Automated non-destructive 3D printing filament material properties monitoring based on electric permittivity, longitudinal encoding and diameter multi-axes real-time measurements

Abstract

Rapid prototyping is an essential part of today’s research and development process. The ability to produce objects quickly, cost-effectively and on-site is critical to meeting this fundamental requirement. One of the factors that leads to inconsistencies and defects in the produced parts is the uncompensated change in material properties used in the material extrusion 3D printing manufacturing process. This creates the need for a real-time, low-cost filament quality monitor that can characterize the material properties of the filament along its length. This can be achieved by tracking the variation in measured capacitive tube capacitance and diameter of different sensor types over multiple selected axes and encoding the results to a specific fragment of filament used in material extrusion 3D printing. With such collected data it is possible to monitor factors such as material moisture, roundness, internal and external defects, component proportions, relative electrical permeability, Poisson’s ratio and material type. This work presents the first proof of concept of such a device and describes its operating principle in detail. As examples of applications, filament material type recognition is presented based on the characteristics of several types of filaments from different manufacturers, the process of moisture absorption over time for selected filaments is described, and the detection of defects of varying degrees is shown.