Custom 3D Printer Assembly & Firmware Optimization

I undertook the complete assembly and calibration of a custom 3D printer from a kit-based platform, transforming raw mechanical components into a fully functional, high-precision additive manufacturing system. This hands-on project required meticulous attention to mechanical alignment,  including frame squareness, belt tensioning, linear rail installation, and extruder assembly  alongside deep electrical integration of stepper motors, endstops, heating elements, and temperature sensors. On the firmware side, I compiled and configured Marlin directly on an Arduino-based RAMPS 1.4 controller, tuning critical parameters such as acceleration, jerk, steps per millimeter, and thermal runaway protection. I also implemented automatic bed leveling using a BLTouch sensor and calibrated the extrusion multiplier and retraction settings to eliminate stringing and improve surface finish. Beyond basic assembly, I optimized the printing environment by integrating GNU/Linux-based slicing tools (Cura / PrusaSlicer) and experimented with advanced materials including PETG and TPU. This project deepened my understanding of real-time control systems, motion planning algorithms, and the hardware-software interface at a granular level — knowledge I have since applied to embedded robotics and IoT systems.