Design, Calibration, and Troubleshooting of a Modular Low-Cost 3D Printer Based on Open-Source Technologies

Abstract

This paper presents the design, construction, and calibration of a modular low-cost 3D printer based on open-source technologies, developed as part of an academic research project. The printer utilises fused filament fabrication (FFF) and is built using locally available materials and components, including a T-slot aluminium frame, NEMA 23 stepper motors, and an Arduino Mega 2560 with RAMPS 1.4 control board. The system integrates Marlin firmware and CURA slicing software, enabling autonomous operation via an LCD panel and encoder interface. A detailed methodology is provided for mechanical assembly, electronic integration, firmware configuration, and calibration procedures. Special attention is given to the challenges encountered during the initial testing phase, including filament feeding issues, thermal inconsistencies, and mechanical misalignments. Solutions such as replacing inadequate components (e.g., fibreglass bushings with PTFE), adjusting spring tension, and refining firmware parameters are discussed. The results demonstrate successful printing of complex geometries after iterative calibration, validating the printer’s performance and replicability. This work contributes to the democratisation of additive manufacturing by offering a replicable, open-source solution for educational and prototyping purposes. The findings are relevant to machine design, automation, and robotics communities seeking practical insights into low-cost fabrication systems.