Fused deposition modeling (FDM) is a technology used for modeling, prototyping, and production. FDM works on an additive principle by laying down material in layers. Acrylonitrile butadiene styrene (ABS) polymer is used to make the product.

The 3D object can be created with different software like Rhino, Auto cad and 3D-Max and the file should be exported with file extension .stl format. This design is created in Auto cad.

The estimated cost for this product is around $15 with the rate of ABS product as $5 per cubic inch.

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Process for printing:

Firstly the computer should be turn on and then the FDM machine pressing the Start button to warm up the machine. The machine temperature for ABS material should be: modeling material -270, support material – 265 and envelope -70 centigrade. Open the STL extension file through software named insight and the typical setup for ABS plastic should be:

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Do set up as following:

  • Reorient as required thinking about how the support material will support the model. Generally, it should be rotated so that the support material and build time is minimal. Click STL ROTATE to reorient the 3d.
  • Scale it as required to limit the size of prototype. Click STL units and scale. As I had designed the model in real scale of size ( 2.26 cubic inch) the size of 3d model was made of small size. So I didn’t need to rescale it.
  • In upper left of the screen, there are different icons and they are required to press in sequence

First: press slice icon

Second: press generate support icon

Third: press toolpaths icon

Then press save icon to save toolpaths file

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In the FDM machine:

  • Arrange the foam placement as required
  • Click auto shut off status
  • The pause button is needed to be turn off so that FDM can receive the information from the computer.

Now the build icon can be pressed in insight screen:

  • In the pack and download dialog box, the information regarding estimated model and support material to be used and total time estimate can be known.

In this project:

Model material used: 2.26 cubic inch

Support material used: 0.60 cubic inch

Total time estimate: 8hr 57min

Click the icon to send the job.

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  • Then press the pause button to turn it off so that FDM will be go through initialization routines and extruding support material and wipe the tips.
  • Remove excess material from tips and reposition the tip to front left to build the model and place the tip just above the foam.
  • Now press the pause button light

After the estimated time, the product is ready. The product comes with support material which need to be removed carefully.

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After removing the support material, the final product is ready.

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