Custom 3D Printer

Overview

This project consists of a fully custom-built 3D printer, designed and assembled from scratch. I worked on every aspect of the machine, including mechanical structure, motion system, electronics, firmware configuration, and calibration.

The goal was to deeply understand how FDM 3D printers work and to gain hands-on experience with mechatronics, embedded systems, and motion control.

Mechanical Design

• Custom frame and structure design
• Linear motion system setup
• Belt tensioning and alignment
• Lead screw and axis calibration
• Vibration reduction and rigidity optimization

Electronics & Motion Control

• Stepper motor selection and configuration
• Motor drivers tuning
• Endstop wiring and safety setup
• Power management
• Thermistors and heaters configuration

Firmware – Marlin

I configured and customized the Marlin firmware to match the printer’s hardware and motion system.

• Axis steps per mm calibration
• Acceleration and jerk tuning
• Thermal protection configuration
• Bed leveling system
• Custom compile and deployment

Challenges

• Mechanical alignment issues
• Stepper motor noise and skipped steps
• Thermal stability
• First-layer consistency
• Firmware debugging

What I Learned

• Motion systems and kinematics
• Embedded firmware configuration
• Hardware-software integration
• Troubleshooting complex systems
• Iterative prototyping