A Material-Recycling Unit for the Fused Deposition Modelling of Three-Dimensional Printing Systems
<p>(<b>A</b>) Sub-assembly of the spooler system (front view). (<b>B</b>) Top view with a blue circle showing the clearance for the spool when turning around the motor axis.</p> "> Figure 2
<p>Single-piece design created for 3D printing. (<b>A</b>) Model ready for 3D printing. (<b>B</b>) Cross-sectional view of the model with no 90° roofs/overhangs. (<b>C</b>) fully assembled model.</p> "> Figure 3
<p>Sub-assembly of extruder system with transparency mode turned on for the barrel to show the auger bit.</p> "> Figure 4
<p>(<b>A</b>) Part front, which is placed on the build plate. (<b>B</b>) Chamfered overhang/roof (circled) to enable printing without supports in tight spaces.</p> "> Figure 5
<p>Sub-assembly of control and display system.</p> "> Figure 6
<p>Outer displayed case with circular cut-outs.</p> "> Figure 7
<p>Sub-assembly of the filament-positioning system with transparency mode turned on for outer casing to show the internal components.</p> "> Figure 8
<p>(<b>A</b>) Final concept assembly. (<b>B</b>) The prototype of the 3D printer filament-recycling machine.</p> "> Figure 9
<p>12 V 20 A power supply used for the machine.</p> "> Figure 10
<p>(<b>A</b>) Display and control system. (<b>B</b>) The main menu and extruding ABS menu.</p> "> Figure 11
<p><b>Left:</b> spooler system when in operation. <b>Right:</b> spool is removed from the motor shaft.</p> "> Figure 12
<p>Filament-positioning system in the home position.</p> "> Figure 13
<p>(<b>A</b>) Fully assembled extruder system and (<b>B</b>) two cooling fans pointing at the filament path for the cooling of the newly made filament.</p> "> Figure 14
<p>Extruder in operation while extruding PLA for the first time.</p> "> Figure 15
<p>The auger bit position (the thickness of the yellow lines indicates the width of the gap).</p> "> Figure 16
<p>Type (<b>A</b>) larger PLA chip size and type (<b>B</b>) ideal chip size for extruding.</p> "> Figure 17
<p>(<b>A</b>) CAD model of the chip collector and collector tube. (<b>B</b>) Gap between the chip collector and tube shown in a yellow circle. (<b>C</b>) High-temperature-resistant PTFE tape is used to cover the gap.</p> "> Figure 18
<p>3DP-MRM workflow chart.</p> ">
Abstract
:1. Introduction
2. Materials and Methods
2.1. Spooler System
2.2. Extruder System
2.3. Display and Control System
2.4. Filament-Positioning System
2.5. Prototype and Validation Experiment
3. Results
3.1. Power Supply and Wiring
3.2. Display and Control System
3.3. Spooler System
3.4. Filament-Positioning System
3.5. Extruder System
4. Discussion
5. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Category | Details | Design Intention |
---|---|---|
Performance | Material available | PLA and ABS. |
Input material type | Plastic waste and industrial pellets. | |
Heating time (to 200 °C) | Under 10 min. | |
Included options | Extruder, mixer, automatic spooler, and filament positioner to avoid a tangled filament spool. | |
Heating element | Heating band. | |
Temperature | The maximum nozzle temperature is 300 °C. | |
Filament thickness | 1.75 mm. | |
Tolerance | ±0.06 mm. | |
Cooling system | Forced fan cooling. | |
Extruder | Forced extrusion using a compression screw. | |
Sensors | Filament thickness, nozzle temperature, filament continuity sensor, motor speed controller. | |
Extrusion speed | 300 g/h. | |
Continuous operation | A 4 h maximum production of 1200 g of filament. | |
Supply voltage | Internal 220 V A.C. power supply with built-in electrical fuse | |
Noise and vibration | Must be able to operate in an office or lab environment with minimum noise and vibration. | |
Size and weight | Weight | Under 8 kg. |
Dimensions | Maximum of 420 mm × 370 mm × 240 mm. To be usable in a desktop environment. | |
Cost | Product cost | GBP 250. |
Aesthetics | Chassis | Separate high-strength chassis to support all the major components. |
Body | Semi-box design with all major components designed to be inside the cover panels. Aesthetically pleasing, to be used in a desktop or lab environment. | |
Manufacturing | Material | ABS, aluminium, and steel. |
Method | FDM printing, laser cutting, lathe turning. | |
Ergonomics | User interface | Easy to operate without complicated settings to choose from. |
User training | No user training is required to operate the machine. | |
Safety | Safety guards | All the sharp moving components, hot surfaces, and high-current wires must be secured and out of reach during regular operation. |
Heat protection | Heat protection tapes, heat protection guards, overheat shutoff, overheat warnings, heat protection padding around hot components, and ceramic separators to protect all components from hot parts. | |
Electrical Fuse | Electrically fused. | |
Transportation | Shipping | Minimum-sized and difficult-to-break components to minimise damage during shipping. Must be able to be shipped by land, air, and sea. |
Packaging | All the components are packaged and secured. The total volume and weight of the packaging must be low to be able to be shipped internationally by air or sea in an economical manner. | |
Environment | Working condition | To be used in a desktop or small-space environment. |
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Share and Cite
Nattukallingal, M.N.; Ran, Z.; Abass, A. A Material-Recycling Unit for the Fused Deposition Modelling of Three-Dimensional Printing Systems. Appl. Sci. 2023, 13, 7515. https://doi.org/10.3390/app13137515
Nattukallingal MN, Ran Z, Abass A. A Material-Recycling Unit for the Fused Deposition Modelling of Three-Dimensional Printing Systems. Applied Sciences. 2023; 13(13):7515. https://doi.org/10.3390/app13137515
Chicago/Turabian StyleNattukallingal, Mohammed Nuwaid, Ziying Ran, and Ahmed Abass. 2023. "A Material-Recycling Unit for the Fused Deposition Modelling of Three-Dimensional Printing Systems" Applied Sciences 13, no. 13: 7515. https://doi.org/10.3390/app13137515
APA StyleNattukallingal, M. N., Ran, Z., & Abass, A. (2023). A Material-Recycling Unit for the Fused Deposition Modelling of Three-Dimensional Printing Systems. Applied Sciences, 13(13), 7515. https://doi.org/10.3390/app13137515