Design and Construction of a Belt-Assisted Vertical Extrusion Based Fused Deposition Modeling 3D Printer for Automated Part Removal

Abstract

Abstract In recent years, Fused Deposition Modeling (FDM) has become one of the most used three-dimensional (3D) printing processes because of its cost effectiveness and universal approach towards user-friendliness. FDM uses a layering process to build 3D models layer-upon-layer using a varied range of materials from thermoplastic to pharmaceutical materials. However, FDM has a considerable number of challenges to overcome, especially for its use in line production. One possible solution for a more line-production friendly FDM process could be the use of a continuous moving build surface, similar to more conventional line production processes. In this paper, we propose a customized FDM 3D printing system with a moving belt-style build surface and kinematics that allow layers to be printed parallel to the build surface. Unlike other existing belt-FDM systems, the developed FDM printer will deposit filament perpendicular to the bed, allowing the user to utilize conventional 3D printing slicing software, depend less on support structures, and design parts in a traditional manner. Moreover, after completion, these parts can be ejected automatically to allow repeated prints without human intervention, making the printing process faster and more cost-effective. A belt-assisted vertical extrusion based FDM prototype 3D printer has been designed, constructed, and then tested to gain experimental data on continuous 3D printing using thermoplastic polymers as a printing material. Results of testing and experimentation verified certain key design elements and how they could improve continuous printing and automated 3D printed part removal. Experiments also revealed how nozzle temperature, bed temperature, and the moving speed of the nozzle introduce challenges not seen in traditional FDM printers with static beds.