Abstract

Last write
Introduction
This section will be divided into three subsections: 1) background of 3D printing and its
application, why 3D printers need to replace step motor by servo motor 2) literature review about
its principle and structure 3) the challenge and benefits in using servo motor aiming to optimize
and expand applications of 3D printers in complex region.
1. Goals
The core task of this research on designing the 3D-FDM (Fused Deposition Modeling)
printer ultilizing servo motors to significantly increase printing speed and accuracy in handling
complex or high-resolution products. Servo motors offer superior control over position, speed,
torque will make sure the precise and smoth movements during rapid operations. This allows for
more accurate layer deposition and faster print times, reducing issues such as layer misalignment
and dimensional inaccuracies that are common with stepper motor-driven printers (traditional 3D
printers). This research will include both mechanical design and control system to fully utilize
the advantages of servo motor technology in additive manufacturing.
FDM is one of the earliest 3D printing technologies and was used by the author to
produce his first medical model in 1999. An FDM printer is essentially a robotic glue gun; an
extruder either traverses a stationary platform, or a platform moves below a stationary extruder.
Objects are 'sliced' into layers by the software and coordinates transferred to the printer.

2. Background and literature review

3D printing mean slicing product into layers by layer technique, linking together,with this
technology any product can be manufactured with 3D model( by CAD ). This method change the
world industry producting technique.Three-dimension printing is not a new manifacture method,
it appear in plenty fields of manifacturing such as healthcare, industry, education and art. This
approach will cost less waste, energy and bring highly accuracy production.
Step motors are highly used in 3D printers because of its low cost and simplicity.
However, they have limitations such as unaccuracy, low speed and heat release, which make
them only suitable for basic tasks. In order to that, the industry need a better way to manufacture
which lead them to servo motor – know for the high speed, coordinated multi-axis movement
and precise motion since its close-loop control system
3. Challenges and benefits
3.1. challenges
 High cost: The servo motor, driver and other control materials required higher cost than
step motor because of its continuos positioning , which make the widely application in 3D
printers even more difficult
Complex control system: Servo motor need the closed-loop control feedback system,
with complex algorithms like PID to accurately control velecity and position motion. Which
increase the challenges in programming and fine-tuning the system
Signal Interference: Servo systems are sensitive to electromagnetic interference (EMI)
because they need a complex feedback mechanisms (encoder) to measure the right position and
speed of motor, which can affect the performance of the printer, especially in industrial
environments.
The need of high level sensors : To be more accuracy, the servo system require high-
resolution sensors. However, using these sensor will increase complexity of tuning and handling
data, requiring meticulous calibration of the system to prevent inaccuracies.
Coordinating multiple motion axes: Coordinating multiple motion axes in complex 3D
printing systems, especially those powered by servo motors, can be a difficult task. Each axis
may require independent feedback while still needing to function in sync. This challenge
demands sophisticated control solutions for multiple axes and accurate kinematic adjustments to
ensure proper coordination.
3.2. benefits
Servo motors operate on a closed-loop control system, continuously adjusting their
position, velocity, and acceleration based on feedback. For this reason, servo motors offer key
advantages in precision engineering:
High Accuracy and Repeatability: Servo motors provide exceptional precision due to
their closed-loop control and continuous feedback systems. This allows for consistent and
repeatable positioning, making them ideal for high-precision motion in turning point in the
printing process so that even tiny deviations can be produce
Dynamic Performance: Known for their ability to handle rapid acceleration and
deceleration, servo motors are well-suited for environments that require quick, responsive
movements. They offer high performance under dynamic conditions, ensuring fast operation
without compromising on accuracy, making them valuable in automated manufacturing and
packaging systems.
Load Resilience : Servo motors excel in maintaining position even under varying loads.
This ensures stable performance, regardless of shifts in external forces or weight, making them
highly reliable in applications with unpredictable conditions, such as robotics and industrial
machinery.
Energy Efficiency : Operating efficiently across a broad speed range, servo motors
optimize energy use by adjusting power consumption based on demand. This results in lower
operational costs and energy savings,even lower heat release lead to expand the lifespan of 3D
printers, making them ideal for industries focused on both performance and sustainability.
Smooth Operation : Servo motors deliver smooth, precise motion control, even at low
speeds. This makes them particularly useful in delicate applications, such as medical devices and
precision 3D printing, where stability and fine-tuned movements are essential.
Research Phase
1. 3D Printer Model and System Structure:
- Machine Frame Design:

2. Motors and Control System:

Panasonic Servo Motors: The MHMJ042G1U servo motors are selected for the X and Y
axes due to their accuracy in positioning and ability to meet the necessary torque and stability
requirements. The MBDKT2510CA1 driver will ensure the motors’ performance and precision
during operation.
Stepper Motor for Z-axis: A stepper motor will be used on the Z-axis, optimized for
stable vertical movement, which requires less speed, making it both cost-effective and reliable.
3. Sensors and Feedback System:
AS5600 Position Sensor: AS5600 sensors will be attached to both X and Y axes to provide real-
time positional feedback, enabling precise adjustments of the servo motors. Using Hall effect
technology and an I2C interface, the AS5600 offers high accuracy and easy integration with the
control system.
LM35 Temperature Sensor: The LM35 temperature sensor will be integrated to monitor the
temperature of motors and critical components. This sensor offers accurate temperature
measurements and easy connectivity with the microcontroller, protecting the system from
overheating and ensuring stable operation.

1. Introduction to PID Control

Proportional-Integral-Derivative (PID) control is a commonly used algorithm in industrial
applications due to its ability to deliver precise control with minimal complexity. In a 3D printer
with servo motors, PID ensures smooth motor movements, crucial for both positioning and
speed. By minimizing the error between the target output and actual output, PID continuously
adjusts control inputs to optimize performance.
The controller's three components Proportional (P), Integral (I), and Derivative (D) work
together to respond to immediate errors, correct cumulative errors over time, and predict future
errors, providing a balanced, dynamic system response.
2. Theoretical Framework
1. Proportional Term (P)
The proportional term responds directly to the current error, which is the difference between the
desired and actual output, such as the servo motor's position. It reduces the system's rise time, but
if improperly tuned, it can cause oscillations. In 3D printing, precise tuning is crucial to prevent
overshooting, which may lead to defects or vibrations. Mathematically, the proportional term is
given by:
P=Kp.e(t)
Where Kp is the proportional gain, and e(t) is the error at time term (I).
2. Integral Term (I)
The integral term corrects residual errors left by the proportional action by summing errors over
time. This ensures the system reaches the desired setpoint. However, if the integral gain is too
high, it may cause a slow response or instability, known as the integral windup effect.
Mathematically, the integral term is represented as:
I= Ki.0te dτ
Where Ki is the integral gain, and is the integration variable representing time.
3. Derivative Term (D)
The derivative term predicts future errors by analyzing the rate of change, helping to reduce
overshooting and oscillations. In systems like 3D printers with rapid movements, it ensures
smoother transitions by slowing the system down as it nears the setpoint, improving accuracy
and stability. Mathematically, the derivative term is given as:
D=Kd . de(t )dt
Where Kd is the derivative gain, and de(t)dt is the rate of change of the error with respect to
time.
4. Tuning the PID Parameters
The effectiveness of a PID system depends on the correct tuning of its parameters Kp, Ki, Kd.
We decide to use Auto-tuning method for several reasons:
 Real-time adjustment: Auto-tuning continuously adjusts PID parameters based on
feedback, ideal for systems like 3D printers with varying conditions (e.g., load changes).
  Precision and speed: It dynamically balances precision and speed without manual
intervention, ensuring smooth control and optimal performance.

 Ease of
implementation: Compared to manual tuning (e.g., Ziegler-Nichols), auto-tuning is
simpler to integrate and reduces the risk of instability or poor print quality.

Figure 1: Scheme of relay-base PID autotuning

Source: www.researchgate.net - Ismael Minchala
5. Conclusion
In this project, PID control combined with Auto-tuning ensures precise and efficient motor
operation in a 3D printer. Auto-tuning adjusts the Proportional, Integral, and Derivative
parameters in real time, optimizing performance under varying conditions. This method balances
speed and accuracy while simplifying tuning, enhancing print quality, and providing reliable,
high-speed printing.

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