(Đồ án hcmute) design and implementation of a multicolor 3d printer

MINISTRY OF EDUCATION AND TRAINING HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION GRADUATION THESIS MECHATRONIC ENGINEERING TECHNOLOGY DESIGN AND IMPLEMENTATION OF A MULTICOLOR 3D PRINTER ADVISOR: VU QUANG HUY, PhD PHAM BACH DUONG, M.Eng STUDENT’S NAME: PHAM XUAN CHIEN STUDENT’S ID: 13146023 STUDENT’S NAME: NGHIEM LUONG HAI STUDENT’S ID: 13146057 STUDENT’S NAME: HA XUAN THANG STUDENT’S ID: 13146197 SKL 0 6 Ho Chi Minh city, July 2017 an UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING DEPARTMENT OF MECHATRONICS GRADUATION THESIS DESIGN AND IMPLEMENTATION OF A MULTICOLOR 3D PRINTER ADVISOR: VU QUANG HUY, PhD PHAM BACH DUONG, M.Eng STUDENT’S NAME: PHAM XUAN CHIEN (13146023) NGHIEM LUONG HAI (13146057) HA XUAN THANG (13146197) ACADEMIC BATCH: 2013 - 2017 MAJOR: MECHATRONICS Ho Chi Minh City, July 2017 an SOCIALIST REPUBLIC OF VIETNAM Independence - Freedom - Happiness *** Ho Chi Minh City, May 31th 2017 MISSION OF THESIS Student’s name: Pham Xuan Chien Student’s ID: 13146023 Nghiem Luong Hai 13146057 Ha Xuan Thang 13146197 Major: Mechatronics Class: 13146CLC Advisor: Vu Quang Huy, Ph.D Phone number: Delivery date: 20/2/2017 Submission date: 23/7/2017 Title of thesis: Design and implementation of a multicolor 3D printer The original data, documents: -Documents about assembly and calibration of 3D printer -Datasheets of electronic components -Articles of multicolor methods -The Firmware and slicer software from open source Main content: -Research on rapid prototyping -Design a model of 3D printer and implement it -Experiment 3D printed products through for analyzing and evaluating product quality Product: -A 3D printer has size of 200x200x100 mm, solid mechanics and stable operation -3D printed products have diverse colors, high precision and good surface quality Program Chair Advisor i an SOCIALIST REPUBLIC OF VIETNAM Independence - Freedom - Happiness *** ADVISOR’S COMMENT Student’s name: Pham Xuan Chien Student’s ID: 13146023 Nghiem Luong Hai 13146057 Ha Xuan Thang 13146197 Major: Mechatronics Title of thesis: Design and implementation of a multicolor 3D printer Advisor’s name: Pham Bach Duong, M.Eng COMMENTS The content of thesis and workload allocated: Advantages: Improvement points: Thesis defense approval: Yes  No  Evaluation remark: Grade: (in word: ) Ho Chi Minh City, July 2017 Advisor (Name, signature) ii an SOCIALIST REPUBLIC OF VIETNAM Independence - Freedom - Happiness *** REVIEWER’S COMMENT Student’s name: Pham Xuan Chien Student’s ID: 13146023 Nghiem Luong Hai 13146057 Ha Xuan Thang 13146197 Major: Mechatronics Title of thesis: Design and implementation of a multicolor 3D printer Reviewer’s name: Nguyen Vu Lan, Ph.D COMMENTS The content of thesis and workload allocated: Advantages: Improvement points: Thesis defense approval: Yes  No  Evaluation remark: Grade: (in word: ) Ho Chi Minh City, July 2017 Reviewer (Name, signature) iii an ACKNOWLEDGEMENT Firstly, we wish to thank our parents and our friends for their supports and encouragement throughout our study Secondly, we would like to express our gratitude to Dr Vu Quang Huy - the project supervisor, for his patient guidance, enthusiastic encouragement and invaluable comments on this project Thanks to his advices and assistances in keeping our progress on schedule Our grateful thanks are also extended to Mr Trung – the specialist in 3D printing workshop, for his supports in offering us the resources, troubleshooting and increasing the qualification of our 3D printing products They did contributed a lot in helping us to successfully complete project “Design and implementation of a multicolor 3D printer” In the implementation process of the project, there would certainly be some inevitable mistakes, we hope to receive your comments for future improvements Ho Chi Minh City, May 31th, 2017 Group of students: Pham Xuan Chien Nghiem Luong Hai Ha Xuan Thang iv an ABSTRACT In this project “Design and implementation of a multicolor 3D printer”, our group sets the goal to make a 3D printer that can print not only in single color but also in multiple colors automatically without changing the filament manually The printer is designed according to the Cartesian structure, with dimension of printing is 200x200x150mm The 3D printer model is designed on Solidworks according to the intended size Based on the model, we analyze and calculate to purchase and outsourcing materials For multicolor printing, we use the Diamond Hotend that has three inputs, one output and a small color mixing chamber Repetier host is used to choose color for product and send G-code to Arduino After months of project implementation, our group has achieved some results The 3D printer can print the product that has 200x200x100 mm dimension It operates smooth with an average speed of 40 to 60 mm / s Products with a slight deviation of 0.1 to 0.2 mm With the use of Diamond Hotend, the 3D printer prints products that has from one to four colors are quite good, the surface of them is smooth When printing five-color products, they are quite bad with the surface deformation Filament usually get stuck on Diamond Hotend Keywords: Rapid prototying, 3D printing, multicolor, Diamond Hotend, filament jam v an CONTENTS COVER PAGE PAGE MISSION OF THESIS i ADVISOR’S COMMENT ii REVIEWER’S COMMENT iii ACKNOWLEDGEMENT iv ABSTRACT v LIST OF ABBREVIATIONS viii LIST OF TABLES ix LIST OF FIGURES AND CHARTS x CHAPTER 1: OVERVIEW 1.1 The necessary of the thesis 1.2 Scientific and practical meanings 1.3 Research objectives of the thesis 1.4 Object and goal of the study 1.5 Research Methodology 1.6 Introduction to rapid prototyping technology [1] 1.6.1 General principles 1.6.2 Features 1.7 The introduction and development of the RAP method [9] 1.7.1 Early period: Manual Sampling 1.7.2 Second period: virtual prototyping or creation software 1.7.3 Third period: RAP process 1.8 Application of RAP CHAPTER 2: LITERATURE REVIEW 2.1 Some methods of template creation [10] 2.1.1 SLA method (Stereo Lithography Apparatus) 2.1.2 Solid Ground Curing (SGC) 2.1.3 LOM (Laminated Object Manufacturing) 2.1.3 SLS (Selective Laser Sintering) 10 2.1.4 3D FDM Printing Method (Fused Deposition Manufacturing) 11 2.1.5 Analysis of 3D FDM (Fused Deposition Manufacturing) 12 2.2 Multicolor printing solutions 13 2.2.1 Using multi nozzle 13 vi an 2.2.2 Palette method [4] 15 2.2.3 Diamond Hotend [7] 16 2.2.4 Multicolor filament [11] 17 2.3 The effect of temperature on the operation of the printing [8] 18 CHAPTER 3: DESIGN AND ANALYSIS 20 3.1 Mechanical design 20 3.1.1 The structure of 3D printer [3] 20 3.1.2 Analysis of axis-driven motors 23 3.1.3 Analysis of transmission mechanisms 26 3.1.4 Check the deviation on the axes 28 3.2 Electronic design 29 3.2.1 Controller unit [1] 29 3.2.2 Driver modules 31 3.2.3 Driver ICs 31 3.3 Control system 33 3.3.1 Repetier Console 33 3.3.2 Programming in Arduino 34 3.3.3 Adjust PID temperature of extruder [6] 35 3.3.4 Custom Slicing with Slice Software 36 3.3.5 Multi-material printing with Repetier Host 36 3.3.6 Interpolation 38 3.3.7 Convert data from CAD to G-code 39 3.3.8 Read and process G-code data 40 CHAPTER 4: EXPERIMENTS AND RESULTS 42 4.1 Modes of experiments: 42 4.1.1 Target value 42 4.1.2 Testing criteria 42 4.1.3 Manually control: 42 4.1.4 Automatic control: 43 4.2 Analysis and comments: 48 4.3 Bill of materials 51 CHAPTER 5: CONCLUSION AND RECOMMENDATIONS 52 REFERENCES 53 APPENDIX 54 vii an LIST OF ABBREVIATIONS ABS Acrylonitrile Butadiene Styrene CNC Computer Numerical Controlled CAD Computer Aided Design CAE Computer-aided engineering CAM Computer-aided manufacturing CMM Coordinate Measuring Machine FDM Fused Deposition Manufacturing LOM Laminated Object Manufacturing PLA Poly Lactic Acid FDM Fused Deposition Manufacturing STL Stereo lithography SLA Stereo Lithography Apparatus SGC Solid Ground Curing SLS Selective Laser Sintering SLS Selective Laser Sintering RAP Rapid prototyping viii an + Single color Figure Products with single color: red, cyan, yellow The printed products have a quality equivalent to a single color nozzle, sometimes stained with inactive extruders with only a small amount on layers + Multicolor Diamond Hotend not only can print independent color on a product but also mix color from or extruders Figure 4 Mixing color products When mixing color, the first layers of product are not actually print with mixed color It is still old colors The Diamond Hotend must print more than minutes then a new color appear Some good mixed color is: orange that mixed by red and yellow, green that mixed by yellow and cyan The mixed color between red and cyan is not really make a new color 44 an Figure Products with or independent color While printing, in order to ensure that the color is completely changed to the new color, it is necessary to print a small square cube of 15cm2 to help the nozzle to clean the old filament into a new color while printing in the square In Cura, this feature is called ‘Wipe and Prime Tower’ This gives the product the color of the set but quite waste plastic Figure Printing with “Wipe and prime tower” -Infill test Figure First layer 45 an While multicolor printing, the first layer usually still has many different colors because filaments aren’t ready to mix up or only one color was heated that make the first layer thin and deformed, while printing with one color is not When we adjust the nozzle more than 0.4 mm away from the bed, the filament will not stick to the bed This makes the first layer bad and the next layers are not in the correct position Figure Infill level The infill level is more high, the product is more solid and smooth but it takes long time to print.The vase with 40% infill is printed more than hours With 8% infill, the vase can be printed in hour 30 minutes -Precise test Some samples to measure the error Figure Samples is used for precise test 46 an Angle error test with sample and Table Angle error test with sample and Times Average Error Type Hexagon ( 60 60 60 60 60 60 o angle 60 ) Square (angle 90.5 89.7 89.8 89.5 90.2 89.94 0.06 o 90 ) Test height and diameter of sample with a height (h) of 20 mm, hole diameter (d) of 10 mm, circle diameter (D) of 20 mm The size of the sample is measured by caliper with the error of 0.02 mm Then we compared it with the size of the design model Table 4 Test height and diameter of sample Temperature Layer D d h Error of Error of d Error of h height D (%) (%) (%) 180 0.1 20.5 10.28 20.44 2.5 2.8 2.2 180 0.15 20.3 10.2 20.36 1.5 1.8 180 0.2 20.18 9.86 20.1 0.9 0.7 0.5 190 0.2 20.32 10.16 20.2 1.6 1.6 200 0.2 20.46 10.82 20.28 2.3 1.8 1.4 When changing the layer height from 0.15 to 0.2 mm, the error decreases in both diameter and height This means that the size of the sample is more accurate (less error) when increasing the layer height (layer height should always be smaller than the nozzle diameter), with the same temperature Beside that we also see, the higher of the temperature, the greater of the error -Contour error test Figure 10 Hexagon and circle profile 47 an With samples have simple profile, medium print size, products have smooth surface and little deformation Some simple profile like hexagon, square and circle, the machine operates smoothly, not fluctuate Otherwise, with complex profiles, small print size, products have many false profiles and rough surface While printing ‘Julia Vase’ with a small size 50x48x45 mm, the nozzle is strongly fluctuate Figure 11 Julia Vase 4.2 Analysis and comments: 4.2.1 Success rate With simple and small model and low time to printing in single color, the success rate is quite high ~ 80% On the other hand, if we print or colors, the success rate is approximately 70% With complex profile model, the success rate is decrease to 50% 4.2.2 Error causes findings While printing the model, the printer is still operating but the filament does not flow It usually occurs when using or extruders to printing, so the remains extruder will not operate The filaments are heated instead of flowing down the holes, it flows to Teflon tube of inactive extruder, cooled down and get stuck there This makes the filaments in that extruder cannot be extruded down again Figure 12 Filament stuck in Teflon tube The temperature when printing is too high make liquid melting filament that causing the filament to ooze on the product It is necessary to adjust the lower temperature so that the plastic is heated to a moderate level 48 an Figure 13 High temperature The product is mixed with three colors, a output of nozzle get stuck filament leading to the thin layer of product, different with parameter that we have set up This causes the product surface to be open due to lack of plastic We need to remove the nozzle and clean Figure 14 Error product due to filament jam The filaments flow out and stick on the nozzle, not touching the bed Due to the large impact of nozzle, the hole nozzle is no longer perpendicular to the bed, the filaments can’t flow straight down We need to replace the nozzle Figure 15 The filaments flow out and stick on the nozzle The product after printing is quite deviated, the deformation due to errors of axes So we need to precisely adjust axes of printer 49 an Figure 16 Deviated product 4.2.3 Possible solutions The filament jam problem is the most common problem in Diamond Hotend Our group has several methods to limit the problem to occur frequently: -Drain the filament in each extruder before printing -Do not let the temperature heat up without printing for more than 10 minutes -Reduce retraction distance of extruders -Add some fans to cool down the heat-sinks -Do not use one or two colors too much 4.2.4 Realistic specifications Structure Molding technique Print dimension Diameter of nozzle Material Layer thickness Printing Speed Precise Nozzle temperature Cartesian Fused Deposition Modeling 200x200x110mm 0.4 mm PLA, 1.75 mm diameter 0.1-0.3 mm 40-60 mm/s 0.2-0.4 mm 180oC – 200oC (Max temp:230oC) Stepper motor Printing file format Software Compatibility Working voltage Connection Machine size NEMA 17, Angular distance 1.8 degree STL, G-code Repetier Host, Cura, Slic3r Input: 220V, Output:12V COM, SD card 335*430*385 mm 50 an 4.3 Bill of materials Category Printed parts Rods Mechanical Parts Electronics Screws, Nuts, Washers Quantity 1 1 11 4 2 3 1 1 1 1 41 53 34 33 34 Name X Carriage X End Idler X End Motor Bowden tube Smooth Rod Ø8 Threaded rod M8 Linear Bearing LM8UU Aluminum profile 1m Bearing 624 Bearing 608 Belt GT2 Coupling 5*5 Motor Nema 17 Pulley GT2 Extruder Diamond Hotend Red, Yellow, Cyan filament Pulley Reprap Black Techflex Spiral Wrap RAMPS 1.4 Board Arduino Atmega 2560 Limit switches w/ cables Power supply w/ cables Stepper Expander Heat Cartridge LCD and SD memory card Fan - Quiet 50 mm Square Thermistor Screw M3x14 Screw M3x24 Screw M3x30 Screw M4x20 Screw M8x30 Washer Ø3 mm Washer Ø8 mm Washer Ø10 mm Nut M3 Nut M4 Nut M8 Nut M10 TOTAL Price (VND) 50.000 40.000 40.000 50.000 320.000 320.000 220.000 530.000 25.000 120.000 72.000 58.000 360.000 50.000 480.000 720.000 750.000 165.000 30.000 130.000 250.000 30.000 200.000 50.000 30.000 240.000 30.000 25.000 50.000 7.200.000 51 an CHAPTER 5: CONCLUSION AND RECOMMENDATIONS Conclusion: The 3D printers use FDM methods that are easy to use and the cost of designing is pretty cheap compared to other methods of styling During the test run, our team found many bugs encountered although the design was pre-calculated From those errors through the test run, we have improved and solved the problem due to the influence of the control parameters, thus finding the appropriate parameters for the machine's configuration to increase the accuracy of the prototyping Our 3D printer can make some multicolor products pretty good but also create many products with errors The phenomenon of the filament jam still happens quite often, we cannot completely overcome This isn’t meet our goals Developments: The goal that our group wants to accomplish is to make a larger-size 3D printer to print large size products without slicing the model to small models This makes us to print many and use glue to combine them together In order to have good first layer, we have to manually adjust screws to level the bed, which can be time consuming and tedious Additionally, this process often has to be repeated after several prints due to the possibility of the bed going out of alignment after several hours of use, so we also want to add ‘Auto bed leveling’ option by using an Inductive Sensor to our 3D printer to ensure the nozzle is always the perfect distance away from the print bed and a perfect first layer every time To limit filament jam, we want add some cooling surround nozzle to reduce temperature in heat sinks 52 an REFERENCES [1] Arduino, "https://store.arduino.cc/usa/arduino-mega-2560-rev3," 2013 [Online] Available: https://store.arduino.cc/usa/arduino-mega-2560-rev3 [Accessed 22 2017] [2] J Průša, "www.prusaprinter.com," 27 11 2016 [Online] Available: http://www.prusaprinters org/original-prusa-i3-mk2-multi-material-upgrade-release/ [Accessed 2017] [3] Makezin, "www.makezin.com," 10 2015 [Online] Available: http://makezine.com/2015/0 /10/cartesian-delta-polar-common-3d-printers/ [Accessed 22 2017] [4] Mosaic, " https://www.mosaicmanufacturing.com/," MosaicManufacturing, 2016 [Online] Available: https://www.mosaicmanufacturing.com/ [Accessed 20 2017] [5] Popolu, "Popolu.com," Popolu, 2013 [Online] Available: https://www.pololu.com/product/2133 [Accessed 20 2017] [6] R Sierra, "http://www.mibqyyo.com," 14 12 2015 [Online] Available: http://www.mibqyyo com/en-articles/2015/10/14/adjusting-the-pid-of-your-3D-printer/#/vanilla/discussion/embed /?vanilla_discussion_id=0 [Accessed 05 2017] [7] Reprap.me, "RepRap.org," RepRap, 15 2016 [Online] Available: http://reprap.org/wiki/Diamond_Hotend [Accessed 2017] [8] Swindon, "www.swindon-makerspace.org," 19 11 2014 [Online] Available: https://www.swindon-makerspace org/2014/11/19/how-to-3d-print-with-flexible-filaments/ [Accessed 25 05 2017] [9] T G Terry Wohlers, History of additive manufacturing, Newyork: Abastis, 2014 [10] T Quang, "cnc3s.com," CNC3S Co., Ltd., [Online] Available: http://vietcad.com.vn/vietcadforum/index.php/forum/vietcad/144-t-ng-quan-v-cong-ngh-t-o-m-u-n [Accessed 18 2017] [11] Unicofil, "http://www.unicofil.de/en/," Unicofil, [Online] Available: http://www.unicofil.de/ en/ [Accessed 20 2017] 53 an APPENDIX Appendix User Manual Open Repetier host, choose Config  Printer Settings to configure for 3D printer -In tab Connection, select ‘Port’ to connect 3D printer and ‘Baud Rate’ to transfer data -In tab Extruder: 54 an + Adjust ‘Number of Extruder’ to set the number of colors that you want + Set a checkmark in the box Printer has a Mixing Extruder + To enter a color representation in Repetier-Host of the mixed filament, for each of extrudes below enter a name, then click the color rectangle, click Define Custom Colors >> and enter the following Red, Green and Blue values: -In tab Scripts: +Click the drop down menu Scripts and select Script (alternatively select Start Code in order to use this color scheme every time you slice) +In order to setup colors on virtual extruders, we write in the text field below use command M163 and M164 + M163 - Set Mix Factor M163 [P] [S] with [P] is Mix factor [S] is Component index + M164 - Save Mix M164 S with S is Tool index (0 if none) +Examples: Save a 60/40 mix as tool index 5: M163 S0 P0.6 M163 S1 P0.4 M164 S5 -Slic3r's Printer Settings: 55 an +Go to General - Advanced - place a check mark next to "Use firmware retraction" +Go to Extruders (1, 2, etc) - Retraction - set Lift Z: as this behaviour is already set via firmware retraction +Open a connection to your printer via Repetier-Host and press Alt+E to edit ‘Marlin Firmware EEPROM Settings’ and enter your desired values, the default values are as follows:  Retraction length [mm]:  Retraction length extruder switch [mm]:  Retraction speed [mm/s]: 50  Retraction z-lift [mm]: 0.3  Extra extrusion on undo retract [mm]:  Extra extrusion on undo switch retract [mm]:  Retraction undo speed [mm/s]: 20 +Click OK to save settings to EEPROM and close the window -In tab ‘Object Placement’, add object and combine them to a group, select color for each part -In tab ‘Slicer’, select slicer software to slice object -After connection to the printer is established, in the right pane of the main window select the tab Manual Control and press the encircled number This will send the specific color scheme to the firmware -In tab ‘Print Preview’, click ‘Print’ 56 an Appendix MarlinFirmware https://drive.google.com/drive/folders/0B3qDWH77NbUbkd6cTEtUGUxVWs?usp =sharing Appendix Drawing of Diamond Hotend Appendix Random mixing color for printing https://drive.google.com/file/d/0B3qDWH77NbUMnVUcTg1a29Ubms/view?usp=s haring 57 an an ... kind of material so there will be no material jam Figure 15 Add material at the heat transfer location [8] 19 an CHAPTER 3: DESIGN AND ANALYSIS 3.1 Mechanical design 3.1.1 The structure of 3D printer. ..UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING DEPARTMENT OF MECHATRONICS GRADUATION THESIS DESIGN AND IMPLEMENTATION OF A MULTICOLOR 3D PRINTER ADVISOR: VU QUANG HUY, PhD PHAM... autotune and place them in the variables Figure 24 Adjust PID on Marlin firmware 3.3.4 Custom Slicing with Slice Software Each slice software have advantages and disadvantages, we use many software