Rapid Prototyping (RP) has transitioned from a basic visualization tool into a robust production methodology capable of fabricating complex functional components. This paper presents a structured, comprehensive study on the design, calibration, and manufacturing efficiency of custom mechanical parts using a desktop Fused Deposition Modeling (FDM) system. Utilizing a Creality Ender-3 V3 SE platform, various functional elements—including calibration cubes, mechanical gears, brackets, and threaded fasteners—were modeled via Computer-Aided Design (CAD) and processed into physical components using Polylactic Acid (PLA). The investigation provides a detailed framework of the additive workflow, detailing slicing parameter optimization alongside an exhaustive cost analysis encompassing material utilization and regional domestic electrical tariffs (UGVCL, Gujarat). The empirical outcomes validate that optimized desktop FDM printing yields a highly dependable, dimensionally accurate, and economically disruptive alternative to conventional subtractive manufacturing techniques for small-scale engineering applications and vocational laboratories.

Keywords: Additive Manufacturing, Fused Deposition Modeling, CAD Modeling, Cost Optimization, Mechanical Components.