In-Situ Monitoring and Diagnosing for Fused Filament Fabrication Process Based on Vibration Sensors.

Fused filament fabrication (FFF) is one of the most widely used additive manufacturing (AM) technologies and it has great potential in fabricating prototypes with complex geometry. For high quality manufacturing, monitoring the products in real time is as important as maintaining the FFF machine in the normal state. This paper introduces an approach that is based on the vibration sensors and data-driven methods for in-situ monitoring and diagnosing the FFF process. The least squares support vector machine (LS-SVM) algorithm has been applied for identifying the normal and filament jam states of the FFF machine, besides fault diagnosis in real time. The identification accuracy for the case studies explored here using LS-SVM is greater than 90%. Furthermore, to ensure the product quality during the FFF process, the back-propagation neural network (BPNN) algorithm has been used to monitor and diagnose the quality defects, as well as the warpage and material stack caused by abnormal leakage for the products in-situ. The diagnosis accuracy for the case studies explored here using BPNN is greater than 95%. Results from the experiments show that the proposed approach can accurately recognize the machine failures and quality defects during the FFF process, thus effectively assuring the product quality.

Machine Learning-Based Operational State Recognition and Compressive Property Prediction in Fused Filament Fabrication.

3D printing has exhibited significant potential in outer space and medical implants. To use this technology in the specific high-value scenarios, 3D-printed parts need to satisfy quality-related requirements. In this article, the influence of the filament feeder operating states of 3D printer on the compressive properties of 3D-printed parts is studied in the fused filament fabrication process. A machine learning approach, back-propagation neural network with a genetic algorithm (GA-BPNN) optimized by k-fold cross-validation, is proposed to monitor the operating states and predict the compressive properties. Vibration and current sensors are used in situ to monitor the operating states of the filament feeder, and a set of features are extracted and selected from raw sensor data in time and frequency domains. Results show that the operating states of the filament feeder significantly affected the compressive properties of the fabricated samples, the operating states were accurately recognized with 96.3% rate, and compressive properties were successfully predicted by the GA-BPNN. This proposed method has the potential for use in industrial applications after 3D printing without requiring any further quality control.