Rapid prototyping by FFF

RAPID PROTOTYPING BY "FUSED FILAMENT FABRICATION" (FFF)

GABRIELA CLEZAR RIBEIRO

TUTOR: PIERRE-JACQUES LIOTIER

2

SUMARY

INTRODUCTION

WHAT IS A 3-D PRINTER?

FUSED FILAMENT FABRICATION

REP RAP

CONCLUSION

PERSPECTIVES

3

INTRODUCTION

• 1980 – Industrial 3D printers in order to

rapid prototyping and research

• 2003 – Growth of the 3D Printer and

reduction of the cost → more accessible to

consumers

• 2010 – RepRap project can do a 3D printer

replicable : ↓↓ cost

INTRODUCTION



REP RAP

MECHANICAL CONSTRUCTION

ELECTRONIC MOUNTING

SOFTWARE INSTALLATION

CONCLUSION

PERSPECTIVES

CHOSEN MODEL

4

Overall objective:

• Develop metal parts from rapid prototyping using

the combination of RP with lost-wax casting

Means used:

• Buy 3D printer

• Build 3D printer

• Print a polymers parts

• Study of the wax and the temperature to be used

• Make a nozzle to print with wax

• Adapt other parts

• Printing with wax (not enough time to do the job)

• Improve wax printer (not enough time to do the job)

INTRODUCTION



REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES

5


• Its is the printout of real objects from 3D drawings

• How to do this?

• This is done in layers, the virtual 3D object is cut

into layers 2D and it is printed layer by layer

• It’s used in traditional rapid prototyping

• Advantages: speed, ↓ cost, possibility of color

• Fields: jewelry, footwear, design, architecture,

engineering, automotive, aerospace, dental,

education and many others

INTRODUCTION



REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES

6

• Methods of 3D printing:

• Molten polymer deposition like fused filament

fabrication

• Granular materials deposition, like selective laser

sintering

• Photopolymerization, like digital light processing

• Chosen Fused filament fabrication for its low

cost, practicality, possibility several studies

INTRODUCTION


REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES


7


Thermoplastic is liquefied and extruded by a nozzle that

follows a path defined by software

• The object is printed from the bottom up trough an

extruder nozzle

• Layers ≈ 0,04 mm thick

• The nozzle of the extruder can move in the 3D in

relation to base and it’s heated to melt the extruder

material.

• The machine is controlled by a numerical mechanism.

• Can be used different kinds of materials, with different

properties of strength and melt temperature.

INTRODUCTION



REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES

8

• Advantages:

• FFF provides tools for procedure of product

development and realization of the rapid feedback

of the design.

• Low geometrical limitation.

• Limitations:

• Materials – polymers and ceramics.

• Rare metals parts

• The RepRap Project is an initiative that proposes

this kind of printer with replicability and in a low

cost: reason for the choice

INTRODUCTION



REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES

9

REP RAP• Replicating Rapid-prototyper:

• Print all parts in plastics and requires electronics, motors, metal

rods.

• Use a free software → Open Source designs

• Copyleft attitude → the author impose restrictions: copies,

distribution and modification, but same rights in the all versions

• Why?

• Diffusion of knowledge

• Collaboration in developing technology

• There is already one association in Saint-Etienne linked to the Ecole de

Art et Design (ESADSE) that uses a 3D printer → Le Garage

INTRODUCTION



REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES

10

Chosen Model• We choose a mendel model and bought a

printed prototype

INTRODUCTION



REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES

11

INTRODUCTION



REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES

• Our assembled prototype

12

INTRODUCTION



REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES

• Reference axes of the machine

• The plate can move in the Y-axis• The X-axes can move the extrusion

nozzle by the x direction and can move up and down the Z-axis

13

INTRODUCTION



REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES

• Axe y

• Axe x

• Axe z

14

Mechanical Construction

Assembly plan

INTRODUCTION



REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES

INTRODUCTION



CHOSEN MODEL

15

INTRODUCTION



REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES

REP RAP

CHOSEN MODEL


CHOSEN MODEL

16

Improvements• Problems with some dimensions

• Improve some

parts

INTRODUCTION



REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES

REP RAP

CHOSEN MODEL


CHOSEN MODEL

17

Electronic Wiring

• We use a RAMPS 1.4, a motherboard MEGA

2560 and the endstops.

INTRODUCTION



REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES

18

Improvements

• The RAMPS assembly

plan isn't the same

that we had

• We did not know

where were the

connectors:

• We was verified with

the voltmeter

INTRODUCTION



REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES

REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


19

Software Installation

• We use linux

• We downloaded and installed the necessary

software

• It need do a firmware on the motherboard

• So that the motherboard connect to the

software, which interprets the 3D planes

INTRODUCTION



REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES

20

CONCLUSION

• We are far of the overall objective, but we already

have made good progress

• I hope the printer starts to work until the end of

the project

• It's a first step to a laboratory with practical

studies

• in the rapid prototyping by FFF

• Free software

• Replicability machines

INTRODUCTION



REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES

21

PERSPECTIVES

• Print the first part in polymer

• Choose of the wax or waxes

• Make a nozzle to print with wax

• Adapt other parts

• Prints with wax

• Develop metal parts from rapid prototyping

• Using the combination of RP with lost wax casting

• Use of lost-wax casting with quality and complex

patterns with lower cost and shorter times

INTRODUCTION



REP RAP

CHOSEN MODEL


ELECTRONIC MOUNTING


CONCLUSION

PERSPECTIVES

22

BIBLIOGRAPHY• CREATE IT REAL.. 3D Printer technology. Retrieved on:

http://www.createitreal.com/index.php/en/3d-printer/48, accessed on February 12.

• GNU OPERATION SYSTEM. What is copyleft?. Retrieved on: < http://www.gnu.org/copyleft/ >, accessed on February 12.

• KOCHAN, D.; CHUA, C. C.; ZHAOHUI, D. Rapid prototyping issues in the 21 st century. Retrieved on: <http://www.graco.unb.br/alvares/DOUTORADO/omega.enm.unb.br/pub/doutorado/disco3/papers/primeira_pesquisa_bibliografica/telemanufatura70.pdf>, accessed on February 12.

• LE GARAGE. La associatio Le Garage. Retrieved on: <http://legarage-gpl.org/legarage>, accessed on February 12.

• LILLI MANOLIS SHERMAN. 3D Printers Lead Growth of Rapid Prototyping. Retrieved on: <http://www.ptonline.com/articles/3d-printers-lead-growth-of-rapid-prototyping>,accessed on February 12.

• ROBERT A. GUTH. How 3-D Printing Figures To Turn Web Worlds Real. Retrieved on: <http://www.zcorp.com/documents/194_2007-1212-Wall%20Street%20Journal-3DP%20Turns%20Web%20World%20Real.pdf>, accessed on February 12.

• WILLIAM PALM. Rapide prototyping printer. , 2002. Retrieved on: <http://www.me.psu.edu/lamancusa/rapidpro/primer/chapter2.htm#applications>, accessed on February 12.

• WIKIPEDIA. 3D Printing. Retrieved on: <http://en.wikipedia.org/wiki/3D_printing#cite_ref-17>.accessed on February 13.

• REPRAP.ORG. About the RepRap project. Retrieved on: <http://reprap.org/wiki/RepRapWiki:About>,accessed on February 13.

Date post:	07-May-2015
Category:	Technology
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Rapid prototyping by FFF

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