Introduction

This week in Mechanical Design and Machine Design was focused on understanding how to create a complete machine by combining ideas, design, fabrication, and testing into one process. The main goal of this assignment was to learn how a simple concept can be converted into a working model by following proper steps like planning, designing, material selection, fabrication, assembly, and programming. In this process, we worked as a team where tasks were divided based on our strengths, which helped us complete the project more efficiently. I worked on the designing part of the machine, while my teammate handled the hardware assembly, and both of us contributed to programming and testing. This assignment helped us understand the importance of teamwork, step-by-step workflow, and problem-solving while building a machine. It also showed that designing is not only about making a model, but also about thinking practically so that the machine can be built and function properly in real life.

Final machine video

Group assignment tasks:-

Design a machine that includes mechanism, actuation, automation, function, and a user interface.

Build the mechanical parts of the machine and operate it manually.

Document the complete group project along with individual contributions.

What we learned:-

This week we learned how to design and build a machine from an idea. We understood that a machine is made step by step, not all at once.

We learned:-

• How to convert an idea into a simple design
• Basics of mechanical parts and how they connect
• How to divide work in a team
• Importance of planning before making anything
• How design, electronics, and programming work together

We worked as a team of two members:

Arati Bhosale

I worked on the design part of the machine. I created the model and planned how parts will fit together.

Ashish Shende

He worked on hardware assembly, like fixing parts and building the structure.

Both of us

We worked together on programming and machine testing. This helps us to do team work and share responsibilities.

Weekly Planning:

We followed a simple plan to complete our work:

• 1.Idea:-We thought about what machine to make and discussed different ideas.
• 2.Design:-Created sketches and design of the machine.
• 3.Material Selection:-Decided what materials are needed.
• 4.Material Purchase:-Bought required materials from the market.
• 5.Fabrication:-Cut and prepared the parts
• 6.Assembly (Hardware):-Joined all parts to build the machine.
• 7.Electronics Setup:-Connected motors, wires, and other components.
• 8.Programming:-Wrote code to control the machine.
• 9.Testing:-Checked if the machine works properly and fixed errors.

1.Idea

In the beginning, we discussed different ideas for our machine and after discussing with our mentor we came up with two concepts:

• String Art Machine-A machine that can create patterns by arranging threads in a structured design.
• Clay Printer-A machine that can print or shape objects using clay material in a controlled way.

After comparing both ideas, we decided to make the clay printer. We chose this idea because it includes more learning opportunities like material handling, controlled movement, and better integration of mechanism, actuation, and automation. It also allowed us to explore how a machine can create physical objects layer by layer.

Sketch and Design

After finalizing the idea of the clay printer, we created simple sketche using chatgpt to understand the structure and working of the machine. The sketch helped us plan the arrangement of parts, movement, and overall design.

After finalizing the concept through initial sketches, the complete machine was designed using SolidWorks.Each component was modeled by considering accurate dimensions, alignment, and assembly requirements.

We designed some base parts and use grabcad for taking 3d parts of the components like screws, aluminium extrusion, bearings, leadscrews,nema 17 motors.

During the design process, several practical factors were considered to ensure successful fabrication and assembly.

1.Manufacturability

The design was created in a way that all parts can be easily fabricated using available tools and processes such as cutting, drilling, and basic machining. Complex geometries were avoided to reduce fabrication difficulty.

2.Availability of Standard Components

Standard and easily available components such as stepper motors, rods, fasteners, and electronic parts were selected to simplify sourcing and replacement.

3.Ease of Assembly

The design ensures that all components can be assembled without interference. Proper spacing, alignment, and mounting provisions were included to avoid conflicts between moving parts.

Mechanism selection

Together as a group, we explored different motion mechanisms suitable for building a 3D printer, considering factors such as complexity, cost, and ease of fabrication. After evaluating multiple options, we selected the H-Bot mechanism for our printer.

Mechanical Design

After finalizing the mechanism and overall concept, the detailed design of the machine was carried out using SolidWorks.Each component of the printer was modeled individually by considering accurate dimensions, required tolerances, and functional requirements. The design process began with basic structural elements such as the frame, followed by motion components including rods, motor mounts, and the extruder assembly.

Following are the parts made using solidworks

Here is assembly

Material selection:-

Material Purchase:-

Fabrication:-

After completing the design phase, the fabrication process was started by preparing all the required parts as per the finalized dimensions.The fabrication process began with a preliminary prototype using cardboard to validate the design before working with final materials.

Laser cutting:-

Cardboard Prototyping

Initially, base parts were cut using cardboard and assembled to verify the design. This helped in checking whether all holes on the main parts were properly aligned. Ensuring this alignment was important so that the lead screw and guide rods could pass through smoothly and hold the structure together.

After this we move forward for acrylic cutting process.

So, first we take screws, bolts,nuts and many more material from old printer and collect them for assembly.

3D printing

We also print 3D parts required for our machine.

After cutting we started assembling process.So we started assembly one by one.

Electronics and Marlin Firmware:-

The clay 3D printer integrates electronic components and control software to achieve precise motion and controlled material extrusion. The system is based on a microcontroller platform that interprets commands and drives actuators accordingly.

1. Microcontroller(Arduino mega) and Shield

An Arduino Mega we used as the main controller of our system. It is interfaced with a motor driver shield RAMPS 1.4, which simplifies connections between the microcontroller and other components.

Connection:

The Arduino Mega 2560 is directly mounted below the RAMPS 1.4 shield.RAMPS plugs into the Mega using stacked headers.

Once connected, the Arduino Mega acts as the central processing unit of the system. It receives G-code commands from the computer through USB communication and processes them using firmware. After processing the instructions, it generates precise digital control signals such as step and direction pulses required for motion control.The RAMPS shield works as an interface between the Arduino and the physical components of the machine. It takes the control signals from the Arduino Mega and distributes them to different parts of the system such as stepper motor drivers, limit switches, and other peripherals. It also handles power distribution from the external power supply to the motors and drivers.In operation, the Arduino Mega and RAMPS shield work together as a single control unit. The Arduino interprets the movement instructions, while the RAMPS shield ensures that these instructions are executed by driving the stepper motors and reading feedback from limit switches. This combination allows precise and synchronized movement of the X, Y, and Z axes of the clay printer.

All code files

Click here to download code files