Design and Development of a Computer Numeric

Controlled 3D Printer, Laser Cutter and 2D Plotter

all in one machine
Muhammad Talal Shahid(1) Muhammad Ammar Khan(1) Muhammad Zubair Khan(2)
Mechanical Engineering Department Mechanical Engineering Department Mechanical Engineering Department
Institute of Space Technology Institute of Space Technology Institute of Space Technology
Email: [email protected] Email: [email protected] Email: [email protected]

Abstract—This paper proposes the technique used to design power consumption. [2] Laser diodes can be used to cut the
and develop a Computer Numeric Controlled 3D Printer, Laser material as well as engrave materials like wood, Acrylic and
cutter and 2D Plotter all in one machine. The specialty of this plastic etc. [3] With the increase in technology a machine
machine is that the user will not have to change tool whenever
he/she wants to perform any other operation. So this machine is also produced to draw images, charts, electronic circuits
can not only 3D print an object it will also be able to laser cut etc. which uses a pen as a tool to plot various things that
(or engrave through laser) an object and it will also produce machine is called 2D plotter. [4] A 2D plotter can be made
2D drawing for particular object. Frame of the machine and using all the stepper motors or with a servo motor in z-axis
the working of the components will be based on the Cartesian along with stepper motors in x and y axis. [6] Normally all
type of 3D printers. It is a commercially viable and cost effective
machine. The paper also describes the analysis and calculations these technologies are controlled through Computer Numeric
performed for the choice of different electrical and structural Control (CNC) system in which microprocessor is used which
components of this machine. is capable of processing logical instructions interfaced with a
Keywords—Computer Numeric Controlled(CNC), 3D Printer, computer. The logical instructions are provided by using a
Laser Cutter, Laser Engraver, 2D Plotter, Arduino, Ramps, computer in the form of code or text or image which is then
Stepper Motors, Static Structural, Equivalent Stress, Total De-
formation, Harmonic Response. transformed into a machine language, usually called G-Codes,
by microprocessor to be executed by the machine. This paper
I. I NTRODUCTION describes the technique required to merge all these techniques
With the rapid development in science and technology the in one machine. [5] Arduino is used as a microcontroller and
conventional means of manufacturing are losing their spot also works as microprocessor which can be easily programmed
due to some unconventional techniques like 3D printer, Laser and one can easily erase previous program defined on it. [15]
cutter etc. The use of these unconventional techniques has not Ramps 1.4 controller board is also used in accordance with
only revolutionized the process of manufacturing but it also Arduino to control the process.
speeds up the process and increases accuracy too. [11] 3D
printer is an addictive manufacturing process in which layers II. P ROBLEM S TATEMENT
are added step by step. Till now various techniques for 3D To improve the performance of any machine every param-
printer are developed including SLA, FDM, SLS and LOM eter has to be kept in mind from start so that will not cause
etc. [10] Various kind of techniques also have been developed problems in future. There are various problems that may come
in order to level the heatbed automatically also. [7] This paper during the manufacturing of this machine which will disturb
discusses the FDM technique for 3D printing in which the the accuracy of this machine. The common problems include
filament is first melted into a molten state and the allowed to the coding of Arduino for all three processes, alignment
solidify after a layer has been formed. [8] FDM is a faster of components, vibrations due to motors, power of motors
technique than the other ones but lacks in higher resolution if required to lift the tool post and move the heatbed in x
much care is not taken. [9] There are some 3D printers which and y axis, load bearing capacity of belts and lead screws,
also use multi extruders to mix different colors and to print stresses produced in structure during the different processes,
a colorful object. [14] Similarly various types of lasers have power requirement for laser diode and the design of extruder
also been developed which include CO2 laser, micro-jet laser to reduce heat transfer back towards the filament. All these
and plasma laser etc. Laser frequency, number of passes, focal things are core of this machine, failure in anything may fail
length and engraving speed effect on material removal rate by the rest as well so the required theoretical and simulation based
a laser diode. [1] Delta techniques for laser engraving process analysis are necessary in order to reduce the risk of failure.
are also used in order to reduce the moving components hence This paper elaborates the design and development of all in
obtaining higher speeds and acceleration while reducing the one machine by performing necessary theoretical calculation,

978-1-5386-7729-2/19/$31.00©2019 IEEE

Proceedings of 2019 16th International Bhurban Conference on Applied Sciences & Technology (IBCAST) 569
Islamabad, Pakistan, 8th – 12th January, 2019
simulation based analysis. Loads and torques required for the position can be set in order to achieve the desired process. The
motors are calculated theoretically while stresses in the frame rest of the wiring is same as used for Cartesian 3D printers.
and other components of machine, vibrations produced due to
applied moments of stepper motors and the thermal analysis of C. Laser Cutting Speed
extruder are performed by running different simulations using The depth of the laser cut depends upon laser wattage,
Ansys software. power, number of passes and speed of laser cutting. It also
depends upon the type of the material. Tables I, II, III & IV
III. W ORKING AND T HEORETICAL C ALCULATIONS
show some numerical values for these factors for Acrylic.
A. Mechanical Design
The machine is built using Cartesian type 3D printers TABLE I
design. The main difference lies in its tool post. In 3D printers, L ASER R ASTER E NGRAVING [16]
only the extruder is mounted at the tool post. But to fulfill the Laser wattage Laser Power Cutting Speed Pass Depth of Cut
purpose of this machine, the tools required for laser engraving 25 53 100 1 0.002”
and 2D plotting are also mounted on the same tool post i.e. 30 44 100 1 0.002”
laser module and pen respectively. A possible configuration is 35 38 100 1 0.002”
40 34 100 1 0.002”
shown in fig 1:

TABLE II
D EPTH R ASTER E NGRAVING [16]

Laser wattage Laser Power Cutting Speed Pass Depth of Cut

25 100 60 1 0.001”
30 100 64 1 0.001”
35 100 68 1 0.001”
40 100 73 1 0.001”

Fig. 1. Tool Post

TABLE III
B. Electrical Circuit V ECTOR E NGRAVING [16]

Arduino is used as the microprocessor while Ramps 1.4 Laser Wattage Laser Power Cutting Speed Pass Depth of Cut
board used as the controller board. This board is also used 25 6 4 1 0.005”
30 5 4 1 0.005”
for 3D printers. This same board was utilized for all three
35 4 4 1 0.005”
processes. 40 3 4 1 0.005”

TABLE IV
V ECTOR C UTTING [16]

Laser Wattage Laser Power Cutting Speed Pass Depth of Cut

25 100 0.1 1 0.25”
30 100 0.4 1 0.25”
35 100 0.6 1 0.25”
40 100 0.9 1 0.25”

In order to increase the depth of cut with low power, one can
reduce its speed and increase the number of passes required.
Fig. 2. [17] Ramp 1.4 Board
D. Convective heat transfer coefficient
The D9 port in ramps board is used to power the part
cooling fan. Its power can be varied from 0 to 255 with the Heat transfer coefficient can be found using following
increments of 1. This port can be switched on and off by relations: [21]
using commands 106 and 107 respectively. The optical laser µCp
Pr = (1)
diode can be attached to this port to fulfill the purpose of k
laser engraving. The on and off G-codes will be replaced by The values for dynamic viscosity of air, Specific Heat of air
106 and 107 respectively and its power could be controlled by and thermal conductivity were taken 1.849 x10−5 kg/m-s, 1007
using any number from 0 to 255 with 0 zero being minimum j/kg-K and 0.02551 W/m-k respectively. [22] All these value
and 255 being the maximum power. If the function of part are at room temperature i.e. 25° C. By using the equation (1)
fan is also required then a switch can be used at D9 port. Its Prandtl Number value is found to be 0.72.

Proceedings of 2019 16th International Bhurban Conference on Applied Sciences & Technology (IBCAST) 570
Islamabad, Pakistan, 8th – 12th January, 2019
 By using the above relations (7,8,9,10,11&12) calculated
V ρd values for Fa ,Fg ,Fab ,Fai ,Fw &Ff are 3N, 0N, 17.2N, 0.1044N,
Re = (2)
µ 9.8N, 4.9N respectively. By summing all the forces the value
The values for velocity of air, density of air diameter of ex- of effective tension (Te ) is 35.004N.
truder were taken 2.5m/s, 1.184kg/m^3 and 0.01m respectively 2) Torque:
at the temperature of 25◦ C.[22] By using equation number (2) d
τ = Te × (13)
the value of Reynolds’s number came out to be 1595.46. So 2
the flow is laminar. This torque is required by the motor to move the tool-post
in x axis smoothly which is 0.222Nm.
N u = 0.683 × Re0.466 × P r0.33 (3)
G. Torque Calculation along Y-axis
Also, Torque along the Y-Axis can be found as described below:
[18]
hd
Nu = (4) 1) Effective Tension for Heat Bed: In Y-axis the length belt
k is 1.6 m, mass of heatbed is 2kg.
Using equations (3&4) the value for convective heat transfer By summing all the forces as in equation in Y-axis as in
coefficient is equal to 19.04 W/m2 − k. equation (6) the effective tension is 58.5N.
E. Steps per millimeter. 2) Torque: This torque is required by the motor to move
the heatbed platform in y axis smoothly without any jerks
Number of steps required for the stepper motor to move during the motion. By using pitch diameter of idler pulley
the platform one millimeter can be found using following and effective tension as in equation (13) the torque in Y-axis
equation: [20] is found to be 0.37 Nm.
Srev fm H. Torque Calculation to Raise the Load on Z-axis
(5)
pNt The amount of torque required to raise the load in Z-Axis
The steps per revolution for stepper motor is 200, microstep- can be determined as below: [19]
ping factor is 16, pitch of belt is 2mm and number of teeth 1) Force Required:
of pulley is 20. By using equation (5), number of steps per l
[( πdm ) + f]
millimeter were calculated as 80 steps/mm. PR = F × (14)
fl
1 − ( πdm )
F. Torque Calculation along X-axis
The force required to raise the load is found by using the
Torque along the X-Axis can be found as follows: [18] equation (16). The values for mean diameter, friction factor,
1) Effective Tension: lead, load are 0.007 m, 0.78, 0.008 m and 20 N respectively.
Te = Fa + Ff + Fw + Fg + Fab + Fai (6) By putting these values in above equation its value is 31.94 N
2) Torque for raising the Load: Torque required to raise
The acceleration of belt (a) is 3 m/s2 , mass of slides the load. In Z-axis to find the torque equation (17) is used.
(ms ) is 1 kg, the belt inclination angle (β) is taken 0 as it By putting the required values its value is 0.11 Nm.
horizontal, the length of belt (L) is 1.2 m, width of belt (b)
is 0.006m, diameter of bore for idler pulley (db ) is 0.005 m, (F ×dm ) (l + π×f ×dm )
TR = × (15)
pitch diameter of pulley is 0.01273 m, coefficient of friction 2 (π×dm − f ×l)
(µr ) of polyurethane belt is 0.5. [23] IV. S IMULATION A NALYSIS R ESULTS
The Simulation based analysis of the frame and other
Fa = ma ×a (7)
components were reduced into two steps in order to reduce
the computational time required to perform analysis each time
Fg = ms ×g×sinβ (8) on the whole structure. The analysis were first performed
separately on x and y axis assemblies to find out the stresses
produced in the respective axis components and to check if
(Wb ×L×b×a)
Fab = (9) vibrations were also in accordance with the required limit.
g
After that, the whole structure was assembled and the analysis
mi of the whole structure were performed to check that if the x
Fai = (db )2
(10) and y axis assemblies comply with the whole structure. The
2(1 + (d)2 )
analysis were done using different thickness of acrylic frame
Fw = ms ×g (11) and different thickness of structural steel rods. The final results
for the most suitable thickness of frame and rods are shown
below in this section while the comparison between torque
Ff = µr ×ms ×g×cosβ + Ff i (12) values calculated in above section and different thickness of

Proceedings of 2019 16th International Bhurban Conference on Applied Sciences & Technology (IBCAST) 571
Islamabad, Pakistan, 8th – 12th January, 2019
frame and rods is shown at the end of this section. The working
are of the printer is set to be 330mm x 330mm.
A. Structural and Vibrational Analysis along X-axis
The moment applied in this axis was calculated above which
is as same as the torque required by the motor in order to
move the plate form in the respective axis i.e. 0.222Nm. The
diameter of the rods was varied until the deformation and
stresses produced were in desired limits. Fig. 6. Deformation due to Vibrations

in the respective axis i.e. 0.37Nm. The diameter of rods and

thickness of frame were varied to achieve the desired limits
of stresses and deformations produced.

Fig. 3. Stresses along X-axis

Fig. 7. Stresses along Y-axis

Fig. 4. Deformation along X-axis

1) Structural Analysis: The structural analysis results

shown in figure 3&4 depict that the deformation due to
the applied torque is within our tolerance limit and stresses Fig. 8. Deformation along Y-axis
produced are also in the safe region. So we can move towards
the harmonic analysis with the same configuration and dimen- 1) Static Structural: Figure 7&8 show the structural anal-
sions. ysis for y axis assembly. Maximum deformation during the
structural analysis came out to be 6.9542 x 10−5 m and the
maximum stresses produced were also the safe region so we
can now move onto the harmonic analysis with the same
dimensions.

Fig. 5. Stresses due to Vibrations

2) Harmonic Analysis: The amount of stresses and defor-

mation increased in harmonic analysis due to the vibrations
produced in the structure by the torque applied by the stepper Fig. 9. Deformation due to Vibration
motor as shown in figure 5&6 but these are still in tolerance
limit. 2) Harmonic Analysis: The results in harmonic analysis
shown in figure 9&10 depict that the amount of maximum
B. Structural and Vibrational Analysis along Y-axis stresses produced and the maximum deformation also in-
As calculated above the moment applied in this direction is creased due to the vibrations produced by the stepper motor
the moment required by the stepper motor to move the heatbed but still these values are in our safe region.

Proceedings of 2019 16th International Bhurban Conference on Applied Sciences & Technology (IBCAST) 572
Islamabad, Pakistan, 8th – 12th January, 2019
 Fig. 10. Stresses due to Vibration Fig. 14. Deformation due to vibration

C. Analysis of the Full Model 2) Harmonic Analysis: Stresses and deformation produced
in harmonic analysis is greater than those produced in struc-
After performing analysis in all three axis, the whole model
tural analysis furthermore it is also greater than those produced
was assembled in order to check if any factor was causing
in each axis separately as shown in figures 13&14. But these
our model to fail. The thickness of the frame was varied
values are still tolerable so the same values of thickness of
accordingly to reduce the stresses and deformation in the
frame and rods diameter, i.e. 10mm and 8mm respectively,
structure produced by the applied load and torques.
can be used for the fabrication of this machine.
D. Comparison of results at applied torques.
The torques applied in x, y and z axis found were 0.222Nm
, 0.37 Nm and 0.11Nm respectively. The comparison between
the values of different thickness of rods and frame with
maximum deformation and maximum stresses produced at
these applied torques is as below:

TABLE V
Fig. 11. Stresses in the whole structure C OMPARISON WITH DIFFERENT ROD THICKNESSES

Rod Thickness Max. Deformation (Rods) Max. Stresses (Rods)

4mm 1.637 mm 7.932 x 107 Pa
6mm 1.112 mm 5.483 x 107 Pa
8mm 0.530 mm 2.717 x 107 Pa

TABLE VI
C OMPARISON WITH DIFFERENT FRAME THICKNESSES

Frame Thickness Max. Deformation (Frame) Max. Stresses (Frame)

5mm 1.053 mm 2.5734 x 106 Pa
Fig. 12. Deformation in the whole structure 8mm 0.735 mm 2.8253 x 106 Pa
10mm 0.424 mm 2.3251 x 106 Pa
1) Static Structural: The structural analysis shown in fig-
ures 11&12 show that with the applied moment in all axis, the The results from simulation analysis helped to improve the
amount of deformation is also increased as compared to the structure of machine for a given torque hence providing the
previous analysis performed on each axis separately. But the optimal values of thickness of frame and rods. These analysis
deformation and stresses produced are still in the safer region were also benefical in the designing process as thorugh this
so we can now perform harmonic analysis. we became aware about the stress concentration areas.
E. Thermal Analysis for Extruder
It is desired to reduce the temperature flowing from the
hotend back to the extruder otherwise the filament will get
melted before reaching the nozzle. A heat transfer coefficient
of 19.04 W/m2 k was chosen against the 2.5m/s velocity of
the air provided by extruder fan. The material of extruder was
set to Aluminum 6063. The number of fins were varied until
\
the desired temperature at the extruder was obtained.
Fig. 13. Stresses due to vibration Figure 15 shows results after performing thermal analysis
on the extruder. The glass transition temperature for ABS

Proceedings of 2019 16th International Bhurban Conference on Applied Sciences & Technology (IBCAST) 573
Islamabad, Pakistan, 8th – 12th January, 2019
 [3] G. R. T.-A. Review and D. K. Patel, “Parametric Op-
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[4] S. Ranjan, “Design and Implementation of low-cost
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[5] B. Moharana, R. Gupta, and B. K. Kushwaha, “Op-
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2014.
[6] M. B. Halli and N. S. R, “DESIGN AND IMPLE-
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[7] M. Kamruzzaman, K. Prince, M. Ansary, and A. S.
V. C ONCLUSIONS Mondol, “Implementation of a Low-cost CNC Plotter
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processes all by itself using a large platform of 330mm x Bhawana, H. Kavana, and K. V Rao, “Robotic 2D
330mm concluded as follows: Plotter,” vol. 3, no. 10, pp. 300–303, 2014.
[9] “DEVELOPMENT OF LASER CUTTING AND
a) The same ramps 1.4 control board can be used to
ENGRAVING MACHINE A THESIS SUBMITTED
operate 3d printer and the laser module to achieve
IN PARTIAL FULFILLMENT OF THE REQUIRE-
the desired process.
MENTS FOR THE DEGREE OF Bachelor of Tech-
b) The depth of laser cut is directly proportional to
nology in Industrial Design By Mukesh Kumar (
its wattage, power and the number of passes while
111ID0508 ) Under the supervision of Prof B . B
inversely proportional to the speed at which laser is
. Biswal Department of Industrial Design National
moving.
Institute of Technology , Rourkela April 2015,” no.
c) The values of torques in all 3 axis were also found
April, 2015.
hence defining the torque requirement for the stepper
[10] T. Finnes, “High Definition 3D Printing – Comparing
motors in the respective axis.
SLA and FDM Printing Technologies,” vol. 13, 2015.
d) This calculated torque was applied to the whole
[11] B. S. Shahi, “ADVANCED MANUFACTURING
structure in order to find out the proper thickness for
TECHNIQUES ( 3D PRINTING ),” no. 4, pp. 16–23,
frame and rods. By varying the thickness of frame
2016.
and rods it was observed that the maximum stresses
[12] S. Bhandari and B. Regina, “3D Printing and Its
produced and the maximum deformation of the frame
Applications,” vol. 2, no. 2, pp. 378–380, 2014.
and rods decreased with the increase in thickness.
[13] J. Q. Al-maliki and A. J. Q. Al-maliki, “Interna-
e) Simulation analysis also depicted that the deforma-
tional Journal of Advances in Computer Science and
tion and stresses produced were greater in harmonic
Technology The Processes and Technologies of 3D
analysis than the structural analysis due to the vibra-
Printing,” vol. 4, no. 10, pp. 161–165, 2015.
tions induced by stepper motors.
[14] A. Pirjan and D.-M. Petrosanu, “The impact of 3d
f) Thermal analysis showed that the amount of heat
printing technology on the society and economy.”
transfer from the extruder with the help of fan was
[15] D. Ph and M. Engineering, “Research Article RAPID
increased by increasing the number of fins around
PROTOTYPING / RAPID TOOLING – A OVER
the extruder.
VIEW Address for Correspondence.”
g) It is a commercially viable machine.
[16] M. Safety et al., “Material Settings Guide.”
h) According to the market survey performed through
[17] W. Gorman, “Building a 3D Printer : Motors and
different sources this machine will cost less than
Controls.”
US$350.
[18] GATES MECTROL, INC., "Timing Belt Theory",
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A PPENDIX
Te Effective Tension
Fa Acceleration Force
Ff Frictional Force of Linear Bearings
Fw External Force or Work Load
Fg Component of weight of the slide
Fab Inertial Forces to accelerate Belt
Fai Inertial Forces to accelerate Idler Pulley
ms mass of slider
a Acceleration
µr Dynamic Coefficient of friction
Ff i Load independent resistance
β Angle of incline of linear positioner
L Length
b Belt width
mi mass of idler
db Diameter of idler bore
d Diameter of idler
τ Torque
PR Force required to raise the Load
dm Mean diameter
l Lead of Power screw
f Friction factor
F Load
TR Torque required to raise the Load
Re Reynolds Number
V Velocity
ρ Density of air
d Diameter of Extruder
µ Viscosity
Pr Prandtl Number
Cp Specific Heat at constant pressure
k Thermal Conductivity
Nu Nusselt Number
h Convective Heat Transfer coefficient

Proceedings of 2019 16th International Bhurban Conference on Applied Sciences & Technology (IBCAST) 575
Islamabad, Pakistan, 8th – 12th January, 2019