3-D Printer for Full-Size Flight Vehicle Structures

The goal of this project is to design and fabricate a large-scale prototype 3-D printer capable of printing parts as large as 50 by 50 by 25 inches and of reaching and maintaining temperatures required to print high-grade thermoplastics such as Ultem. The design focused on system robustness and longevity and on the safety of the operator and bystanders. The system was built mostly using off-the-shelf components with provisions for an insulating enclosure for high-temperature printing. The extrusion system was designed to use any filament on the market, and the bed can support a print job of over 350 pounds. Nozzles of various sizes allow the user to adjust for different part sizes, accuracy, and printing speed. The prototype includes a software interface for customizing and estimating print times and materials needed.