Abstract ID#: 3347
Category: Engineering and Technology
Undergraduate
Improving Reliability in Fused Filament Fabrication
Abigail Moadab
Introduction
The purpose of this research is to improve fused filament fabrication (FFF)
reliability by measuring the temperature of deposited filament. First, a slicer was
developed in Python to obtain full control over the data sent to the printer. The
next step is to integrate thermal infrared (IR) sensors around the extruder of the
FFF printer to get temperature readings of filament as it is extruded. Once these
temperature values have been obtained, a feedback control system can be set
up to ensure that the deposited filament is actually at the nominal printing
temperature. This will be accomplished by redirecting the printer to check the IR
sensors for temperature values and bypassing its internal temperature sensors.
If successful, this research could expand the applicability of FFF printers in
industrial settings because of an improved reliability and a better awareness and
detection of defects and heterogeneities within printed products.
This diagram shows the intended
placements for the IR sensors.
The current plan is to use 3
sensors and design 3D printed
parts to attach them to the
extruder with. It’s important that
the attachments and sensors do
not interfere with the extrusion
process in any way!
Approach
§ A Slicer was developed in Python to allow us to send commands to the printer with no
ambiguity or uncertainty on what data is being sent.
§ Then, 3 infrared heat sensors will be integrated into the printer (right at the extruder!)
to obtain an accurate reading of the filament temperature as it’s deposited.
§ That output will then be used in a feedback loop to improve and optimize filament
temperature.
Important Parameters
§ Extrusion Temp.: Printing should take place at the maximum temperature the
material can withstand before degrading – this maximizes tensile strength
st
§ Print Bed Temp.: Improves adhesion of 1 layer to build plate
§ Layer Thickness: thinner layers tend to increase Elastic Modulus
§ Print Speed: Generally, an increase in print speed can improve tensile strength,
but this parameter is also dependent on temperature.
Inconsistencies in the above parameters affect the material properties of the
printed part; reducing inconsistencies in these parameters will improve FFF
reliability. Extrusion temperature is among the most important of parameters as it
affects extruder flow rates and bonding between layers, which is why we chose to
focus on controlling that variable.
Impact & Expected Results.
More standardization in extrusion temp. in FFF
addresses the lack of FFF reliability in precise
industrial applications!
Having a higher extrusion temp. can:
§ Increase print quality
§ Improve interlayer bonding, which improves
tensile strength
§ Minimize accumulation of thermal stress
All of which improve the overall mechanical
properties of the part!
This diagram shows the feedback loop
to be used. The output from the
sensors will be used to compare sensor
filament temperature to the printer’s
temperature data and increase
temperature as needed. This will
ensure that measured temperature is
the nominal printing temperature.
Contact: moadab.a@husky.neu.edu