Development of a large-scale multi-extrusion FDM printer, and its challenges

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 large-dimensional multi-extrusion FDM printer is developed at the workshop and printed several large-dimensional 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 length–width–height (L–W–H), 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).