Design and Thermal Analysis of FDM Based 3D Printer

Three-dimensional (3D) printing has emerged as one of the most important technologies in modern manufacturing. Unlike conventional subtractive manufacturing methods, additive manufacturing builds objects layer by layer directly from digital models, reducing material wastage and enabling rapid prototyping. Among the various additive manufacturing technologies, Fused Deposition Modelling (FDM) is widely used due to its simplicity, affordability, and ease of operation. This paper presents the design, fabrication, and thermal analysis of a low-cost FDM-based 3D printer developed using readily available components. The complete printer assembly was designed using SolidWorks software and fabricated to provide an economical solution for educational and prototyping applications. Thermal analysis of the extruder nozzle was carried out to evaluate temperature distribution, heat transfer characteristics, and extrusion performance during ABS filament printing. Brass was selected as the nozzle material due to its high thermal conductivity and cost-effectiveness. Simulation results indicated a maximum temperature of 508 K and a minimum temperature of 416 K across the nozzle. The analysis confirmed uniform heat distribution and efficient thermal behavior, leading to improved extrusion quality and dimensional accuracy. The study demonstrates that a reliable and efficient 3D printer can be developed at low cost without significantly compromising performance.