Three Dimensional Printing with Embedded Electronics

Current 3D printers in the market prints a non working 3D model using different materials for example if it is given a 3D model of a car key it will print it but you wont be able to use its buttons to unlock the doors or the trunk. It will just be a plastic model without any working electronics in i

Project Title

Three Dimensional Printing with Embedded Electronics

Project Area of Specialization

3D/4D Printing

Project Summary

Current 3D printers in the market prints a non working 3D model using different materials for example if it is given a 3D model of a car key it will print it but you wont be able to use its buttons to unlock the doors or the trunk. It will just be a plastic model without any working electronics in it.

The goal of this project is to build a working prototype using a 3D printer instead of just a plastic model which current 3D printers make. We will achieve this goal by using conducting ink to print a circuit board inside the model. We will take a 3D printer and attach a second extruder (syringe pump based) so that it extrudes the conductive ink. This means that the end product will be a fully functioning prototype of any model you wish to print. Major use of this project is in rapid prototyping in the manufacturing industry.

Project Objectives

To build a 3D printer which is able to embed electronic devices inside the models it prints without any human intervention.

To save time and costs of rapid prototyping in industry.

Use of eco friendly materials in an economic way.

Project Implementation Method

To implement this project a 3D printer which supports dual extrusion is modified on both hardware and software end.

On the hardware end a syringe pump based extruder is designed and attached to the printer. This will be used extrude liquid conductive ink in order to print the circuit.

On the software end generally the CAD model is converted to an STL file before being sent to the printer. This file is basically 2D layers which the printer will print on top of each other. It will then be decided where in the model do we need the circuit board to be printed. The STL file will then be edited and the circuit parameters to be printed will be added between those layers. This will be done manually.

After the CAD model and the PCB file has been merged this single file will then be sent to the printer. When the printer will come to the layer where we need to print the circuit it will switch to the second extruder and use it to print the circuit. After it has been printed it will again swith to the first extruder and print the rest of the CAD model.

A pause and resume function will also be added in order for an IC to be placed manually on the circuit.

Benefits of the Project

There are numerous benefts of this project.

Instead of building two separate things(plastic casing and Printed circuit boards) separately they are now being made simulatneously. This reduces cost and saves time.

Moreover in the rapid prototyping industry where numerous prototypes are to be made with minor changes this project will be most ideal for that case and will save cost, time and material.

Printing circuit boards using the etching method wastes a lot of copper. This will be a more economical way to print circuits.

Technical Details of Final Deliverable

The final deliverables will be an advanced 3D printer which will take a single file containing information of both the 3D model and the circuit to be printed and where to be printed.

Final Deliverable of the Project

HW/SW integrated system

Core Industry

Manufacturing

Other Industries

Core Technology

3D/4D Printing

Other Technologies

Sustainable Development Goals

Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Responsible Consumption and Production

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com