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Fused deposition modeling (FDM) is a widely implemented manufacturing technique typically used for rapid prototyping of custom components or geometries. Unfortunately, FDM printers are often limited by build volume, print quality, and print time. Build volume is traditionally fixed, such that components larger than a given printer volume must be printed separately as segmented components, and subsequently bonded to one another. Beyond the limitations of the build volume, the quality of prints is another key concern. The components that make up a larger 3D printer often cannot produce the fidelity of a smaller precise printer, thus limiting the device to solely larger components. Print time is also a function of the previous limitations; a faster print will typically have lower quality and a smaller print will often print quicker.
This project seeks to address the limitations of a traditional FDM printer through the development of a modular 3D printer. Standard 3D printers operate with a rigid metal frame that inhibits the freedom to increase the print volume. The design proposed would allow a 3D printer to expand or contract in build volume while also allowing the user to customize needs depending on requirements of print fidelity or print time. The modularity further allows for compact storage and the ability to be transported for on-site prints, which would be particularly useful for wearables and orthopedic adjustments for athletics or within the medical field.
In fact, compact storage size to maximum expanded printer size aims to be a 1 to 10 ratio. The design is self-printing, in that frame components are manufactured from the printer itself, to elongate the dimensions, without sacrificing print fidelity. Any desired build volume can be easily accommodated by printing additional frame components. Such a design is ideal for custom wearables or large-scale projects where a rigid printer structure occupies excessive space. This could prove especially useful for astronauts where cargo shipments are dependent on volume and mass or in fields where custom-fitted wearables are required, such as in athletics or the medical field.
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