Ex. No. 6 - SIMULATION OF FUSED DEPOSITION MODELING PROCESS

DATE: 27-05-2023

AIM:

To simulate the Fused Deposition Modeling (FDM) process.

REQUIREMENTS:

System - Windows 7 or higher, 1 GB RAM.

PROCEDURE:

STEP 1: Click on 'Base'. Base and Build Platform will be displayed on the left side of the screen.

STEP 2: Click on 'Extruder' then extruder and extruder nozzle will be displayed.

STEP 3: Click on 'Material Spool' then material spool will be shown.

STEP 4: Click on 'Filament' then filament will be added.

STEP 5: Click on 'Start Process' to begin the process.

STEP 6: After the process is complete click on 'Stop Process' to view product generated using FDM process.

OUTPUT:

Step 1:

Base:

Explanation:

In Fused Deposition Modeling (FDM), the build platform is an essential component of the 3D printer. It serves as the foundation on which the object being printed is constructed layer by layer. The build platform needs to be sturdy and properly leveled to ensure accurate and consistent printing.

The build platform is typically made of a solid material, such as aluminum or glass, which provides a flat surface for the object to be printed. Some 3D printers may also have a heated build platform to help improve adhesion between the first layer of the object and the platform. The heating can prevent warping and promote better layer adhesion, especially for materials like ABS.

A foam base, as you mentioned, is not typically used as a component of the build platform in FDM printing. However, a foam base can be used as a surface to support and protect the build platform. It can provide cushioning to minimize the risk of damage to the platform or the printed object during the printing process.

The foam base may also help with leveling the build platform by providing a soft surface that can conform to slight irregularities or variations in the build platform's flatness. Additionally, the foam base can help absorb vibrations and reduce noise generated by the 3D printer.

Step 2:

Extruder:

Explanation:

In the Fused Deposition Modeling (FDM) process, the extrusion nozzle and extrusion head are integral parts of the 3D printer. They play a crucial role in depositing the molten filament material layer by layer to create the printed object. Here's a breakdown of their functions:

Extrusion Nozzle:

The extrusion nozzle, also known as the hot end or print head nozzle, is a small cylindrical component at the end of the printer's extruder assembly. Its main function is to melt and extrude the filament material.

1.)Heating:

The extrusion nozzle contains a heating element, typically a small electric heater, that raises the temperature of the nozzle to the melting point of the filament material. This allows the filament to soften and become malleable for deposition.

2.)Filament feeding:

The extrusion nozzle has a narrow opening through which the filament material is fed. The filament is typically a thermoplastic material, such as ABS or PLA, which is loaded into the printer's extruder assembly.

3.)Material extrusion:

Once the filament material is heated and reaches the molten state, it is pushed or extruded through the nozzle's opening in a controlled manner. The extrusion nozzle determines the diameter of the extruded material, which affects the level of detail and resolution in the printed object.

Extrusion Head:

The extrusion head is a broader term that refers to the entire assembly that includes the extrusion nozzle along with other components responsible for filament feeding and movement. It encompasses the extruder motor, filament drive mechanism, and sometimes the cooling system.

1.)Filament feeding mechanism:

The extrusion head houses the filament drive mechanism, which can consist of a gear or a drive wheel that grips the filament and pushes it towards the extrusion nozzle. The motor in the extrusion head drives this mechanism, advancing the filament as required.

2.)Filament guiding:

The extrusion head also contains a filament guide tube or pathway that guides the filament from the spool to the extruder assembly. This ensures smooth and consistent filament movement during the printing process.

3.)Cooling system (if applicable):

In some 3D printers, especially those that print with materials requiring active cooling, the extrusion head may also include a cooling fan or fans. These fans help to rapidly cool the newly deposited material to solidify it before the next layer is added, preventing sagging or deformation.

Step 3:

Material Spool:

Explanation:

In Fused Deposition Modeling (FDM) process, the "build material spool" refers to the spool or reel that holds the filament material used for printing.

The filament material, typically in the form of a long, thin strand wound onto a spool, is fed into the 3D printer from this spool during the printing process. The spool holds a considerable length of filament, allowing for extended printing sessions without interruption.

The build material spool is typically placed on a spindle or holder located on the 3D printer itself. The filament is then fed through the filament guiding system, which leads it into the extrusion head where it is melted and deposited to create the printed object.

The spools can vary in size, material type, and color, depending on the specific filament being used. Some printers have built-in filament holders or spool compartments, while others may require external spool holders to be attached.

It's important to properly handle and store the filament spools to protect them from moisture and maintain their quality. This can involve using desiccant packs or storage containers with airtight seals to minimize exposure to humidity.

Step 4:

Filament:

Explanation:

In the Fused Deposition Modeling (FDM) process, filament refers to the material that is used as the feedstock for 3D printing. It is a long, thin strand of thermoplastic material that is typically wound onto a spool.

When selecting a filament, it's important to consider the desired properties of the printed object, such as strength, flexibility, heat resistance, and appearance. Additionally, each filament material may have specific requirements for printing parameters like temperature, nozzle size, and cooling settings. Always refer to the manufacturer's guidelines and recommendations for optimal printing conditions.

Filament is loaded into the 3D printer's extruder assembly, where it is fed into the extrusion head. The extrusion head heats the filament, melting it to a semi-liquid state, and then extrudes it layer by layer to build the object based on the 3D model.

Step 5:

Start Process:

Explanation:

Start the printing process:

Transfer the sliced file to the 3D printer. The printer will heat the nozzle to melt the filament, which will be deposited layer by layer according to the sliced file.

Build the base layer:

The printer starts by creating a base layer, also known as a raft or brim, which provides a stable foundation for the model and helps with adhesion to the build plate.

Build the model layers:

The printer moves the nozzle in a controlled manner, extruding molten filament to create each layer. The material solidifies quickly upon deposition.

Add support structures:

If the model has overhangs or complex geometries that require support, the printer may create support structures using a different material or the same material in a different configuration.

Step 6:

Stop Process:

Explanation:

Cool down and remove support:

Once the printing is complete, the model needs to cool down to ensure stability. If support structures were used, they can be removed by hand or using appropriate tools.

Post-processing:

Depending on the desired outcome, post-processing steps such as sanding, painting, or additional finishing may be performed to enhance the appearance and functionality of the printed object.

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