LEAM - EXIST Transfer of Research in large format 3D printing
LEAM is developing local temperature control for 3D printing through material extrusion. Instead of protecting the temperature of the entire component, only the currently printed web is monitored and, if necessary, corrective action is taken in the process control.
Duration
01.09.2022 – 29.02.2024
Funding authority
Federal Ministry for Economic Affairs and Climate Action of Germany
Motivation
One problem with material extrusion 3D printing is that the layering of molten plastic creates weak points where the layers don't bond properly. These weaknesses can cause the end product to fail under stress, making it difficult to predict the quality of printed objects. The process requires a balance between the need for the layers to be hot enough to fuse together, yet cool enough to maintain their stability. This trade-off usually results in sacrifices in efficiency and strength. The process temperatures are difficult to predict because they depend on many factors, including the process control and the component geometry, but also the environmental conditions and the material composition have an influence.
Method
With the help of the machine data, infrared images are analyzed on the machine using edge computing and the layer temperature is determined. If the component threatens to become unstable or if the material is already too cold, the process control is adjusted to counteract this. For this purpose, additional actuators such as fans are switched on as required. In this way, the temperature can be controlled within a narrow process window and the printing time can be reduced by up to 50%.
