Quality Assurance and Inspection of Additive Manufactured Components in the Fused Filament Fabrication Process
Inline Inspection of Additive Manufacturing Process with Infrared Cameras from Optris
Challenge
In Fused Filament Fabrication, uneven temperature distribution causes poor first-layer adhesion, cracking, delamination, and inadequate infill, which compromise mechanical strength and surface quality. Maintaining optimal and stable thermal conditions throughout the printing process is essential to avoid defects and ensure dimensional accuracy.
Solution
By monitoring thermal profiles in real time, infrared cameras enable immediate detection and correction of temperature-related issues during printing. This in-situ feedback loop improves process control, enhances layer bonding, and identifies structural flaws and surface defects without interrupting the production process.
Benefits
- Prevents first-layer detachment by ensuring consistent bed and nozzle temperatures
- Enhances structural integrity by detecting cracks and delamination early
- Reduces scrap by identifying inadequate infill and voids in real time
- Minimizes surface roughness and irregularities through active process adjustment
- Supports reliable production of safety-critical 3D printed components
Optimizing Fused Filament Fabrication Parameters: Tackling Adhesion, Clogging, Delamination, and Infill Issues
Fused Filament Fabrication (FFF), also known as strand deposition, is a common additive manufacturing method. This process involves the layer-by-layer deposition of molten plastic filament to create 3D objects. The plastics used in FFF are the same thermoplastics found in conventional manufacturing processes, making plastic the most prevalent material for 3D printing in FFF and other Extrusion Additive Manufacturing (EAM) variants. Various polymers can be utilized, including acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polylactic acid (PLA), high-density polyethylene (HDPE), PC/ABS, polyethylene terephthalate (PETG), polyphenylsulfone (PPSU), and high-impact polystyrene (HIPS). These materials are well-suited for measurement with long-wavelength infrared sensors.
Temperature is a critical factor in the FFF process, as it directly influences the quality of the printed parts. Various parameters are set for the extrusion process, such as nozzle temperature, print bed temperature, print speed, and material flow rate. Deviations can occur if these parameters are not optimally adjusted, and products are produced outside the production tolerances.
One of the most common challenges in the Fused Filament Fabrication printing process is insufficient adhesion of the first layer to the printing platform. This will result in deformation and detachment, making the entire printed object defective. Temperature distribution plays a crucial role here, as the print bed and nozzle temperature must be precisely adjusted to ensure optimum adhesion.
Another common issue is material cracks and delamination caused by uneven cooling and internal stresses in the component. These defects can significantly affect the printed object’s mechanical properties and structural integrity.
Given that all these issues are partly temperature-related, it becomes evident that a robust and sufficient temperature monitoring method is not just a recommendation, but a necessity. Such a method is crucial for identifying and addressing these issues, thereby ensuring the quality and integrity of the printed objects.
In-situ Feedback Loop through Thermal Camera Improves Extrusion Process
The Optris PI 640i thermal imaging camera provides an advanced solution for quality assurance in the Fused Filament Fabrication (FFF) process by enabling precise monitoring and analysis of temperature distribution during and after printing. The thermal camera is instrumental in detecting and eliminating typical problems such as insufficient adhesion, cracks, delamination, voids, and surface defects.
During the printing process, the Optris PI 640i uses passive thermography to monitor the process-related heating of the material. By displaying the temperature distribution in real time, the thermal camera can immediately detect deviations and anomalies, providing reassurance about its real-time monitoring capabilities. For example, uneven heating of the first layer, which leads to deformation and detachment, can be detected and corrected at an early stage.
To detect internal defects such as cavities, the component is heated in specific profiles, and the subsequent temperature measurement allows for precise localization of inadequate infill structures. This nondestructive in situ feedback is particularly important for safety-relevant products.
The PI 640i high-resolution infrared camera also helps to detect surface defects. Uneven layer lines and surface roughness caused by fluctuations in the material flow or mechanical problems in the printer can be reliably minimized.
The thermal camera provides detailed thermographic data that enables immediate analysis and adjustment of printing parameters to achieve a uniform and high-quality surface structure.
Achieving Consistent Quality in Fused Filament Fabrication with the Accurate Thermal Cameras
The PI 640i offers significant advantages in the Fused Filament Fabrication (FFF) process, especially due to its high resolution and thermal sensitivity. With an optical resolution of 640×480 pixels and an outstanding thermal sensitivity of 40 mK, the PI 640i is capable of extremely precise temperature measurements. This is particularly important in the FFF process, where a consistent and controlled temperature of the nozzle and print bed is critical to the quality of the printed parts.
Another advantage of the PI 640i is its ability to capture radiometric video at a frame rate of 32 Hz and even 125 Hz in subframe mode. This high frame rate allows for accurate monitoring and analysis of rapid temperature changes and dynamic processes in 3D printing.
The PI 640i, with its interchangeable lenses, offers a level of adaptability that reassures about its versatility. These lenses cover different fields of view (15°, 33°, 60° and 90°), providing flexibility in adapting to different printer sizes and applications. This adaptability allows users to select the focus and field of view according to specific requirements, enhancing the camera’s versatility.
The PI 640i, with its robust design, offers a level of durability that provides a sense of security. It is designed for use in industrial environments, with an IP67 rating that protects it against dust and water and allows it to withstand temperatures from 0 °C to 50 °C during operation. With separate accessories, the camera’s robustness can be increased even further, ensuring its reliability and durability even under demanding conditions.
Various interfaces and a comprehensive software package facilitate integration into existing systems. The camera can be connected via USB 2.0 or, optionally, via a Gigabit Ethernet (PoE) interface. The Optris PIX Connect software package enables simple setup and remote camera monitoring.
In addition, the camera offers several industrial process interfaces, including analog and digital inputs and outputs and relays for alarm and fail-safe functions.
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Talk to us about your IR Temperature Measurement Requirements
There are over 300 different pyrometer variants to choose from in the Optris infrared pyrometer portfolio each optimized for material, spot size, distance from the target, and environmental conditions. Fortunately, there is a trained engineer to phone or chat with to guide you through the process of choosing the perfect infrared sensor for your application.
The same support is available for the extensive IR camera product line.
