DefinePK

Abstract

Additive manufacturing (AM) has revolutionized modern production by enabling the layer-by-layer fabrication of functional components directly from digital designs. Among various AM processes, Fused Deposition Modeling (FDM) has emerged as one of the most widely adopted methods due to its simplicity, material versatility, and cost-effectiveness. This paper presents the design, construction, and comprehensive performance evaluation of a low-cost, portable 3D printer based on the FDM technique. The proposed system emphasizes affordability, reliability, and maintainability through the use of open-source hardware and readily available components, including the Arduino Mega 2560 microcontroller, RAMPS 1.4 driver board, and NEMA 17 stepper motors. The printer was designed with a wooden frame to enhance rigidity and reduce vibration while maintaining a compact footprint. Both mechanical and electronic subsystems are fully integrated under Marlin firmware, allowing precise control of motion and temperature. Experimental trials demonstrated a maximum build volume of 250 mm × 250 mm × 250 mm and an average dimensional accuracy within 0.3 mm, validating the system’s capability for academic and prototyping applications. A detailed cost analysis revealed that the printer reduces manufacturing expenses by more than 60% compared to commercial alternatives, without compromising print quality or reliability. Furthermore, the study explores key process parameters influencing print accuracy and surface finish, including layer height, extrusion temperature, and print speed. The results confirm that high-quality FDM printing can be achieved at minimal cost, paving the way for affordable, locally manufactured, and customizable 3D printing solutions in developing regions.