility study is resource determination.
4.1 Economic Feasibility
As the proposed project consists of less mechanical structure
and less electronic kits are involved in it the cost onof the
project is comparatively low i.e. is 75% reduction when
compared to the existing model or machine. Hence the
proposed model will be feasible to implement and will reduce
the cost.
FIGURE 1. EXISTING SYSTEM
4.2 Operational Feasibility
Since the project possesses only a simple additional
programming into the Arduino, there is no complex process
involved in the process. As extruding operation happens
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INTERNATIONAL JOURNAL OF SCIENTIFIC & TECHNOLOGY RESEARCH VOLUME 9, ISSUE 01 , JANUARY 2020
automatic and the human intervention is needed only on
loading and setting the melting temperature of the material.
Being a simple process, even a unskilled labor can do this
process very efficiently.
4.3 Technical Feasibility
Technical success of the system relies upon the work
expected from the mechanical and electrical section. The
fabrication of the project is simple it contains simple
mechanical structure. The integration of the sensors and other
electronic components are simpler and easy to integrate and
work.
5
DESIGN SPECIFICATIONS
5.1 Conceptual Design
ISSN 2277-8616
9
DC Fan
12V DC
10
Motor controller
12V DC
11
I2C Module
5V DC
6 FABRICATION PROCESS
6.1 CAD Modelling
Designing is the most important stage of any product. This
machine is designed using solid works software. Initially the
part drawings were made to the dimension specified and then
the parts are assembled as shown in Figure 4. The reason for
choosing solid works over AutoCAD is the fact that the ease
with working in the former one. Figure 4 shows the solid-works
model of the proposed system.
FIGURE 3. 3D PRINTER FILAMENT EXTRUDER
CONCEPTUAL DESIGN
From the conceptual design the morphology analysis is made
as follows and with the help of Design Data book various
components suitable for each function in the process are
selected.
5.2 Components
Based upon the design calculations and according to the need
as required in the project, the components are carefully
selected and listed in the Table 1.
FIGURE 4. SOLIDWORK MODEL OF THE PROPOSED
SYSTEM
6.2 Electrical Section
The electrical section consists of microcontroller circuit, relay
circuit. All the circuit connections are given with the
microcontroller circuit which is built using a microcontroller
development board. Relay board has relays which convert the
signals from the microcontroller to actuating components. The
Proteus model of the project is shown in the Figure 5.
TABLE 1. COMPONENTS USED
S.No.
Components
Descriptions
1
Thermister
5V DC
2
Relay module
5V DC, 230V AC
3
Drill bit
Wood
4
Heating Cartridge
12V DC
5
Microcontroller
Arduino Uno
6
DC Motor
12V DC
7
LCD Display
5V DC
8
Cylindrical pipe
½ inch dia
FIGURE 5. PROTEUS MODEL
The signals from the microcontroller cannot be directly used
for outputs.so the required voltage is achieved by relays.
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ISSN 2277-8616
6.3 Mechanical Section
The mechanical section consists of frame or chassis which
forms the base of the prototype on which the extruder, hopper
and electronics system can be placed. The mechanical section
consists of frame for horizontal setup which is fixed and frame
to cylindrical pipe which has a drill bit fixed inside it. A slot is
made on the cylindrical pipe and a hopper is fixed on it where
the ABS pellets are loaded. A die is fixed at the end of the pipe
with the specified diameter of hole in it through which the
filament extrudes.
FIGURE 7. 3D PRINTER FILAMENT EXTRUDER
SETUP
6.4 Working Principle
Figure 6 shows the block diagram of the proposed system
which involves the process.
7
CONCLUSION AND SCOPE FOR FUTURE
7.1 Conclusion
The prototype for 3D printer filament extruder was successfully
developed. The developed system has the ability to produce
filaments from the wasted materials during the process. The
whole setup is miniaturized as possible which is a portable
one and can be adopted to small scale industries and also to
educational institutions. This developed product reduces
maintenance; no trained labours are required and overall
reduce the operating cost and investment of the machine. The
greater accuracy and control over the process can be
achieved. Real time implementation of this system may
require some changes in design according to the need of the
customer.
FIGURE 6. BLOCK DIAGRAM OF THE
PROPOSED SYSTEM
The whole setup consists of two sections, mechanical and
electrical. The mechanical setup consists of a hopper which is
fitted on the cylindrical pipe is used to load the ABS granules.
A wooden drill bit which is used to drive the pellets is placed
inside the cylindrical pipe. A DC motor or actuator is used to
rotate the drill bit inside the pipe and the speed of the motor is
controlled with the help of a 12V DC motor controller. Two
heating cartridge of 12V DC is clamped on the pipe to heat
and melt the filament and a temperature sensor(Thermistor) is
also clamped on it to measure the temperature and it is
controlled within a specified range with the help of the
microcontroller and also the temperature values can be
viewed on LCD display. Once the granules are loaded and the
motor is turned on the drill bit starts to rotate and this bit
carries the granules from the hopper to the die through the
cylindrical pipe. During this time the material is heated and
melted inside the pipe with the help of heating cartridge which
is clamped on the pipe and the sensor senses the temperature
and sends feedback to the controller which keeps the
temperature within the specified range. Then this melted
material comes through the die as a filament and gets
solidified on room temperature. In order to increase the
solidification process a 12V DC electrical fan is placed on both
the sides of the die to cool it and the filament is fed to the roller
to roll it. The full set up of the proposed model of filament
extruder is shown in Figure 7.
8 REFERENCES
[1] Adhiyamaan Arivazhagan, Masood.S.H., 2014,
Dynamic
Mechanical
Properties Of ABS Material Processed by Fused
Deposition
Modelling,International
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of
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and
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2(03),pp.2009-2014.
[2] Antonim Durna, 2017, Modification Of The Nozzle
Assembly in a 3D Printer For Printing Materials With
Higher Melting Temperatures, Chinese Journal of
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[3] Alvaro Goyanes Fused-filament 3D printing of drug
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Pearce.M., 2014, Life Cycle Analysis of Distributed
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of
Post-consumer
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Density
Polyethylene for 3D Printing Filament.
[5] Mark D Grooms, 2016, Filament Extruder for
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Das, Mitchell Jihnson.D., Parminder Singh Badwal,
Doug Mclean, Lan Gibson, 2017, A Low corbon
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[7] Rina Abdullah, Zairi Ismael Rizman, Nik Nur Shaadah
Nik Dzulkefli, Syilaizawana Ismail, Rosmawati Shafie,
Mohammad Huzaimy Jusoh, 2016, Design an
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ISSN 2277-8616
Automatic Temperature Control System for Smart
Tudung Saji Using Arduino Microcontroller, ARPN
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[8] Seyeon Hwang, Edgar Reyes, Kyoung Sik Moon,
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