Design of Multi-Cell FDM Build Bed Systems for Optimal Material Usage in Additive Manufacturing Process

Abstract

Support structures are essential in additive manufacturing (AM) processes such as material extrusion, particularly for fabricating parts with overhanging features. However, conventional supports are typically removed after printing and cannot be reused, resulting in significant material waste and increased printing time. To address these limitations, this research introduces a novel multi-cell FDM build bed support system designed to minimize support-related challenges in fused deposition modeling (FDM). The proposed system employs an array of movable pins that function as a dynamically adjustable build platform controlled by an Arduino-based program. During the printing process, the pins elevate layer by layer, corresponding to the layer thickness. Each pin automatically stops at a predetermined height through an electromechanical control system. The lifting mechanism operates via a programmable stepper motor, whereas magnetic coupling between permanent magnets and metallic washers ensures stable support and protects the printed component from damage during detachment. Additionally, a hybrid support approach has been developed for printing curved geometries. This method combines traditional printed supports with the multi-cell FDM bed system, allowing the adjustable platform to provide sufficient support and significantly reduce the need for printed material. For highly complex overhangs beyond the bed′s adjustable range, conventional supports are selectively employed. Experimental results demonstrate that the proposed multi-cell FDM build bed system achieves up to 16.22% reduction in material consumption and 22.19% reduction in printing time compared with tree support and conventional FDM printing methods.