Profile monitoring based quality control method for fused deposition modeling process

He, Ketai; Zhang, Qian; Hong, Yili

doi:10.1007/s10845-018-1424-9

Cited by 58 publications

(17 citation statements)

References 30 publications

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“…In addition to projects that include mounting vision sensors on the extrusion head, another relevant approach is the stationary mounting of the camera with a view on the build platform. In this scenario, the entire layer is captured in one image acquisition [100,101,[104][105][106][107][108][109][110][129][130][131][132][133][134]. In one of the projects [131][132][133], statistical process control is used to evaluate the quality of the layer contours.…”

Section: D Visionmentioning

confidence: 99%

Process monitoring for material extrusion additive manufacturing: a state-of-the-art review

et al. 2021

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Qualitative uncertainties are a key challenge for the further industrialization of additive manufacturing. To solve this challenge, methods for measuring the process states and properties of parts during additive manufacturing are essential. The subject of this review is in-situ process monitoring for material extrusion additive manufacturing. The objectives are, first, to quantify the research activity on this topic, second, to analyze the utilized technologies, and finally, to identify research gaps. Various databases were systematically searched for relevant publications and a total of 221 publications were analyzed in detail. The study demonstrated that the research activity in this field has been gaining importance. Numerous sensor technologies and analysis algorithms have been identified. Nonetheless, research gaps exist in topics such as optimized monitoring systems for industrial material extrusion facilities, inspection capabilities for additional quality characteristics, and standardization aspects. This literature review is the first to address process monitoring for material extrusion using a systematic and comprehensive approach.

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Section: D Visionmentioning

confidence: 99%

Process monitoring for material extrusion additive manufacturing: a state-of-the-art review

et al. 2021

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“…Building complex geometries using 3-D printing technology can cause many errors. The study of geometric accuracy, as one of the most important indicators of 3-D printing product quality, has become the subject of many research works (He et al , 2019; Huang et al , 2015; Xu et al , 2013; Huang et al , 2014). The source of inaccuracy of printed parts, regardless of the type of the 3-D printing method, may be the model or processing errors.…”

Section: Characteristics Of Three-dimensional Printing Powder Technologymentioning

confidence: 99%

A pilot study to assess an in-process inspection method for small diameter holes produced by direct metal laser sintering

Deja

Zieliński

2019

RPJ

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Purpose The purpose of this study is to evaluate the geometric quality of small diameter holes in parts printed by direct metal laser sintering (DMLS) technology. An in-process optical inspection method is proposed and assessed during a pilot study. The influence of the theoretical hole diameter assumed in a computer-aided design (CAD) system and the sample thickness (hole length) on the hole clearance was analyzed. Design/methodology/approach The samples are made of two different materials: EOS MaragingSteel MS1 and aluminium alloy EOS Aluminium consisted of straight through holes of different diameters and lengths. Dimensional and shape accuracy of the holes were determined with the use of the image processing software and the computer analysis of two-dimensional (2-D) images. The definition of the equivalent hole diameter was proposed to calculate the hole clearance. Feret’s diameters were determined for the evaluation of the shape accuracy. Findings The dependency between the equivalent hole diameter and the theoretical diameter was approximated by the linear function for a specific sample thickness. Additionally, a general empirical model for determining the hole clearance was developed, allowing for calculating the equivalent hole diameter as a function of a sample thickness and a theoretical hole diameter. Practical implications Developed functions can be used by designers for a proper assignment of a hole diameter to achieve the required patency. The relevant procedures and macros based on proposed empirical models can be embedded in CAD systems to support the designing process. Originality/value The analysis of the geometric quality of the holes in parts printed by DMLS was based on the computer analysis of 2-D images. The proposed method of assessing the shape accuracy of straight through holes is relatively cheap, is widely available and can be applied to the features of other shapes produced by three-dimensional printing.

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“…Optical imaging has also been used to inspect form errors in the fabricated part, i.e. by extracting the shape of the layer outer boundary imaged from above (He et al , 2019) or the silhouette of the part while observing from the side (Lyngby et al , 2017). Thermal imaging in the infra-red range has been also applied to monitor the processing conditions of the layer (Dinwiddie et al , 2013) and to investigate the temperatures at the hot end of the extruder (Pollard et al , 2017).…”

Section: Introductionmentioning

confidence: 99%

Towards the development of a smart fused filament fabrication system using multi-sensor data fusion for in-process monitoring

Moretti

Bianchi

Senin

2020

RPJ

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Purpose This paper aims to illustrate the integration of multiple heterogeneous sensors into a fused filament fabrication (FFF) system and the implementation of multi-sensor data fusion technologies to support the development of a “smart” machine capable of monitoring the manufacturing process and part quality as it is being built. Design/methodology/approach Starting from off-the-shelf FFF components, the paper discusses the issues related to how the machine architecture and the FFF process itself must be redesigned to accommodate heterogeneous sensors and how data from such sensors can be integrated. The usefulness of the approach is discussed through illustration of detectable, example defects. Findings Through aggregation of heterogeneous in-process data, a smart FFF system developed upon the architectural choices discussed in this work has the potential to recognise a number of process-related issues leading to defective parts. Research limitations/implications Although the implementation is specific to a type of FFF hardware and type of processed material, the conclusions are of general validity for material extrusion processes of polymers. Practical implications Effective in-process sensing enables timely detection of process or part quality issues, thus allowing for early process termination or application of corrective actions, leading to significant savings for high value-added parts. Originality/value While most current literature on FFF process monitoring has focused on monitoring selected process variables, in this work a wider perspective is gained by aggregation of heterogeneous sensors, with particular focus on achieving co-localisation in space and time of the sensor data acquired within the same fabrication process. This allows for the detection of issues that no sensor alone could reliably detect.

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Profile monitoring based quality control method for fused deposition modeling process

Cited by 58 publications

References 30 publications

Process monitoring for material extrusion additive manufacturing: a state-of-the-art review

Process monitoring for material extrusion additive manufacturing: a state-of-the-art review

A pilot study to assess an in-process inspection method for small diameter holes produced by direct metal laser sintering

Towards the development of a smart fused filament fabrication system using multi-sensor data fusion for in-process monitoring

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