Development and Evaluation of a Cost-Effective Desktop 3D Printing System for Rapid Prototyping

The rapid advancement of additive manufacturing has transformed prototyping and small-scale production by enabling the creation of complex geometries and customizable products through layer-by-layer fabrication. This paper presents the design, development, and evaluation of a cost-effective desktop 3D printer optimized for rapid additive manufacturing using Fused Deposition Modeling (FDM) technology. The printer combines a rigid aluminum extrusion frame, NEMA 17 stepper motors, a Bowden extruder with an all-metal hotend, and open- source electronics controlled by a 32-bit microcontroller running Marlin firmware. It supports a variety of thermoplastic materials such as PLA, ABS, PETG, and TPU, achieving print speeds up to 60 mm/s while maintaining dimensional accuracy within ±0.2 mm. Key features include automated mesh bed leveling, PID thermal control, and a user-friendly touchscreen interface. Iterative testing revealed improvements in filament handling and vibration control, confirming the printer’s suitability for edu- cational, research, and light industrial prototyping applications. This project highlights the potential of modular, customizable 3D printing platforms to democratize rapid additive manufacturing.