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Mechanical Engineering

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Impact of Endurance Testing on the Thermal Performance of a Retrofitted FDM 3D Printer Nugroho, Alexander Ariantono; Christanto, David; Bramantyo, Laurentius Yudha; Santoso, Bondan Wiratmoko Budi; Ign. R. Haryosuprobo; Mardiatno
Jurnal Rekayasa Mesin Vol. 21 No. 1 (2026): Volume 21, Nomor 1, April 2026
Publisher : Mechanical Engineering Department - Semarang State Polytechnic

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.32497/jrm.v21i1.7025

Abstract

The reliability of retrofitted Fused Deposition Modeling (FDM) 3D printers is affected by thermal stability during long print cycles. This study evaluated the thermal performance of a retrofitted BFB 3D Touch Cartesian FDM printer equipped with dual extruders, automatic bed leveling, a BTT SKR v1.4 controller, and a 24 V/360 W power supply unit (PSU). An 80 × 80 × 80 mm calibration cube was printed for 5 h to impose a continuous thermal load. Surface temperatures of stepper drivers, stepper motors, mainboard, PSU, and heated bed were measured with a TR-10 thermal imager at 1 h intervals, while bed preheating was recorded for 7 min at P1-P4 and the bed center. The Y1 driver reached 68.7 °C at hour 3, the PSU reached 65.0 °C at hour 5, and the extruder motor reached 52.7 °C. The bed center reached 59.2 °C at minute 7, but the corner regions were lower and locally non-monotonic. These fluctuations are interpreted as effects of local heat-transfer non-uniformity and measurement instability rather than uniform bed cooling. This study shows that driver and PSU cooling, cable-size verification, repeated measurements, and bed insulation are required to improve retrofit-printer reliability in extended operation.  
Enhancing Bed Alignment and Reducing Calibration Time in 3D Printers Using Auto Leveling with PI Control Wongsoatmojo, Andreanto; Pratama, Fransiskus Arjuna Davin; Ign. R. Haryosuprobo; Nugroho, Alexander Ariantono; Santoso, Bondan Wiratmoko Budi; Mardiatno
Jurnal Rekayasa Mesin Vol. 21 No. 1 (2026): Volume 21, Nomor 1, April 2026
Publisher : Mechanical Engineering Department - Semarang State Polytechnic

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.32497/jrm.v21i1.7027

Abstract

Manual bed leveling in fused deposition modeling (FDM) 3D printers is operator-dependent and often produces an uneven nozzle-bed gap, which reduces first-layer adhesion and dimensional repeatability. This study developed a retrofittable auto leveling system based on Proportional-Integral (PI) control for a Cartesian 3D Touch 3D printer at Politeknik ATMI Surakarta. The system combines a 3D Touch probe, three NEMA 17 motorized bed supports, one fixed-jaw reference, DRV8825 drivers, an Arduino Mega 2560, and a Raspberry Pi 4B to measure the bed at nine probing points and physically correct the bed height. Bed deviation was defined as the difference between the maximum and minimum measured height at the bed support reference points. Five Kp-Ki combinations were tested using a 0.05 mm tolerance. The best response was obtained at Kp = 1.0 and Ki = 0.03, completing calibration in 223 s with four iterations and a 0.016 mm deviation. Across five trials, auto leveling reduced the average calibration time from 594.4 s to 255.4 s (57.0%) and reduced the average bed deviation from 0.2228 mm to 0.0232 mm (89.6%) compared with manual leveling. ASTM D638 Type I print validation showed 90% successful squareness. The results demonstrate that PI-controlled physical bed alignment can improve calibration efficiency, repeatability, and first-layer reliability in low-cost FDM printers.
Co-Authors Bondan Wiratmoko Budi Santoso Bramantyo, Laurentius Yudha Christanto, David Ign. R. Haryosuprobo Nugroho, Alexander Ariantono Pratama, Fransiskus Arjuna Davin Wongsoatmojo, Andreanto