Low-Cost Online Dimensional Quality Monitoring in 3D Printing using Standardised Cyber-Physical Production Architecture

Abstract

Implementing online quality control systems offers significant benefits, such as improved product quality and safety, greater visibility, and enhanced control. A robust and inexpensive quality control system is necessary to improve product quality, reduce costs and inefficiencies. This research aims to develop a standardized in-situ monitoring system for 3D printing processes to track geometric variations, integrate design and production data, and ensure replicability. Experiments were conducted by varying key parameters, namely, feed rate (50%, 75%, 100%), layer height (0.1 mm, 0.2 mm, 0.3 mm), and belt tension levels (high, moderate, low) to assess their impact on FDM machine performance and product accuracy. A standard square shell design was used to validate the data collection system, followed by tests on different geometries. Results indicated that the developed solution effectively detected and tracked performance variations, particularly those caused due to belt tension, ensuring consistent accuracy across varying operating conditions. The novelty lies in its detailed error analysis, utilizing baseline error patterns as reference standards by comparing real-time manufacturing data with computer aided designs. This enables early detection and measurement of deviations, reducing defects and material waste while saving costs, improving processes, and supporting smarter manufacturing in line with Industry 4.0. © This is an open access article published by the IET under the Creative Commons Attribution License (http://creativecommons.org/licenses/by/3.0/)