PRJ // 0082021–2022MANUFACTURING
Custom Large-Format FDM 3D Printer
400 × 400 × 400 mm FDM printer built from scratch, tuned for accuracy, thermal stability, and low cost.
TimelineNov 2021 — Dec 2022 · 14 mo
RoleSole owner: mechanical, electronics, integration
SkillsFrame · Motion · Thermal · Marlin firmware
Outcome0.05 mm accuracy · 24+ hr prints
Overview
Designed and built a large-format Cartesian FDM printer capable of long, high-accuracy prints. Balanced structural rigidity, thermal stability, and component cost to rival commercial systems at a lower price.
The Problem
Commercial large-format printers are costly and often compromise on accuracy or thermal stability when scaled up. Maintaining flatness, repeatability, and consistent extrusion over long cycles is challenging at larger volumes.
My Approach
Engineered a rigid 2020/2040 aluminum extrusion frame with custom aluminum gantry. Cartesian motion with Z on lead screws, X/Y belt-driven with NEMA 17/23. BTT SKR v1.4 controller with TMC2209 drivers running Marlin firmware. Tuned firmware and hardware for accuracy and repeatability.
Key Results
Completed 24+ hour continuous print cycles. Achieved 0.05 mm dimensional accuracy. Printed PLA, ABS, PETG, TPU without warping. Consistent layer quality across the full bed. Used to fabricate parts for other projects including the Underwater ROV.
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