INTRODUCTION
Problems
Candy evokes nostalgic memories of childhood and is a beloved treat enjoyed globally While often associated with sweetness and color, this article focuses on the fascinating aspect of candy shapes These shapes are typically formed using molds or crafted by skilled artisans, with molds offering limited designs and artisans providing a vast array of creative options We will explore the innovative combination of these two methods to create unique and artistic candies.
In today's world, automation has become a well-known concept that significantly benefits businesses through innovative technologies Automated systems are increasingly demonstrating their ability to save labor, energy, and materials while enhancing quality and precision.
Automation technology plays a crucial role in developed countries, particularly in the food industry, by enhancing productivity and ensuring quality Its implementation reduces human error while also improving hygiene and safety standards As automation continues to evolve, its significance in boosting efficiency and innovation within the food sector becomes increasingly vital.
The 3D printing industry represents a significant trend in the fourth industrial revolution, transforming the production of complex parts through minimal operations In recent years, the application of 3D printing technology in the culinary field has garnered attention from researchers, although it remains underexplored in Vietnam Implementing 3D printing in the food sector, particularly for product creation and decoration, can propel the Vietnamese food industry forward This technology allows for the efficient production of candy and other food items, replacing traditional manual methods with machine-based processes, thus saving time and enabling large-scale manufacturing.
The scientific and practical significance of the topic
3D printing has transformed object creation, including the candy industry 3D candy printers hold both scientific and practical importance, enabling the production of intricate shapes and designs that are challenging or unfeasible to achieve manually.
2 technology also allows for the creation of custom candies that can be tailored to individual tastes and preferences o Scientific significance:
3D candy printers exemplify the innovative use of 3D printing technology in food production, enhancing food printing techniques and enabling the creation of intricate, customized food designs.
Candy printers utilize specially formulated edible materials to create intricate shapes and structures The development of these materials involves extensive research and experimentation to ensure they meet safety standards while also providing the right texture and taste for successful printing.
The integration of 3D printing technology in candy making requires a deep understanding of ingredient behavior and the printing process Researchers are able to investigate innovative techniques and refine printing parameters, ultimately enhancing the quality, consistency, and efficiency of candy production This advancement holds significant practical implications for the confectionery industry.
3D candy printers offer the ability to create customized candies featuring intricate designs, personalized messages, and unique shapes This advanced level of customization not only enhances the consumer experience but also provides opportunities for make-to-order gifts, event decorations, and branding purposes.
3D candy printers enable confectioners and individuals to unleash their creativity by transforming intricate designs into edible masterpieces These printers allow for the precise production of detailed patterns, logos, and sculptures, elevating the artistic expression within the candy-making industry to new heights.
3D candy printers enhance manufacturing efficiency and flexibility by automating the production of complex candy shapes and designs, significantly reducing manual labor This technology streamlines processes, saving both time and resources Additionally, the flexibility of 3D printing enables rapid prototyping and small-batch production, eliminating the necessity for costly molds or tooling.
3D-printed candies offer a unique novelty that captivates consumers, with their distinctive shapes and designs enhancing visual appeal This innovative approach makes candies more engaging and memorable for individuals of all ages, presenting an opportunity to attract a wider audience.
3 confectionery companies to differentiate their products and capture consumer attention in a competitive market
3D candy printers significantly enhance confectionery manufacturing by pushing creative boundaries, allowing for personalized designs, and offering consumers unique experiences.
Research objectives of the topic
⮚ To research the current state of 3D-printed food and analyze its implications in the confectionery industry
⮚ To design a 3D candy printer that meets specific requirements and challenges associated with printing edible candies
⮚ To manufacture and test the 3D candy printer, evaluating its performance and quality in producing customizable candies
⮚ To assess the potential impact of 3D candy printing on the confectionery industry and identify future possibilities for advancement.
Research subjects
+ 3D printer frame has a cube form (according to 3 axes x, y, z)
+ Candy print head (with heating, observation, and adjustment)
+ MKS Mini12864 V3.0 Mini LCD12864 Display Controller 3D Printer
+ LCD Unit 12864 GLCD Liquid Crystal Screen Tablet LCDS
Research methods
The team has been guided by the instructor to thoroughly address the topic, conducting extensive online research and observing real machines These efforts have led to the identification of essential requirements and the establishment of research directions for the group's model.
✔ Literature Review: Conduct a comprehensive review of existing literature, academic papers, patents, and technical documentation related to candy 3D printing
✔ Experimental Studies: Conduct controlled experiments to investigate specific aspects of candy 3D printing
✔ Material Development: Research and develop new edible materials suitable for the 3D printing of candies
✔ Printing Techniques: Investigate different printing techniques and technologies for candy 3D printing
✔ Sensory Evaluation: Conduct sensory evaluations to assess the taste, texture, and overall sensory qualities of 3D-printed candies
✔ Food Safety and Quality Assurance: Investigate food safety considerations related to candy 3D printing
✔ User Feedback and Consumer Studies: Conduct surveys, interviews, or focus groups to gather feedback from consumers or potential users of 3D-printed candies
✔ Process Optimization: Explore optimization techniques for improving the efficiency, speed, and accuracy of candy 3D printing.
Graduation project structure
The graduation project consists of 6 chapters, which are:
Chapter 2 refers to the theoretical basis
Chapter 4 is about design calculations
Chapter 5 selects the components and circuit systems
FUNDAMENTAL THEORY
Overview of 3D printers
In the 1980s, the foundation of 3D printing was laid with the invention of Stereolithography (SLA) by Charles Hull, who subsequently co-founded 3D Systems Corporation This innovative process utilized a UV laser to solidify layers of liquid photopolymer, resulting in the development of the first-ever 3D printer.
- The 1990s: Other additive manufacturing technologies, such as Selective Laser Sintering (SLS) and Fused Deposition Modeling (FDM), were developed, expanding the range of materials that could be used for 3D printing.[6]
Figure 2 SEQ Figure_2 \* ARABIC 1: The first 3D printer - SLA technology
Figure 2.1: The first 3D printer - SLA technology
Figure 2.2: Engineer Charles Hull is the first 3D printer manufacturer in the world (Photo: Live Science.)
- In the early 2000s: 3D printing gained traction in industries like aerospace and automotive for rapid prototyping and production of specialized components.[6]
- Improved Resolution and Materials: Advances in hardware, software, and materials led to higher-resolution prints and the ability to work with a wider range of materials, including metals and ceramics
- Increased Speed and Efficiency: Ongoing developments focused on enhancing printing speeds and overall efficiency, making 3D printing more practical for various applications
In 2009, Adrian Bowyer launched the RepRap project, which pioneered the idea of self-replicating 3D printers capable of manufacturing many of their own components This innovative initiative significantly contributed to the rise of affordable desktop 3D printers, transforming the landscape of personal manufacturing.
- Consumer Accessibility: In the following years, several companies began manufacturing and selling consumer-oriented 3D printers at more affordable prices, making the technology accessible to a wider audience
- Expanding Material Options: New materials, such as carbon fiber composites, flexible filaments, and bio-compatible polymers, have been introduced, enabling a broader range of applications
The first version of Reprap Figure 2.3: The first version of Reprap
3D printing has revolutionized the medical field by enabling the creation of personalized implants, prosthetics, and detailed anatomical models Recent advancements in bioprinting are driving significant progress in tissue engineering and regenerative medicine, offering promising solutions for future healthcare challenges.
- Industrial and Manufacturing Applications: 3D printing has been embraced in industries such as architecture, automotive, aerospace, and fashion for rapid prototyping, tooling, and even end-use part production
2.1.5 Current State and Future Directions
- Today, 3D printing continues to grow rapidly with ongoing advancements in speed, precision, and material capabilities
- Focus on Sustainability: Efforts are being made to develop eco-friendly materials, improve recycling processes, and reduce waste generated during 3D printing
- Customization and Personalization: Increasing adoption of 3D printing enables personalized and on-demand production, catering to individual needs and preferences
- Integration with Industry 4.0: 3D printers are being integrated with automation, robotics, and Internet of Things (IoT) technologies, allowing for remote monitoring, data exchange, and automated production processes
A 3D printer is a device that creates three-dimensional objects by adding successive layers of material based on a digital design or model
It uses various printing technologies, such as Fused Deposition Modeling (FDM), Stereolithography (SLA), Selective Laser Sintering (SLS), and others, to build objects layer by layer
The 3D printing process consists of several key steps: first, a digital 3D model is created or sourced using computer-aided design (CAD) software or 3D scanning Next, slicing software prepares the model by dividing it into thin cross-sectional layers Following this, the appropriate printing material, such as plastic filament, resin, or powdered material, is loaded into the 3D printer Finally, the printer either heats or liquefies the material for Fused Deposition Modeling (FDM) or Stereolithography (SLA), or selectively sinters or fuses it using Selective Laser Sintering (SLS) technology to build each layer.
The printer meticulously adds layers sequentially until the complete object is created After the printing process is finished, the object often needs additional finishing touches, which may include the removal of support structures, sanding, or painting for a polished appearance.
- Prototyping: 3D printing is widely used for rapid prototyping to validate designs, test functionality, and identify potential improvements before mass production
- Manufacturing: It is increasingly utilized for small-scale production of specialized parts, customized components, or limited production runs
- Education: 3D printers are used in educational settings to teach design, engineering, and manufacturing principles, allowing students to bring their ideas to life
- Healthcare: Medical applications include the production of patient-specific implants, prosthetics, anatomical models for surgical planning, and even 3D-printed organs in the field of bioprinting
- Architecture and Construction: 3D printing is employed for creating detailed architectural models, scale replicas, and even large-scale building components
- Art and Design: Artists and designers use 3D printers to create intricate sculptures, jewelry, fashion accessories, and other artistic creations
- Fused Deposition Modeling (FDM): Most common and affordable type, extrudes thermoplastic materials layer by layer
- Stereolithography (SLA): Uses a UV laser to solidify liquid resin layer by layer, producing high-resolution prints
- Selective Laser Sintering (SLS): Utilizes a high-power laser to selectively sinter powdered materials, such as plastics, metals, and ceramics
- Digital Light Processing (DLP): Similar to SLA but uses a digital light projector to cure the resin
- Binder Jetting: Bind's layers of powdered materials using a liquid binding agent
- Metal 3D Printers: Specialized printers that use metal powders, employing technologies like Direct Metal Laser Sintering (DMLS) or Electron Beam Melting (EBM)
- Materials: The range of printable materials continues to expand, including advanced composites, metals, ceramics, and bio-compatible substances
- Speed and Scale: Ongoing advancements focus on increasing printing speeds and enabling large-scale printing for bigger objects or even building structures
- Bioprinting: Progress in 3D printing living cells and tissues holds promise for applications in regenerative medicine and drug testing
- Industry 4.0 Integration: 3D printers are being integrated with automation, robotics, and IoT technologies
Products on The Market
The Ultimaker S5 is a high-quality, professional 3D printer known for its reliability and large build volume With dual extrusion capabilities, it enables the production of intricate models and multi-material prints, making it an ideal choice for advanced 3D printing needs.
12 Double spool holder with NFC cable
The Formlabs Form 3 is a highly regarded desktop SLA 3D printer that delivers exceptional print quality and user-friendly operation By employing a laser to cure liquid resin, it produces precise and intricately detailed prints, making it a top choice for both professionals and hobbyists.
The Prusa i3 MK3S+ is a popular open-source FDM 3D printer known for its affordability and reliability It offers a large build volume, advanced features, and high-quality prints
The Creality Ender 3 Pro is a budget-friendly FDM 3D printer suitable for beginners and hobbyists It offers decent print quality, a stable frame, and a compact design
7 Material rack and spool holder
The LulzBot TAZ 6 is a dependable FDM 3D printer known for its large build volume and versatility It offers an open filament system and auto-leveling capabilities, along with a sturdy frame that ensures high-quality and consistent prints.
Figure 2.19: Direct-drive and Bowden tool head Figure 2 SEQ Figure_2 \* ARABIC 18:
LulzBot TAZ 6 Figure 2.18: LulzBot TAZ 6
Common Types of Candy
Chocolate bars are delicious confections made from sweetened and flavored chocolate, available in diverse varieties such as milk, dark, and white chocolate These treats often include extra ingredients like nuts, caramel, or nougat, enhancing their flavor and texture.
Examples: Snickers, Kit Kat, Twix, Milky Way
Hard candies are created from cooked sugar syrup that solidifies upon cooling, resulting in a wide array of shapes, sizes, and flavors Designed for slow dissolution in the mouth, these treats offer a delightful and lasting taste experience.
Examples: Jolly Ranchers, Life Savers, Werther's Original
Gummy candies are characterized by their soft and chewy texture, made primarily from gelatin, sugar, and flavorings, and are available in various shapes and flavors Similarly, jelly candies share this chewy consistency but are usually fruit-flavored and have a translucent appearance.
Examples: Gummy bears, Gummy worms, Jelly beans
Figure 2.20: Hard Candy Figure 2.20: Hard Candy & Chocolate Bars
Licorice candy, a delicious and chewy treat, is primarily made from the extract of licorice root Available in a variety of forms such as twists and ropes, it can be either soft or firm, and is often enhanced with additional flavors.
Caramel candies are made by heating sugar, butter, and cream to create a smooth and creamy texture Toffee is similar to caramel but is often harder and more brittle
Examples: Werther's Original, Milk Duds, Heath Bar
Figure 2.22: Gummies and Jelly Candies
Figure 2.24: Caramel and Toffee Figure 2.21: Gummies and Jelly Candies & Scandinavians and Salty Black Licorice
Sour candies are known for their tangy and acidic taste They often have a coating of sour sugar or a sour flavor infused into the candy itself, providing a sour sensation
Examples: Sour Patch Kids, Warheads, Sour Skittles
Marshmallows are soft and spongy candies made from sugar, gelatin, and flavorings They have a light and fluffy texture and are commonly used in desserts or as a topping
Examples: Marshmallow Peeps, Rocky Road, Marshmallow Twists
Mints are candies with a refreshing and often minty flavor
They are known for their breath-freshening properties and are available in various forms, including hard candies, chewable tablets, or coated chocolates
Example: Altoids, Tic Tacs, After Eight
Here, our group research focuses on 3D printing hard candy
Figure 2.23: Sour Skittles Candy & Marshmallows
Figure 2.24: Big Sky – Premium Tinned Mints & Candy
Formula and Raw Materials
- Formula: 200g sugar, 90g glucose syrup, 1-2ml food color, 2-4ml flavoring, 3g citric acid,
Sugar is a crystalline carbohydrate known for its sweet taste, widely utilized as a sweetener in food and beverages Sourced from sugarcane and sugar beets, it plays a crucial role in numerous products, including candies, baked goods, desserts, and drinks.
Glucose syrup, often referred to as corn syrup or liquid glucose, is a thick and sweet syrup produced through the hydrolysis of starch, primarily from corn This syrup is predominantly composed of glucose molecules and serves multiple purposes in the food industry, acting as a sweetener, thickener, and humectant It is widely used in confectionery, baking, and as an essential ingredient in many processed foods.
Food color, also known as food dye or food pigment, is a substance used to add or enhance color in food and beverages Available in liquid, powder, and gel forms, food colors can be derived from both natural and synthetic sources They are commonly utilized in a variety of products, including candies, baked goods, beverages, and processed foods, to boost visual and consumer appeal.
Flavoring substances are added to food and beverages to provide specific tastes and aromas, available in natural or artificial forms such as liquids, powders, and extracts These flavorings enhance or replicate flavors like fruit, vanilla, and chocolate across a diverse range of products Citric acid, a natural acid found in citrus fruits, adds a tart flavor and serves as an acidifying agent, enhancing taste and acting as a preservative in items like soft drinks, candies, jams, and sauces.
FDM Method (Fused Deposition Modeling)
Fused Deposition Modeling (FDM) is a 3D printing technique that utilizes thermoplastic materials like PLA and ABS In this process, a filament is heated and melted as it passes through the nozzle, allowing it to be precisely deposited onto the printing bed in layers that match the cross-sectional dimensions of the design.
The layers created during the printing process match the thickness of the cutting layer As the printing progresses, melted plastic fuses together, forming a cohesive layer until the entire sample is complete.
FDM is a cheap 3D printing technology, easy to repair and replace machinery details
FDM technology is efficient for large-scale production, utilizing fewer raw materials and is particularly suited for products requiring bearings Its rapid 3D shaping speed sets it apart from other methods like SLA, LOM, or SLS, which rely on lasers for product creation The simplicity, ease of maintenance, and high reliability of FDM fast-pitching technology make it an attractive option for manufacturers.
FDM fast modeling technology uses non -toxic, odorless thermoplastic material, and therefore will not pollute the surrounding environment The device works to create less noise
Rarely used in assembly because the accuracy is not high Universal bearing capacity
- Heat the nozzle until it reaches the desired temperature The filament will be fed to the extrusion head and then it will melt in the nozzle
The extrusion head operates in the X, Y, and Z axes, allowing it to extrude melted material in fine strands This material is deposited layer by layer onto the platform, where it cools and solidifies.
Once a layer is completed, the build platform descends (or the extrusion head ascends on certain machines) to allow for the deposition of a new layer This cycle continues until the part is fully formed.
Figure 2.28: Principle of Operation of FDM Method Figure 2.25: Principle of Operation of FDM Method
ORIENTATION AND SOLUTIONS FOR MANUFACTURING 24
Machine parameters
- Resolution of a printed layer: from 2 to 5
Machine structure design options
Cartesian transmission: This structure of the printing table moves in the Y direction; the print head will move in the XZ direction
Two XY axes use the belt transmission, Z axis uses a screw screw transmitter - nut
● The advantages of this structure are:
- Simple structure, easy to execute
- Cheap cost, relatively high hardness
- The accuracy of the printing sample is not high
- Because the printing table moves, it is easy to make the first printing class
- Due to the large volume of mobile structures, the inertia is large, easy to vibrate
Use the Delta robot structure, using belt transmission
- High print speed, fast and gentle movement
- Large print size, especially height
- High accuracy and continue printing when a part of the product has been completed
- Complex in design and assembly Causing difficulties in the process of construction and maintenance of printers
- Difficult to overcome when having problems compared to other models
- Limitations in printing complex shapes
In this structure, the printing table will move in the Z direction, the plastic nozzle moves in the XY direction
The two Axles use the belt transmission according to the Corexy structure, the Z axis uses a screw screwdriver
- Simple structure, easy to install
- Can be printed at higher speed than the Cartesian - XZ structure and equivalent to the Delta structure
- Small mobile structures should be small inertia, softer machine
- Equivalent accuracy or higher than the Delta machine
- Difficult to align the print table
- The size of the machine may be slightly large and bulky.
Select the option
Through the discussion of our group choosing option 3, moving according to the Core XY method helps to move effectively and faster than the remaining options.
The order of execution
- Calculation of belt drive design for the XY axis
- Calculate the design of the screw-screw driving drive for the Z axis
- Designing and processing machine parts
- Select and calculate the electric parts
MECHANICAL DESIGN
Chassis Design
The team opted for a profiled aluminum chassis for their 3D printer design, as it effectively meets the requirements without bearing heavy loads This choice not only reduces costs but also facilitates easy disassembly and maintenance, ensuring efficient repairs when needed.
- Dimensions of aluminum profiles used are: 20x20 aluminum profile
- Machining method of machine frame assembly:
+ The machine frame is the most important part, bearing the largest force and ensuring the accuracy of the machine, so it requires high precision when machining
+ It is required to ensure the size of the aluminum bars and their perpendicularity when assembling
+ The aluminum profiles are cut with an alloy blade table saw to ensure the flatness of the section when cutting
+ Aluminum bars are joined together by right angle kegs to ensure perpendicularity, CNC mills ensure flatness and perpendicularity.
Design of the Z axis mechanical assembly
The Z axis, while the least active during operation, significantly impacts product quality due to its role in determining the thickness of printed layers This thickness parameter directly influences the accuracy of the final product, as well as the shadow effects and dimensional tolerances related to the height of the part.
- Normally, for the Z axis, we can use a lead screw - a nut, a lead screw - a ball nut, or a belt
The belt drive system offers a compact design, quiet operation, and ease of implementation; however, the vertical movement of the Z axis can lead to belt slippage In contrast, the lead screw drive with a ball nut is preferred for the Z axis due to its high efficiency, minimal slippage, and quiet functionality.
4.2.1 Calculation of drive lead screw – ball nut on Z axis
The system operates with a maximum part mass of 1 kg, resulting in a weight of 10 N It achieves a maximum travel speed of 20 mm/s and a printing speed of 5 mm/s, with an operating acceleration of 2 mm/s² The engine runs at 1000 rpm and is designed for an operating time of 21,900 hours Additionally, the coefficient of surface smooth friction is set at 0.1, ensuring efficient movement and performance.
When selecting a screw mounting type, there are three commonly used options: fixed-fixed, fixed-support, and fixed-free The fixed-fixed type features two screw heads that are securely fastened, offering high rigidity and the ability to withstand significant loads while minimizing Z-axis vibrations; however, it presents a complex structure that can be challenging to install In contrast, the fixed-support type utilizes a lead screw mounted with a ball bearing, providing lower rigidity and medium load capacity compared to the fixed-fixed option.
The fixed-free mounting type features a straightforward design with a free lead screw, making it easy to install However, it has a low load capacity similar to that of fixed-support mounting and offers less rigidity compared to fixed-fixed mounting types.
Figure 4.: Fixed – Free type Figure 4.4: Fixed - Support type
For the structure of the printer table, because the Z axis moves about 300 mm, we choose the fixed - fixed type
Figure 4.: Vitme Z-axis Figure 4.6: Vitme Z-axis
• The largest vertical force when not machining: 𝑭 𝟏𝒎𝒂𝒙 = 𝟏𝟐 𝑵
• Maximum vertical force when processing: 𝑭 𝟐𝒎𝒂𝒙 = 𝟖 𝑵
• 𝑭 𝟏𝒎𝒂𝒙 , 𝑭 𝟐𝒎𝒂𝒙 : The largest vertical force when not processing and processing
• 𝒏 𝟏𝒎𝒂𝒙 , 𝒏 𝟐𝒎𝒂𝒙 : The maximum rotation speed of the axis when not processing and processing
• 𝒕 𝟏𝒎𝒂𝒙 , 𝒕 𝟐𝒎𝒂𝒙 : The machine time operates in non-load mode and load
Table 4.1: Vertical force and percentage respectively
- Calculation of load: o Static load:
• 𝒇 𝒔 : Static durable coefficient, with tool 𝒇 𝒔 = 𝟏, 𝟐 ~ 𝟐
• 𝑭 𝒂𝒎𝒂𝒙 : The largest vertical force acting on Vitme
For l = 8 mm => nominal rotation speed is:
- L = total length of max moving + nut length, bearing/2 + area length escape = 200 + 30 +
- The type of bearing is fitted at both ends -> f = 3.4
- Choose the rotation speed for the engine about 80% compared to the limited rotation speed, so we have n = 80% Nmax = 80% 1000 = 800 rpm
4.2.2 Calculation of motor for the Z axis
Figure 4 : Calculation of motor (RepRap Calculation) Figure 4.7: Calculation of motor (RepRap Calculation)
Figure 4.8: Optimal layer height for your Z axis (RepRap
Figure 4.8: Optimal layer height for your Z axis (RepRap Calculation)
We selected a Nema 17 stepper motor, measuring 42mm x 42mm x 48mm, based on its static torque and a speed of 1000 RPM.
Table 4.2: NEMA Step Motor Parameters 17
Describe Length Load Moment holds Moment inertia Mass
NO mm Amps Nm g.cm 2 g
Figure 4.10: Step Motor Figure 4.10: Step Motor
Coupling
- The joint is a part of the machine that is responsible for transmitting moments between two different axes [4]
The joint features an axial connection, a clutch, and an automatic clutch, making it ideal for 3D printers Typically, elastic joints made from aluminum alloy are preferred due to their compact size and capacity to transmit high torque effectively.
- We choose the soft joint, because the motor diameter is
5mm, and the selected type of two ends of the shaft is 5 - 8.
Mechanical design of the X axis
4.4.1 Mechanical design of XY axis cluster
The XY axis cluster parameters:
- Working length: Sx = 200 mm; Sy = 200 mm
- Operating time: TL = 21900 h (5 years, 12 hours per day)
The project utilizes a CoreXY transmission structure for its dual-axis system, which is a modified version of Cartesian coordinates This design enables simultaneous movement in two directions, allowing for precise point location within the coordinate system While the CoreXY structure offers several advantages, it also presents certain drawbacks that must be considered.
One key advantage is the presence of two motors that work in coordination, providing greater torque This allows the system to support larger volumes or utilize two smaller engines, which can still effectively transmit power to the axis.
One drawback of simultaneous engine operation is the potential for errors and interference when sending pulses to the engines This coordination can lead to accumulated errors in both engines, ultimately impacting the device's overall performance.
The primary advantage of this transmission type is its speed In many 3D printers, like the Prusa, the Mendel engine is located on the moving parts, which increases the mass and reduces print speed However, this design features lightweight mobile components that minimize inertia, allowing for faster printing speeds.
The CoreXY structure offers a straightforward design that allows for easy installation using just support panels and bearing clusters to guide the belt Its advantages include low installation costs, flexibility in material selection, and compatibility with a diverse range of materials.
When both motors rotate in the same direction, they create movement along the X axis; conversely, when the motors turn in opposite directions, they generate movement along the Y axis.
To select the ideal Nema 17 stepper motor, consider the essential torque of the transmission clusters, step-by-step division, suitable shape and size, cost, popularity, and quality Utilize the parameters outlined in Table 4.2 to make an informed choice that meets your specific requirements.
Choosing the sliding rails
To enhance accuracy and prolong operational time in printing, it is essential to utilize sliding rails for the XY shaft cluster, which is responsible for most of the motion Key factors influencing the choice of sliding rails include machine precision, rigidity, operational duration, and cost considerations The two most crucial aspects when selecting high-quality sliding rails are their load capacity and durability By integrating these parameters, one can ensure optimal load capacity while achieving the best economic value in guide sliding rail selection.
For 3D printers due to the light load requirement, we choose the MGN sliding rail Specifically, slide MGN9H
Figure 4.14: Two different CoreXY belts Figure 4.14: Two different CoreXY belts
Table 4.3: Slide parameters guide MGN9
Figure 4.16: Parameters of sliding rails
Figure 4.16: Parameters of sliding rails
Maximum load calculation on sliding rails
- The distance between 2 other sliding rails: c = 350 (mm)
- The distance between the two slides with the rail: d = 0 (mm)
- The force acting on the axis: F = 0 (n)
- The distance from the force to the center of the axis Y: a = 0 (mm)
- The distance from the force to the center of the axis in the direction X: b = 0 (mm)
- The maximum formula for calculating the force is placed on the sliding life: (4.14)
𝟐 𝒅 Because there is no external force acting on the axis system, the formula can be reduced
With W = m.g = 4.10 = 40 (N), Where M is the mass placed on 2 guide axes
The static load coefficient C0 is determined by the permissible load limit Excessive load or widespread impact on the guide rail can lead to increased concentrated deformation between the leading channels and rollers If this deformation surpasses the allowable limit, it can obstruct the movement of the sliding rail.
Static torque plays a crucial role in determining the final position of the roller on the guide rail, as it experiences the highest pressure due to the distribution of force across the entire roller system The permissible static moment is categorized into three groups, denoted as 𝑴 𝑹.
Static safety factor depends on working and operating conditions A large safety coefficient ensures the system is operated safely and limits impact
In there: 𝑪 𝟎 is 4KN static load coefficient
P is the maximum force placed on sliding rails, P = 20 N
Figure 4.17: The way the Static Momen is allowed to slide Figure 4.17: The way the Static Momen is allowed to slide
We have a static safety factor:
Thus, the meetings are satisfactory
The nominal life expectancy of guide rails is influenced by the actual working load, which can be calculated using the dynamic load and working conditions Additionally, environmental factors such as track stiffness, temperature, and movement conditions significantly impact the longevity of the rail system, making them essential considerations in durability calculations.
In which: L is a nominal life expectancy (km)
To maximize load capacity, rail hardness should be maintained between 58 and 64 HRC A hardness level below this range will lead to a reduced lifespan Additionally, both static and dynamic load capacities are influenced by the hardness coefficient, as illustrated in the accompanying graph It is essential to select a hardness factor of 𝒇 𝑯 = 1 to meet the required standards.
Figure 4.18: Hard and coefficient relationship
Figure 4.18: Hard and coefficient relationship
The temperature coefficient, denoted as 𝒇 𝑻, indicates that when temperatures exceed 100 degrees Celsius, the nominal life expectancy of materials decreases Consequently, both static and dynamic load capacities must be adjusted by this temperature coefficient in calculations Since some rails are composed of plastic and rubber, it is essential to maintain temperatures below 100 degrees Celsius For this analysis, we have selected a temperature coefficient value of 𝒇 𝑻 = 0.95.
The load coefficient, denoted as 𝒇𝒘, is essential for accurately assessing the working load of the Ray, as the actual load tends to be higher than initial calculations This discrepancy arises from vibrations experienced during high-speed operation and impacts during machine startup and shutdown Consequently, it is crucial to factor in the load coefficient, as detailed in the accompanying table.
The impact and slight vibration 15 < V ≤ 60 1,2 ~ 1,5
Based on Table 4.5, we select the load coefficient 𝒇𝒘 = 𝟏, 𝟐
C is the load coefficient of sliding life, C = 2.85KN
Figure 4.19:The relationship between temperature and coefficients
The operating time of sliding rails is:
𝑽 𝒎𝒂𝒙 = 60 mm/s = 1000 m/min, 𝑽 𝒆 is the operating velocity
The X-axis carries a small load, so to make it synchronized and easy to design, we use a sliding life for the X-axis similar to the Y-axis.
Design and process details
For parts that are not available on the market, we designed several details with the main material of aluminum to accomplish the structural assurance
The extruder is made of stainless steel to get a long -lasting heat retention as well as ensure food safety so as not to be infected with metal when exposed
Table 4.6: List of details to be processed
Name Details Quantity Material Processing method Note
Processing the location of the hole to catch the slide
Processing the location of the hole to catch the slide
Processing the location of the hole to catch the slide
Processing the location of the hole to catch the slide
Processing the location of the hole to catch the slide
Processing the location of the hole to catch the slide
Processing the location of the hole to catch the slide
Processing the location of the hole to catch the slide
Machining the right size with the smallest error possible
Machining the right size with the smallest error possible.
Design of candy mix extrusion unit
4.7.1 Designing extrusion head on software
To extrude candy effectively, utilize a cylinder mechanism that applies pressure to the heated candy within the pipe, enabling a printing operation that aligns with the movement speed of the printing head structure.
Figure 4.20: The print head is designed in Solidwork Figure 4.20: The print head is designed in Solidwork
4.7.2 Calculating input materials i Start by deciding on the specific candy design you want to print, including its size, shape, and complexity The design will dictate the amount of material required ii The software should provide you with the volume measurement, typically in cubic millimeters (mm³) or cubic centimeters (cm³) iii Determine the layer thickness you plan to use for printing This refers to the vertical height of each printed layer The layer thickness will affect the number of layers required to build the candy and, consequently, the material needed iv Divide the total height of the candy by the layer thickness to determine the number of layers required Round up to the nearest whole number v Different edible materials used in 3D candy printing have varying densities Check the specifications or consult the manufacturer to determine the density of the specific material you are using The density is typically measured in grams per cubic centimeter (g/cm³) vi Multiply the volume of the candy by the number of layers calculated in step 4 to get the total volume of material needed vii Multiply the total volume of material by the material density to convert it to mass This will provide an estimate of the amount of material required for the print, typically measured in grams (g)
Note: It's important to note that these calculations provide estimates and may not account for factors like wastage, support structures, or variations in print quality
ELECTRICAL SYSTEM DESIGN
Introduction of electrical systems
The electrical system includes: MKS gene circuit board L V2.1, MKS Mini Screen
12864, Step Motor Nema 17, Driver A4988, Journey switch, Burning head, thermal sensor, and honeycomb source
Figture 5.1: Diagram of electronic components
Figture 5.2: Block diagram Figure 5.1: Diagram of electronic components
Microcontrollers
The project utilizes the MKS gene circuit board L V2.1, known for its user-friendly design that caters to beginners Its widespread availability in the market makes it a popular choice, while the straightforward programming language and easy hardware connectivity enhance its accessibility.
The MKS Gen L V2.1 control board is widely used in applications like 3D printing, laser cutting, and CNC engraving, making it a versatile choice for control and automation It is compatible with various step motor drivers, including A4988, DRV8825, and TMC2130, ensuring precise and stable motor control The integration of Mega 2560 and RAMPS chips on a single circuit board optimizes space and enhances operational stability Additionally, high-quality components and superior MOSFETs improve cooling efficiency and load capacity compared to RAMPS 1.4.
5 Support for heat supply AD597/PT100
11 LCD support LCD2004, LCD12864, MKS Mini, OLED
12 Support software Simplify 3D, KISSlicer, Cura, Repetier host…
14 Support printer type Machine 3 -axis X, Y, Z, Detal, I3, Core XY
Driver
The driver is crucial for controlling step motors, as it interprets signals from the main control board and generates the necessary electrical impulses for motor activation By fine-tuning the timing and frequency of these impulses, the driver ensures precise control over the rotation and movement of the step motor Among the various options available, the A4988 and DRV8825 drivers are particularly popular in 3D printer applications.
The A4988 Driver is a compact yet versatile component that supports multiple operating modes and allows for engine adjustments Additionally, it includes an automatic power shut-off feature that activates when the temperature exceeds safe levels, providing essential protection for the system.
Figture 5.3: MKS gene circuit board L V2.1 Figure 5.3: MKS gene circuit board L V2.1
50 engine and control circuit Driver A4988 provides many operating modes for the step motor, including: Full, 1/2, 1/4, 1/8 and 1/16 mode
- Compatible with the engine Step 2A (8VV ~ 35V)
Figture 5.5: Driver connected to MKS Gen L V2.1
Figure 5.5: Driver connected to MKS Gen L V2.1
Switch journey
The cruise switch is a crucial device that restricts the movement range of machinery, robots, and other automated systems The MKS Gen L V2.1 features a circuit that accommodates up to six pins for the journey switch, allowing for defined minimum (min) and maximum (max) positions for each axis.
The Endstop module switch is a crucial component in 3D printing, featuring a compact circuit design that integrates an LED, resistor, and journey switch This circuit is engineered for seamless connectivity with microcontrollers, ensuring efficient operation of the 3D printer switch.
Figture 5.6: System of the legs of Driver A4988
Figure 5.6: System of the legs of Driver A4988
3D printer designs to determine the point of the axis journey, the switch is designed to be easy to use with the accompanying plug wire and active indicator light
MKS Mini Screen 12864
The MKS Mini 12864 screen is a compact graphic display designed for 3D printer control and CNC machines, featuring a resolution of 128x64 pixels and monochromatic output This screen simplifies communication and saves space, connecting easily to microcontrollers like MKS Gen L or Arduino through SPI or I2C interfaces It effectively displays critical information such as temperature, movement speed, the 3D printing process, and error notifications Additionally, users can manage their devices using integrated control buttons, including up, down, and selection options.
The MKS Mini 12864 is compatible with widely used firmware options like Marlin, Repetier, and Smoothieware, facilitating seamless integration and configuration for users It's important to remember that the specific features and characteristics of the screen may differ based on its version and manufacturer.
- Software support Marlin2.0 and Kipper
- Support online adjustment of LCD of the backlight
- Support for installing Gcode backlight, such as: M150 R100 G100 U100
- Support color changes in different states during printing
- Compatible with logic signals 3.3V and 5V at the same time
- SPI communication with the microcontroller server
- Use an SD card socket to order
- There is vertical and side SD slots
Heated
The plastic burner, or printer thermal set, is a crucial part of a 3D printer, primarily responsible for heating the candy extruder Its main function is to heat the candy and facilitate its movement to the print head for effective printing.
- Heating bar, 3D plastic printing heat
- Burning size: 6x20mm (diameter x length)
Temperature sensor
Temperature control is crucial in 3D printing and candy printing, as sensors enable the controller to monitor both the extruder and table temperatures Inaccurate readings of either temperature can lead to subpar printing results, compromising the quality of the final product or even preventing successful prints altogether.
Figture 5.9: 3D printer plastic head Figure 5.9: 3D printer plastic head
In this project, use a 100k NTC temperature sensor with high sensitivity and fast reaction It has a compact structure, easy installation, good temperature range
- High-temperature Teflon temperature: 200 degrees Celsius
- Operating temperature range: -40 degrees C ~ +300 degrees Celsius
- Coefficient of heat sink: 5 MW / C (Static air)
- Heat time constant: 7s (air static)
Power block
The power block serves as the crucial energy supply component for the entire electrical system in 3D printers To ensure optimal operation, it is essential that the power supply maintains a stable voltage and current at all times.
We have 2 options for the power supply of the 3D printer, using honeycomb source or Liteon source
When selecting the right power supply, it's essential to assess the devices in the circuit and their specific voltage and current requirements By understanding the needs of each electrical component, you can effectively identify the most suitable power source Below are some electronic components along with their voltage specifications.
Figture 5.11: Honeycomb source & Liteon source
Figure 5.11: Honeycomb source & Liteon source
Figture 5.12: Wiring diagram Figure 5.12: Wiring diagram
CHAPTER 6: IMPLEMENTATION EXPERIENCE AND RESULT ANALYSIS
Implementation experience
The first test run (when the machine is stable) gave the result as shown in Figure 6.1
The size of the output at the printer was 1.5 mm
- In this test, the printed results are not satisfactory for the following reasons:
+ The extrusion quantity was not uniform, the printing speed was faster than the extrusion quantity
+ The temperature was not enough to loosen the media
+ The printhead temperature was just enough to loosen the print media
+ Pulse adjustment to reduce print speed and increase printhead extrusion speed
Figure 6.: Test results 1 Figure 6.1: Test results 1
The size of this print volume was 1.55 mm
The printing speed was observed to be 20% slower than the initial print, indicating that the coating maintained a high level of stability Additionally, the amount of extruded material remained relatively consistent, suggesting reliable performance throughout the process.
+ The print speed and extrusion speed were just enough to be able to print, but the smoothness of the print layer was still quite rough
+ The temperature this time was 10 degrees Celsius, higher than the last time at the measured temperature of 80 degrees Celsius
- What needed to be adjusted is the right temperature and amount to print consistently
Figure 6.: Test results 2 Figure 6.2: Test results 2
Having given quite a good smooth result through many adjustments, we were able to print the best shape of the product
The print size is 1.6 mm
In our recent printing experiments, we maintained consistent temperature and printing speed while adjusting the printing layer parameters This approach allowed us to evaluate the printed layer size and coating thickness effectively After conducting multiple tests, we successfully established the optimal parameters for our printing process.
Figure 6.: The fifth experiment Figure 6.3: The fifth experiment
After conducting numerous experiments to gather data for producing quality products, it is crucial to recognize that the temperature of the candy differs from that of the chocolate chips, which have lower melting temperatures and require specific testing conditions.
Print files via Cura software
The software used to handle the design file is Cura software which is often used for 3D printer benefits
First, go to Cura software, and select the printer that has already set parameters
Figure 6.: Print by other files Figure 6.4: Print by other files
Then put the printed file (note that the field taken here is the file with the tail ‘ stl’)
When putting the file in the product to be printed, it will be displayed on the work area of the printer installed in advance
Install the printed parameters on the above toolbar to adjust the print speed, temperature, number of printing layers, and support
Figure 6.: Select the installed machine
Figure 6.: The work area is displayed and the product needs to be printed
Figure 6.5: Select the installed machine
Figure 6.6: The work area is displayed and the product needs to be printed
After installing the printing parameters, click "Slice" below to proceed to divide the printing class
Through the process of dividing the “ stl" file printing class will be compiled in the form of “ Gcode" to run 3D printers
After performing the steps above, we through the "Preview" section to conduct the printing of printed layers
Figure 6.: Click on Slice Figure 6.7: Select the toolbar
Save the file to the disk and pass it through the SD card to carry through the printer to perform the construction.
Working principle
- After supplying materials -> Start the printer
- Adjust the temperature to suit the ingredients
- Select the print file -> When the temperature is up enough to print -> Start printing
- After completing the print head will be returned to "home" -> Finished printing
The material is loaded into a container, where it is heated and extruded Utilizing the FDM printing method, 3D printing becomes accessible due to its popularity and relatively low technological complexity, making it straightforward to carry out 3D printing operations.
Figure 6.: Print layer simulation Figure 6.9: Print layer simulation
CONCLUSION
Result
The latest 3D printer operates reliably, producing smooth prints through careful adjustments The quality of the printed products demonstrates the project's capabilities effectively.
The machine is capable of operating in a spacious environment, tailored to the specific case being refined It effectively regulates temperature to melt the printing material, adjusting according to the type of candy being produced.
Currently, the candies used are the type with low melting temperature and fast winter time like: chocolate chip…
3D printing, while innovative, is slower than traditional candy manufacturing methods due to its layer-by-layer approach, which can significantly extend production time, particularly for intricate or large designs This reduced speed may impact the overall output and efficiency of candy production.
Figure 7.: 3D candy printer Figure 7.1: 3D candy printer
When considering 3D candy printers, it's essential to note that their print size and build volume can significantly impact candy production Many printers have limitations that prevent the creation of large or life-sized candies, and a restricted build volume may also reduce the number of candies produced simultaneously.
Achieving high print resolution and a smooth surface finish in 3D-printed candies can be challenging due to the layering process, which often leads to visible layer lines and rough textures These imperfections can significantly affect the aesthetic appeal of the final product.
When printing intricate candy designs, the use of support structures is often necessary to maintain stability and precision However, these supports must be manually removed after printing, which can be a time-consuming process that may involve additional post-processing steps.
3D candy printers and their materials can be costly, particularly when investing in high-quality, professional-grade equipment It’s essential to factor in ongoing expenses such as maintenance, replacement parts, and edible materials to assess the overall feasibility of 3D candy printing.
Ensuring food safety and compliance with regulations is essential when using 3D candy printers The edible materials utilized in the printing process must adhere to health and safety standards to guarantee that the final candies are safe for consumption.
Development
- Upgrade the print material extrusion unit
- Adjusted the mechanism and improved the Z-axis movement
- Improve print speed, research and innovation will focus on optimizing printing processes, enhancing printer hardware and refining material formulations to reduce print time and increase production output
- Currently, the range of edible materials available for 3D candy printing is somewhat limited so further research is needed
- Integrated advanced features such as sample scanning, intelligent operation, control and self-adjusting parameters depending on the printed material
- Strengthen research on printing materials to suit the content of substances meeting safety standards
Trong bài viết "Tính toán thiết kế hệ thống truyền động và lựa chọn hệ thống dẫn hướng dùng cho máy phay CNC" của tác giả Nguyễn Văn Thuận, Trường ĐH Bách Khoa Hà Nội, tác giả trình bày quy trình thiết kế hệ thống truyền động cho máy phay CNC, nhấn mạnh tầm quan trọng của việc lựa chọn hệ thống dẫn hướng phù hợp Bài viết cung cấp các phương pháp tính toán và tiêu chí đánh giá hiệu suất của hệ thống, nhằm tối ưu hóa hoạt động và độ chính xác của máy phay CNC.
[2] Nguyễn Hữu Lộc, Cơ sở thiết kế máy, NXB ĐHQG Tp.HCM, 2016
Thiết kế và chế tạo máy in 3D sử dụng cơ cấu COREXY là một nghiên cứu quan trọng của nhóm tác giả gồm Nguyễn Cảnh Hà, Nguyễn Trọng Kha và Trần Văn Lân Nghiên cứu này được thực hiện tại Trường Đại học Sư phạm Kỹ thuật Thành phố Hồ Chí Minh vào tháng 7 năm 2023 Việc áp dụng cơ cấu COREXY trong máy in 3D hứa hẹn mang lại hiệu suất cao và độ chính xác tốt hơn trong quá trình in ấn.
[4] PGS.TS Trịnh Chất, TS Lê Văn Uyển, Thiết kế hệ dẫn động cơ khí tập 1, Nhà xuất bản Giáo Dục
[5] Trần Ngọc Nhuần (2006),” Phương pháp tính truyền động đai răng”, Tạp chí Khoa học – Công nghệ Thủy sản
[6] “The History of Additive Manufacturing: From The 1980s to Today | Prototal UK.” https://prototaluk.com/blog/history-of-additive-manufacturing/ (accessed Jul 01, 2023)
Some reference websites: https://icdayroi.com https://www.thegioiic.com https://3dlinhkien.com https://sakuravn.com.vn https://technicalvnplus.com https://xtmechanicalblog.com https://www.youtube.com