2017 International Conference on Nascent Technologies in the Engineering Field (ICNTE-2017)

Design and Development of XYZ

Scanner for 3D Printing
Suhas P. Deshmukh1, Mahesh S. Shewale2, Vishal Suryawanshi3, Akhil Manwani3,
Vishal Kumar Singh3, Rushabh Vhora3, Mihir Velapure3
1
Professor, Department of Mechanical Engineering, Sinhgad Academy of Engineering, Pune, India
2
Assistant Professor, Department of Mechanical Engineering, Trinity Academy of Engineering, Pune, India
3
Student, Department of Mechanical Engineering, Sinhgad Academy of Engineering, Pune, India

Abstract—3D printing is future of manufacturing technology
which creates 3D object using 3D digital model. 3D printed
components are very useful in design prototyping as well as
manufacturing commercial products. The present article reviews
the 3D printing process and our development of a new type of
scanner for 3D printing system which achieves faster scanning in
a compact space. It consists of serial XY scanning stage on which
an extruder is mounted and the platform is mounted on Z-stage.
Motion in all three directions is achieved via NEMA17 stepper
motors and a standard ARDUINO microcontroller is used for
controlling motion and speed of the scanning operation. It is
observed that scanning speed of more than 10 mm/s with
positioning accuracy of less than 10 microns is easily achieved.
Keywords—3D printing, Mechatronics, Scanning Mechanism
I. INTRODUCTION
3D printing is a process of building objects through the
technology of additive manufacturing. It is a process where
three dimensional objects are created by placing successive
layers of material. 3D printing, also known as rapid
prototyping, is a mechanized method whereby 3D objects are
swiftly manufactured on a practically sized device that is
connected to a computer holding blueprints for the object. The
concept of using 3D printing for custom manufacturing is
quite exciting to nearly everyone. This revolutionary method
for creating 3D models using inkjet technology helps to save
both time and cost by eliminating the need to design; print and
glue together separate model parts. Creation of a complete
model in a single process using 3D printing is now easily
possible. The basic principles include material cartridges,
flexibility of output, and translation of code into a visible
pattern.
It is having a remarkable impact on many industries in the
private and non-profit sector. The aerospace and automotive
industry have been the first to benefit from this technology
which has managed to produce parts of lower cost and lighter
weight, while also greatly improving strength. This technology
is used to print tools on demand and craft custom products,
reducing expenses related to time, assets, and inventory. Non-
profit organizations are finding applications in the design of
customized prosthetics of arms and limbs for people with
amputees. It’s clear that this technology can potentially alter
manufacturing supply chains, distribution channels, business
models, and revolutionize the small scale manufacturing
segment, giving consumers the ability to produce uniquely
suited products for their needs. There is now space in the
market for lower cost 3D printers that can create healthy
competition by giving both decent quality prints as well as
increased functionality.
They can produce physical models of objects either
designed in a CAD program or scanned with the help of a 3D
Scanner. Printers are used in a variety of industries including
jewellery, footwear, dental and medical industries.
II. HISTORY OF 3D PRINTERS
Charles Hull initially developed the technology for printing
physical 3D objects from digital data in 1984. He termed the
technique as stereolithography and obtained a patent for it in
1986. Stereolithography involves the use of a liquid photo-
curable polymer, which solidifies under the action of light.
Stereo lithography systems became common during the end of
1980s when other similar technologies such as FDM or Fused
Deposition Modelling and SLS or Selective Laser Sintering
were introduced.
FDM involves the use of heating element that heats a
filament unto its melting temperature; the molten filament is
then extruded out of a nozzle in the required shape layer by
layer to get the required part. SLS involves the sintering of a
fusible powder (usually metals or ceramics) by the use of a
high-powered Laser directed at points as described in the CAD
model in a controlled atmosphere
Major products, "Genisys" from Stratasys, "Z402" from Z
Corporation and "Actua 2100" from 3D Systems, were
introduced in 1996.
The initiation of an open source project, named Reprap
(Replication Rapid-Prototyper Project) in 2004, by Adrian
Bowyer, professor at University of Bath was aimed at
developing a 3D printer using FDM technology that could
print most of its own parts; this significantly reduced the cost
of the 3D printing technology and increased its accessibility. It
is the inspiration behind this project and countless others.
III. 3D PRINTERS PROCESS
The primary step for any 3D printing process is the
designing of a 3D CAD model. This can be created using 3D
software programs(such as Catia, Creo, Solidworks and many
such others) in the industry whereas for hobbyists and

978-1-5090-2794-1/17/$31.00©2017 IEEE
 2017 International Conference on Nascent Technologies in the Engineering Field (ICNTE-2017)
consumers there are simpler, more easily available programs.
A digital model can be also prepared by scanning an object
with a 3D scanner. The design model is then ‘sliced’ into
layers, thereby converting it into a file that can be read by the
3D printer. The material processed by the printer is then
layered according to the design model and the selected
process.
Figure 1: Proposed 3D printing Process
3D CAD model
At the initial stage of process the CAD model is designed
of the part to be printed. Suitable CAD software (ProEngineer
Wildfire 4.0) is used to design the CAD model with exact
dimensions of the part to be manufactured. The designed
model is then saved as stereo-lithographic file (STL) to store
model information. STL file is also known as Standard
Tessellation Language file. As explained by Burns
(1993/2015), “An STL (‘StereoLithography’) file is a
triangular representation of a 3D geometrical surface. This
surface is tessellated or broken down logically into a sequence
of small triangles or faces. Each face is described by a
perpendicular height and three other points representing the
apexes of a triangle. The regular format of a .stl file contains
basic data about the envelope of the model and its shape, but
not the way it is built.
Slicing Algorithm
Once the STL file is generated the 3D part is sliced to the
required thickness with each sliced section representing the
2D cross section of the designed model. The base algorithm
includes the cutting of triangles with planes. In FDM, the STL
file gives out the required triangles in order to apply the
melted filament layer by layer onto the printing area. Thus
there are many cutting planes through the object which
parallel to the surface of platform with varying values of
height. The planes intersecting with the object is the layer to
be printed. Plenty of layers printed from the bottom to the top
conclude in the item.
Scan Path
This sliced image then produces the code (through the
program) which is fed through the electronics system to the
driver system. The parameters such as speed of print,
thickness of layer, and infill density can be adjusted according
to the need.
The code generated from slicing the model is passed to the
stepper motor using a suitable electronic configuration
commanding it to perform the required movement of the print
head and bed along with additional extrusion commands
which tell the printer how much filament to unspool into the
hot-end. These instructions are formatted in a standardized g-
code file. Thus layer by layer of the model is printed and the
development continues until the complete part is
manufactured.
Post Processing
After the fabrication of the object, the part may or may not
need post processing depending on the design. In post
processing support material, if used, is removed either by
using suitable chemicals or stripping it way. Since the
chemicals are relatively toxic, care should be taken while
working with these chemicals. To smooth ABS plastic acetone
vapour is used and for PLA hand polishing with
Tetrahydrofuran (THF) is brought in use. The surface of the
model is then finished and cleaned.
IV. XY AND Z SCANNER FOR 3D PRINTER
Proposed 3D printer consists of XY scanning mechanism,
Z-platform, Extruder with its plastic feeding system and base
platform for 3D printer. The objective of this project is the
development of XYZ Scanning System by linking the PC via
Arduino microcontroller.
Planned work targets the following
1. Design modeling of XY and Z scanning stage.
2. Manufacturing of XY and Z scanning system.
3. Linking the 3D printing system with PC via Arduino
board.
4. Motion control of the XY & Z stage.
5. Experimental testing by tracing X, Y and Z direction.
Figure 2 shows, the XY scanning stage that consists of
dual motion segments. The Y axis stage consists of three
support rods (two guide rods and one lead screw) and the
extrusion mount. The supports are located in between the two
side support plates, with the lead screw in between the two
guide rods. Moreover, it allows linear motion of the X stage
along the axis of the rod. A Stepper motor shaft is coupled to
the lead screws of both the axes having, allowing for the
motion of both the Y stage and the X stage platforms together.
Similar to the Y-axis, the X-axis stage also consists of three
supports as two guide rods and lead screw. Moreover, the X
stage is located between the two side support plates to restrict
its linear motion through the X-axis. The entire XY stage
assembly rests on the support rods of square grooved cross-
section made of Aluminum.
Assembly: During the assembly of the entire stage, care has
been taken to ensure the axis alignment and secure fastening
of components. Linear bearings have been press fitted at the
guide way linings in the motion stages itself. Stepper Motor
selection criteria Several factors affects the choice of stepper
motor for particular application such as the type of motor, the
torque requirement of the system, complexity of the controller,
and the physical characteristics of the motor. Selection of
stepper motor is done based on the application.
 2017 International Conference on Nascent Technologies in the Engineering Field (ICNTE-2017)

A standard 1.8 step size stepper motor has 200 steps per
revolution. Single phase full step mode occurs when the motor
is operated with only one phase energized at a time. This Z-stage with
needs the least power from the driver power supply and can be stepper motor
used where the motor is run at a constant speed. On the other
hand dual phase delivers improved torque, but consumes more
power. Half step operation includes alternating single and dual
phase operation and delivers twice the resolution resulting in
increased smoothness at lower speeds. Micro step operation
divides each full step into smaller angles using cosine and sine
functions to drive the windings Thus, considering our
application, a NEMA 17 bipolar stepper motor is selected
which gives the optimal requirements as 1.8 step angle with
4.4 kg.cm of torque which is suitable to lift the load about 1kg.
It is also suitable for micro stepping modes. XY-stages with
stepper motors Extruder

Figure 3: XY and Z-stage for 3D printer

V. INTERFACING OF XY AND Z SCANNER

Figure 2: Stepper Motor based XY scanning Stage
By providing the appropriate tolerances and fits we have
ensured the motion parameters and end fixity factors. With the
use of precision machines for milling, drilling our setup is
ready to assemble. Assembling is ensured by proper axis
alignments. While assembling the entire stage care should be
taken to ensure the axis alignment and fastening methods.
Linear bearing are press fitted at the guide way linings of in
the motion stages. Motor mounting plates are ensured by
straightness measurements with vernier caliper with respect to
support plates. Firstly the Y stage is assembled then X stage is
mounted on it.
Once XY stage is ready, Z-stage was manufactured and
similar way alignment and motion of platform is ensured viva
appropriate experimentations
Figure 4 shows typical interfacing components of XY & Z
scanner and extruder for 3D printer. It consists of PC,
ARDUNIO MEGA2560 microcontroller, stepper motor driver
circuitry, DC power supplies for stepper motor, stepper motor
based XY and Z scanning stage. Stepper motor is operated
using PWM signals and is operated using standard IDE
(integrated development environment) software which
generates signal for motor. The NEMA 17 stepper motor is
connected to an easy driver motor controller board which is
controlled by an ARDUINO MEGA2560 microcontroller by
means of wire connections as shown in block diagram of
Figure 5. The Arduino program is uploaded in the
microcontroller which controls the number of pulses to be
generated for the stepper motor provided with a required
amount of voltage level by means of easy driver circuit.

Figure 4: Interfacing of XY and Z Stage for 3D printer

 2017 International Conference on Nascent Technologies in the Engineering Field (ICNTE-2017)

The Software (IDE): The IDE (Integrated Development and backward movement is controlled with an Arduino
Environment) is a distinct program running on the computer program with a number of steps and speed. Measurements
that can be used to write sketches for the Arduino board in a Table 1 X-Motion Stepping Results at different speed of operation
simple language modelled after the processing language. The
sketch is uploaded to the board: the code that is written is No of
steps
Motion
Expected
Observed X motion Readings
at 200 at 400 at 600 at 800 at 1000
translated into the C language, and is passed to the avr-gcc (mm) RPM RPM RPM RPM RPM
(mm) (mm) (mm) (mm) (mm)
compiler which is a significant piece of open source software
100 0.625 0.485 0.365 0.4 0.389 0.46
that makes the final conversion into the language understood 200 1.25 1.154 1.088 1.02 0.98 0.94
by the microcontroller [6]. 300 1.875 1.843 1.53 1.45 1.49 1.46
The programming cycle on Arduino is as follows: 400 2.5 2.346 2.185 2.8 2.78 2.68
1. Plug the board into a USB port on computer. 500 3.125 3.062 2.98 2.88 2.76 2.68
2. Write a sketch. 600 3.75 3.586 3.39 3.35 3.187 3
700 4.375 4.165 4.08 4 3.75 3.54
3. Upload the sketch to the board through the USB 800 5 4.745 4.6 4.58 4.45 4.32
connection and wait for a few seconds for the board 900 5.625 5.425 5.1 5.09 4.87 4.65
to restart. 1000 6.25 6.105 6.02 5.99 5.86 5.65
4. The board executes the sketch that was written wrote. 1100 6.875 6.765 6.54 6.405 6.3 6.16
1200 7.5 7.438 7.2 7.156 7.09 7.05
1300 8.125 7.985 7.63 7.57 7.34 7.21
1400 8.75 8.59 8.48 8.45 8.27 8.13
1500 9.375 9.185 9.102 9.09 9 8.88
1600 10 9.88 9.58 9.45 9.34 9.12
1700 10.625 10.44 10.15 10.023 9.89 9.65
1800 11.25 11.09 11.85 10.78 10.56 10.44
1900 11.875 11.68 11.52 11.45 11.28 11.13
2000 12.5 12.385 12.2 12.18 12.09 12.12
were taken for 200, 400, 600, 800 and 1000 RPM with varying
number of steps from 100 to 2000 that is for twenty such
readings [7].
Table 2 Y-Motion Stepping Results at different speed of operation
Figure 5: Wiring and connecting stepper motor via stepper Observed Y motion Readings
No of Motion at 200 at 400 at 600 At 800 at 1000
motor driver circuitry steps Expected RPM RPM RPM RPM RPM
(mm) (mm) (mm) (mm) (mm) (mm)
100 0.625 0.598 0.498 0.486 0.501 0.518
VI. EXPERIMENTAL TESTING 200 1.25 1.198 1.098 1.08 1.119 1.208
300 1.875 1.835 1.7 1.66 1.76 1.8
A forward-backward motion programming with Arduino 400 2.5 2.398 2.25 2.12 2.24 2.28
motor shield board is used to trace the translated motion of the 500 3.125 3.08 2.89 2.88 2.938 2.94
stage with the use of digital dial by resting the pointer on the 600 3.75 3.65 3.55 3.45 3.55 3.56
flat surface of translation stage. The readings were taken with 700 4.375 4.305 4.28 4.15 4.23 4.3
800 5 4.85 4.6 4.55 4.58 4.6
varying speeds and number of steps of the motor. Graphical 900 5.625 5.5 5.435 5.34 5.46 5.45
representation shows the variations in the expected and actual 1000 6.25 6.205 5.98 5.9 6.08 6.088
observed translations. 1100 6.875 6.8 6.74 6.63 6.7 6.77
Once the Arduino programming is done and as soon as the 1200 7.5 7.48 7.33 7.22 7.38 7.44
upload button is pressed the XY stage is ready to go 1300 8.125 8.098 7.9 7.88 7.89 7.99
1400 8.75 8.65 8.45 8.32 8.4 8.54
accordingly. Using the Arduino motor shield board with a 1500 9.375 9.305 9.01 9.09 9.08 9.108
forward- backward programming the X and Y motion stages 1600 10 9.98 9.88 9.8 9.99 10.12
translated according to the steps given in the program. Here 1700 10.625 10.6 10.5 10.56 10.52 10.6
the stepper motor has 1.8 step angle means when it completes 1800 11.25 11.2 11.12 11.23 11.34 11.44
one revolution, the number of steps taken by stepper motor are 1900 11.875 11.869 11.89 11.83 11.82 11.95
2000 12.5 12.402 12.42 12.38 12.28 12.38
360/1.8=200 steps. In one complete revolution of stepper
motor the distance travelled is equal to the pitch of the lead
screw. Here the pitch of lead screw is 1.25mm. Thus in 200
steps the distance travelled is 1.25 mm. Using this terminology The table 1 and 2 shows position of X and Y motion stage
the calculations regarding the distance travelled by the motion for given the number of steps from 100 to 2000 and the
stages for a given number of steps in the program gets easier. motion is measured by high resolution digital sensor with a
Now a simple experiment is done to measure the travelled resolution of 1 microns. Positions of motion stages are
distance with a digital dial indicator instrument. The pointer of observed at different operational speeds of 200, 400, 600, 800,
dial is rested on the one of the flat surface in the direction 100 RPM. It is observed that developed motion stage gives an
parallel to the motion of platform as in fig.6.1. The forward accuracy of positioning within 10microns accuracy and is
 2017 International Conference on Nascent Technologies in the Engineering Field (ICNTE-2017)

perfectly aligned and will be further used for 3D printing

application. Similar experimental testing was conducted for Z-
stage movement and it is observed that a positioning
resolution of less than 10microns can be achieved at moderate
speed of operation.

VIII. CONCLUSION
3D printing is an encouraging technology for future
manufacturing and needs further development is needed to
manufacture high-resolution 3D objects at high speed.
Towards development of 3D printer, XY and Z stage is
successfully manufactured and interfaced with PC via
ARDUNIO MEGA 2560 microcontroller and stepper motor
drivers. During experimentations positioning accuracy of less
than 10 microns is achieved successfully in all three directions
scanning at high speed of operation. Further, interface of
extruder to ARDUINO board is to be developed via
appropriate interfacing software.

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