5-Axis 3D Printer

What it does

This 5-axis 3D printer addresses issues in traditional FDM printing, such as layer shifting and Z-axis brittleness, especially for parts with small XY-plane cross-sections, by enabling more precise, multi-directional fabrication.

Your inspiration

Our team was inspired by the limitations we experienced firsthand while printing intricate models with FDM 3D printers. We noticed frequent failures and excessive support materials being used, especially with parts that had small cross-sections or overhangs. After seeing a failed print of a hollow tetrahedron, we realized the core issue was structural weakness and the lack of support-free printing options. Recognizing that commercial printers with a tilting bed solve these problems but are too costly and bulky, we saw an opportunity: to design a compact, affordable nozzle attachment that brings 5-axis capability to existing printers.

How it works

Our design is a modular nozzle attachment that transforms traditional FDM 3D printers into 5-axis machines by adding two rotational degrees of freedom at the extruder. The nozzle can rotate ±90° along the X-axis and ±90° along the Z-axis. These rotations are enabled by stepper motors and 3D printed gears, which reduce the weight on the print head and help preserve the original build volume. To improve material flow without the bulk of Bowden tubes, we integrated a remote direct drive feeder. The system is managed by modified Marlin 2.1 firmware running on a BTT Octopus board with quiet, precise TMC2209 stepper drivers. A cartridge heater and thermistor provide accurate temperature control. Our custom slicing algorithm allows users to define a curved line as their desired slicing axis, then generates curved, 5-axis toolpaths that enable support-free printing and stronger, more efficient builds.

Design process

We began with concept sketches and mechanical design brainstorming, eventually settling on a nozzle-rotating system inspired by head-head 5-axis configurations. Early prototypes focused on motion transmission using stepper motors and gears, with multiple iterations to achieve the smallest size and the highest precision. We faced and resolved issues with thermal degradation of materials around the heater, eventually redesigning the nozzle using metal with high thermal conductivity. To reduce print head weight and improve precision, we developed a remote direct drive feeder with a worm gear and spring-tensioning mechanism. Firmware development started with Arduino GIGA and A4988 drivers, later upgraded to the BTT Octopus board with TMC2209 drivers for better performance and silent operation. We created a modular C++ firmware library and integrated a user-friendly LCD interface. In parallel, we developed a custom slicer that allows a customized slicing axis, which currently handles simple shapes and generates motion-aware toolpaths. We’ve completed partial system integration and begun full-path printing tests. Next, we aim to refine motion control, collision avoidance, and improve the slicer’s automation.

How it is different

Unlike other 5-axis printers that rotate the print bed, which reduces stability and limits print size, our design rotates only the extruder, preserving build volume and improving precision. Competing nozzle-based systems are bulky and limit the printable area; our gear structure and remote feeder setup keeps the print head compact and lightweight. Many existing solutions are too expensive or require significant modifications to the printer—ours is a bolt-on attachment compatible with many commercial models, designed for easy assembly and use. We also developed a dedicated slicer that produces optimized curved toolpaths for 5-axis motion, improving strength and reducing material waste. Our design strikes a unique balance between accessibility, affordability, and advanced functionality, making 5-axis printing available to hobbyists, students, and professionals.

Future plans

In the next phase, we’ll refine the slicer to support the analysis of complex geometries and locate the slicing axis automatically. We plan to complete the integration of the remote direct drive feeder and finalize a compact hardware design. Firmware will be enhanced to support full auto-homing and implement an anti-collision system. We also aim to test across multiple printer models for broader compatibility. Our long-term goal is to release a modular upgrade kit with open-source firmware and slicer software, empowering more users to achieve high-strength, support-free prints at low cost.

Awards

Willy Revolution Awards for Outstanding Innovation in Engineering Design 2025 Shapiro Showcase