In-process inspection for qualification of FDM 3D printed parts

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3D printing has become and important technology in Industry 4.0 (smart-virtual-digital factory). The process**creates a 3D part layer by layer. A filament is continuously fed into an extrusion nozzle and the material is**heated to a molten state before it reaches the nozzle, so it can be deposited onto the platform.**3D printers have been significantly improved over recent years for industrial applications; however, there is no**automated and robust quality control in-process inspection during fabrication. Fused Deposition Modeling**(FDM) 3D printers induce imperfections (defects) into the final parts considering their tolerances. In industrial**applications, companies developed their own requirements and standards to either accept or reject parts based**on the shape, location, and the size of the defects. To fulfill the potentials of FDM 3D printing, automatic**real-time monitoring of the fabrication process is required.**Since FDM 3D printers manufacture a part layer by layer, it is proposed to also inspect the part layer by layer**for any defects. Considering the range of Non-Destructive Inspection (NDI) techniques for composites, and**their advantages and shortcomings, non-contact laser line scanners can be investigated. Output data from**inspection needs to be compared with data from input CAD file and the slicer. The material deposition**(thickness) and direction (bead orientation) can be investigated. Canadian companies involved in 3D printing**will benefit from this technology and can manufacture their parts and inspect them automatically against**requirements provided by their customers. Aerospace, automotive, biomedical healthcare industry are some**examples.