Using Faster R-CNN for intelligent fault diagnosis and correction in additive manufacturing

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This research establishes an innovative runtime-based closed-loop system that uses a deep convolution neural network (CNN) technology to supervise and correct errors in additive manufacturing (AM), boosting both productivity and quality. Currently, AM machines employ fused deposition modelling (FDM) to print 3D objects and provide cost-effective and rapid prototyping and mass production. However, operators have experienced unpredictable levels of printing success and high malfunction rates because of their inability to control printing path deviations. This is due to inaccurate and unstable printers that produce items of inconsistent and often unacceptable printing quality. This research proposes to adopt advanced Faster R-CNN algorithm technology to develop a novel object detection program to address this challenge. This algorithm will use the region proposal network (RPN), which has joint convolutional features with the detection network module, to provide nearly costless region proposals. The use of the RPN will help to determine the interesting areas in the image that may contain printing malfunctions. After that, the algorithm will continue to determine the failure category in the area and specifically modify the size of areas to detect the accurate location. Finally, the automatic control system will adjust and correct printing parameters based on the error information the Faster R-CNN predicted, allowing for the 3D objects being printed to be salvaged. The full development of this algorithm in this research work includes parameters initialization, adjusting the weights and bias of the network and optimizations of printing status. In the end, the outcomes of this research will significantly reduce filament waste and improve FDM printer productivity. The partner organization will benefit from this self-diagnosed system through improved sales, profits, revenue, and the service quality provided to its clients. The results will also help 3D printing technology expand into a wider range of industrial and commercial applications, generating a positive influence on the Canadian economy and business environment.