Factors Effecting Real Time Optical Monitoring of Fused Filament 3-D Printing

This study analyzes a low-cost reliable real-time optimal monitoring platform for fused filament fabrication-based open source 3-D printing. An algorithm for reconstructing 3-D images from overlapping 2-D intensity measurements with relaxed camera positioning requirements is compared with a single camera solution for single side 3-D printing monitoring. The algorithms are tested for different 3-D object geometry and filament colors. The results showed that both of the algorithms with a single and double camera system were effective at detecting a clogged nozzle, incomplete project, or loss of filament for a wide range of 3-D object geometries and filament colors. The combined approach was the most effective and achieves 100 percent detection rate for failures. The combined method analyzed here has a better detection rate and a lower cost compared to previous methods. In addition, this method is generalizable to a wide range of 3-D printer geometries, which enables further deployment of desktop 3-D printing as wasted print time and filament are reduced, thereby improving the economic advantages of distributed manufacturing.