DEVELOPMENT OF A LARGE-SCALE MULTI-EXTRUSION FDM PRINTER, AND ITS CHALLENGES
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Date
2022
Authors
Ali, Md. Hazrat
Kurokawa, Syuhei
Shehab, Essam
Mukhtarkhanov, Muslim
Journal Title
Journal ISSN
Volume Title
Publisher
International Journal of Lightweight Materials and Manufacture
Abstract
This study focuses on the development of a large-dimensional 3D printer and its challenges in general.
The major fused deposition modeling (FDM) printers focus on printing small-scale parts due to their
challenges in printing large-scale objects using thermoplastic polymer filaments. A novel largedimensional
multi-extrusion FDM printer is developed at the workshop and printed several largedimensional
objects to emphasize its prospects in developing large-scale products. The printer has a
print bed with a dimension of 900 mm 1100 mm 770 mm with respect to the lengthewidtheheight
(LeWeH), respectively. There are many challenges to successfully printing large-dimensional objects
using FDM technology. The experimental design elaborates on the challenges experienced during
printing various large-dimensional objects. In addition, the paper focuses on the qualitative analysis of
the optimal process parameters in section 4.5. Based on the experimental results, the key challenges are
found to be uneven bed temperature, bending of print bed due to thermal effect, surface unsticks due to
lack of adhesive force, surrounding temperature, and irregular filament feed. Experimental results also
validate the key design specifications and their impact on enhancing large-scale 3D printing. The
developed printer is capable of printing large-scale objects with five different thermoplastic materials
using five individual extruders simultaneously. It adds a new dimension of flexible automation in additive
manufacturing (AM)
Description
Keywords
Type of access: Open Access, Large-scale, 3D printing, Printing parameters, Adhesion, Temperature control
Citation
Ali, M. H., Kurokawa, S., Shehab, E., & Mukhtarkhanov, M. (2023). Development of a large-scale multi-extrusion FDM printer, and its challenges. International Journal of Lightweight Materials and Manufacture, 6(2), 198–213. https://doi.org/10.1016/j.ijlmm.2022.10.001