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Enhancing dimensional accuracy in 3D printing: a novel software algorithm for real-time quality assessment

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Abstract

Notably, despite the widespread application of 3D printing technology across diverse industries, issues like dimensional variations continue to limit its full-scale production potential. In this research, the dimensional variation between the CAD model and a 3D printed specimen by extrusion technique is investigated by a developed software algorithm. In contrast to previously employed techniques such as coordinate measuring machines, laser scanning, optical profilometry, and CT scanning, which have been highlighted in the literature, the developed software algorithm is cheap and stands out by relying on computer vision for the assessment of dimensional deviations in the printed model. The proposed software algorithm assesses the dimensional quality of 3D printed components through a comprehensive three-step methodology: preparation, measurement, and analysis. The software scrutinizes both the CAD model and the G-code-sliced model, extracting crucial dimensional data that serves as a reference for monitoring deviations during the actual 3D printing process. The software is fully tested across a diverse 3D geometry, capable of predicting real-time dimensional variances that could otherwise result in printing failures. The solution not only ensures the preservation of economic and human resources in additive manufacturing but also enhances the overall efficiency of the process. The paper concludes that the choice of the appropriate method should be contingent on the specific part type and the level of accuracy required.

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Funding

I appreciate the funding/financial support received from the Higher Education Innovation Fund (HEIF) of De Montfort University, Leicester, United Kingdom, under Research Project No.0043.06.

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Authors and Affiliations

  1. School of Engineering and Sustainable Development, De Montfort University, Leicester, UK

    Oluwole K. Bowoto & Seng Chong

  2. Electrical, and Manufacturing Engineering, Wolfson School of Mechanical, Loughborough, UK

    S. Abolfazl Zahedi

Authors
  1. Oluwole K. Bowoto
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  2. S. Abolfazl Zahedi
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  3. Seng Chong
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Contributions

BKO: conceptualization, methodology, software, writing (original draft), project administration, review and editing, and formal analysis. AZ: investigations and data curation. SC: validation and visualization.

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Correspondence to Oluwole K. Bowoto.

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The authors declare no ethical issue; the study was conducted in full agreement with ethical standards.

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The authors declare no competing interests.

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Bowoto, O.K., Zahedi, S.A. & Chong, S. Enhancing dimensional accuracy in 3D printing: a novel software algorithm for real-time quality assessment. Int J Adv Manuf Technol 129, 3435–3446 (2023). https://doi.org/10.1007/s00170-023-12543-2

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  • DOI: https://doi.org/10.1007/s00170-023-12543-2

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