Dynamic Measurements Using FDM 3D-Printed Embedded Strain Sensors

Abstract

3D-printing technology is opening up new possibilities for the co-printing of sensory elements. While quasi-static research has shown promise, the dynamic performance has yet to be researched. This study researched smart 3D structures with embedded and printed sensory elements. The embedded strain sensor was based on the conductive PLA (Polylactic Acid) material. The research was focused on dynamic measurements of the strain and considered the theoretical background of the piezoresistivity of conductive PLA materials, the temperature effects, the nonlinearities, the dynamic range, the electromagnetic sensitivity and the frequency range. A quasi-static calibration used in the dynamic measurements was proposed. It was shown that the temperature effects were negligible, the sensory element was linear as long as the structure had a linear response, the dynamic range started at ∼ 30 μ ϵ and broadband performance was in the range of few kHz (depending on the size of the printed sensor). The promising results support future applications of smart 3D-printed systems with embedded sensory elements being used for dynamic measurements in areas where currently piezo-crystal-based sensors are used.

Fused Filament Fabrication of Piezoresistive Carbon Nanotubes Nanocomposites for Strain Monitoring

“…PLA-carbon based nanocomposites derived from 3D printing have been also investigated on electrical and/or thermal conductivity Ivanov et al, 2019). In order to produce strain sensor by using PLA conductive composites (Maurizi et al, 2019), the dependence of piezoresistive behavior on temperature should be properly considered. In particular taking into consideration the Tg of PLA matrix, a specific approach to compensate the temperature effect on resistivity of PLA conductive sample in the range 20-50 • C has been discussed (Daniel et al, 2018;Coleman et al, 2019).…”

Process Parameters for FFF 3D-Printed Conductors for Applications in Sensors

“…Combining multi-material fused-filament fabrication (FFF) and functional composite materials enables the fabrication of an object with embedded functional elements (sensorics [1], actuation [2], heating [3], and energy storage [4], etc.) in a single-step printing process.…”

“…The piezo-resistive characteristic of conductive FFF materials is often exploited for strain sensing. Maurizi et al [1] printed a functional small-strain-rate sensor in a dual extrusion process. Kim et al [16] and Christ et al [17] researched highly flexible high-strain-rate sensors that can be used in wearable electronics.…”

Printed Strain Gauge on 3D and Low-Melting Point Plastic Surface by Aerosol Jet Printing and Photonic Curing

“…In the field of Industry 4.0, additive manufacturing (AM) is crucial to create and customized prototypes or products of arbitrary shape for reducing lead time, costs, and material wastage [19]. The combination of AM and PE for fabricating smart objects has attracted more attention in recent years [20,21] because printing electronics directly on an object’s surface could take advantage of the PE (low-cost, fabrication flexibility, etc.) and could avoid any installation/assembly and the associated problems [19,21].…”

“…The combination of AM and PE for fabricating smart objects has attracted more attention in recent years [20,21] because printing electronics directly on an object’s surface could take advantage of the PE (low-cost, fabrication flexibility, etc.) and could avoid any installation/assembly and the associated problems [19,21]. Indeed, the installation of electronics and sensors often includes the surface preparation (cleaning, scratching, etc.)…”