Custom Cartesian 3D Printer

A Bowden-drive Cartesian FDM printer, designed, sourced and assembled from scratch
Aluminium extrusion frame with a rod, lead screw and lead nut motion system
Electronics, firmware and calibration done end to end, to repeatable, print-ready performance

TypeIndependent project

My roleDesign, sourcing, assembly, electronics and firmware

ToolsAutodesk Fusion, FDM 3D printing

The finished Cartesian 3D printer with spool holder and LED lighting — The finished printer

Overview

I wanted to understand a 3D printer from the inside, so I built one. Everything was designed in Fusion, from the frame layout and motion system to the printed brackets and the extruder assembly. I then sourced the parts, assembled the machine, wired it up, configured the firmware, and tuned it until it printed reliably.

Design

Full printer assembly in Autodesk Fusion

Frame: black aluminium extrusions form a rigid base and gantry.
Motion system: smooth rods for guidance, and lead screws with lead nuts for the vertical axis.
Bowden extruder: the feeder sits on the frame to keep the moving print head light.
Printed parts: custom motor mounts, rod holders and brackets, designed in Fusion and 3D printed.

Build and Calibration

After mechanical assembly came electronics integration and firmware configuration, followed by rounds of calibration until the prints were repeatable.

Printing a landing gear joint for AeroMIT's competition aircraft

Print head in motion

Printing a test part