Custom FDM for Elastomer Mass Production
From garage prototype to 2,500+ units shipped globally.
Role: Lead Engineer & Founder
Tools: Marlin FW, C++, SolidWorks, MKS Eagle (32-bit), TMC2209
The Challenge
I identified a niche market for diesel engine intercooler seals made from high-performance polyurethane. However, standard FDM printers could not handle soft TPU (Shore 65A) at production speeds—the filament would buckle and jam in the extruder gear path.
The Engineering Solution
Instead of buying expensive industrial printers, I engineered a custom solution:
- Hardware: Retrofitted an Anet A8 Plus frame with a direct-drive extruder path optimized for flexible filaments. Replaced the mainboard with an MKS Eagle (32-bit) and TMC2209 drivers for precise micro-stepping and noise reduction.
- Firmware: Modified Marlin firmware source code. Tuned thermal runaway protection, recalibrated stepper motor current (Vref) for high-torque/low-heat balance, and optimized linear advance settings for elastomeric flow.
Impact & Data Analysis
The system achieved reliable 24/7 operation with near-zero failure rate.
Long-Term Impact Analysis
Data visualized using Python (Pandas/Matplotlib) based on sales logs & fleet mileage assumptions.
Environment: The product restores airtight intake systems, proven to reduce fuel consumption by ~15% and cut CO2 emissions (approx. 770 tons annually across the fleet).