3d-printing setup and real-time imaging of 3d-printed layer bonding

Visualizing Polymer Dynamics for Optimizing 3D Printing Quality

The method of 3D printing is an additive manufacturing technique in which an object is manufactured layer by layer to form the desired shape. This method has a large and diverse user-base thanks to its versatility, affordability, and ease of use. Fused deposition modeling features a moving extruder (with a diameter of hundreds of microns to a couple of millimeters) to deposit molten plastic into the desired shape1. The extruded plastic should behave in a liquid-like manner for a certain duration to achieve good fusion with the previously printed plastic and form a strongly cohesive material. However, the plastic should cool down and solidify quickly after printing to prevent the plastic from flowing away from the print location and reducing the print quality. This delicate interplay between heating and cooling has been shown to directly underpin the balance between the mechanical strength and the geometric accuracy of the final 3D-printed object2. To achieve the optimal heating-cooling balance, the plastic is extruded at a temperature just above its melting temperature, and a fan head, attached to the printer, is used to cool the plastic down quickly. An in-depth understanding of the effects of printing temperatures and cooling speeds could provide the insights required for developing advanced slicing and printing protocols that maximize the mechanical or geometric results in the areas where they are most important. Efforts to gain more insight into these processes often rely on infrared (IR) imaging, which only visualizes the surface temperature3,4,5 and does not indicate the inner temperature of the plastic. Local heating beyond the melting transition drastically increases the polymer mobility and, thus, allows polymer entanglement between the old and new material. This temporally enhanced polymer motion is a requirement for the formation of the final cohesive material6,7, but IR imaging can only measure polymer motion indirectly through the surface temperature8,9. Translating the surface temperature to layer bonding thus necessitates precise knowledge of the core-surface temperature gradient and the associated complex polymer dynamics over a range of time and length scales. A direct measurement of the layer bonding (i.e., the polymer entanglement process) would allow the visualization of the mechanism underlying bulk material cohesion without a priori information or assumptions.
To gain an understanding of the spatial and temporal distribution of layer bonding, an imaging technique that directly quantifies the dynamics of the polymers that make up the plastic filament is employed in this work. This technique, laser speckle imaging (LSI), relies on interferometric light scattering to visualize nanoscopic motions, independent of the chemical composition. Depending on the optical properties of the sample, it can accurately measure several millimeters to centimeters into non-transparent materials10,11,12, unlike IR imaging, which reports only surface temperatures8,9. These attributes have recently made speckle-based methods popular in understanding dynamic processes in a plethora of materials, although they were originally developed for medical applications10,11,12. Recently, LSI has been used to gain insight into the behavior of advanced polymeric materials such as self-cleaning liquid crystal polymer networks13,14, as well as for predicting fracture in rubber15 and for studying self-healing materials16.
The feasibility of applying LSI to 3D printing was showcased in a previous article17, where a portable LSI setup with real-time analysis capabilities was presented, and it was shown that the deposition of molten plastic results in increased polymer motion multiple layers below the current layer. In the paper presented here, systematic research into the effects of the cooling fan speed on the degree of multi-layer bonding is performed. An improved plug-and-play version of the portable instrument is used that can be operated by users without optics or programming expertise. The speckle images are analyzed in real-time using Fourier transforms17, which visualize the amplitude of the speckle intensity fluctuations. This instrument has an additional brightfield camera that is aligned with the speckle camera so that the LSI motion maps can be overlayed with the brightfield images for easier interpretation without the brightfield light affecting the motion maps. The experimental approach presented in this article can be used to gain more insight into the melting, layer bonding, and solidification of extruded plastic during the 3D printing of challenging geometries and materials.

Author Spotlight: Real-Time Imaging of Bonding in 3D-Printed Layers  

Real-Time Imaging of Bonding in 3D-Printed Layers

Our research aims to improve layer bonding during 3D printing. We use a method called laser speckle imaging to visualize the bonding process in real time. These insights will guide the optimization of printing conditions, hopefully leading to enhanced material design and performance.Currently, the layer bonding is studied using infrared imaging techniques that visualize this plastic*surface temperatures. To study layer bonding with infrared imaging, it is assumed that the inner temperature and the surface temperature is equal. Also, the complex relationship between temperature and the plastic fluidity has to be known.We've adapted laser speckle imaging for the use of 3D printing and have shown how to easily obtain deeper understanding of the layer bonding. Our LSI approach measures the polymer motion inside the plastic, visualizing the layer bonding without any assumptions. The technique is also non-invasive, easy to use, and has an excellent sensitivity.The method shown in this research can be used to study 3D prints or patterns that are challenging. The results can be used to understand how the setting should be changed to improve the print's quality.

Watch this Scientific Journal Video about 3D-Printing Setup and Real-Time Imaging of 3D-Printed Layer Bonding at JoVE.com

3D-Printing Setup and Real-Time Imaging of 3D-Printed Layer Bonding  

Start by drawing the object using a 3D drawing software of choice and export the object as a dot SDL file. Next, import the dot SDL file into the slicing software and choose the printing settings. Press the slice button in the slicing software to obtain the layers and travel path of the print head.Save the resulting G-code and send it to the 3D printer. Now start the 3D printer and allow it to warm up. Start the LSI measurement when the plastic starts to extrude to prevent unnecessary data saving.Once the 3D printer is done printing, stop the LSI measurement. Load the resulting data into an image viewing software and visually inspect the printed object. Print quality of the object appeared good with the surface showing layer lines.LSI imaging showed increased polymer motion in the recently printed layers. The experiment when repeated with the cooling fan resulted in slower cooling of the plastic at 0%fan speed, causing poor visual print quality with irregular surface layer lines and blobs. The overall designed geometry was imperfectly reproduced with the windows and holes being deformed.LSI imaging indicated increased polymer motion throughout the whole object. Advanced data analysis for the comparative welding zones of six fan speeds showed peak profile positions at which the polymers were most mobile. The welding zone profiles for 40 to 100%cooling were nearly identical, while the zone for 0%cooling extended over the entire measured area.

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Research

JoVE Journal

Engineering

719 Views.  Wageningen University & Research. Inizia disegnando l'oggetto utilizzando un software di disegno 3D preferito ed esporta l'oggetto come file SDL dot. Quindi, importare il file SDL punto nel software di sezionamento e scegliere le impostazioni di stampa. Premere il pulsante di sezione nel software di suddivisione per ottenere i livelli e il percorso di avanzamento della testina di stampa.Salvare il G-code risultante e inviarlo alla stampante 3D. Ora avvia la stampante 3D e lascia che si riscaldi. Avviare la misurazione ...

Video: 3D-Printing Setup and Real-Time Imaging of 3D-Printed Layer Bonding  

In recent times, 3D printing technology has revolutionized our ability to design and produce products, but optimizing the print quality can be challenging. The process of extrusion 3D printing involves pressuring molten material through a thin nozzle and depositing it onto previously extruded material. This method relies on bonding between the consecutive layers to create a strong and visually appealing final product. This is no easy task, as many parameters, such as the nozzle temperature, layer thickness, and printing speed, must be fine-tuned to achieve optimal results. In this study, a method for visualizing the polymer dynamics during extrusion is presented, giving insight into the layer bonding process. Using laser speckle imaging, the plastic flow and fusion can be resolved non-invasively, internally, and with high spatiotemporal resolution. This measurement, which is easy to perform, provides an in-depth understanding of the underlying mechanics influencing the final print quality. This methodology was tested with a range of cooling fan speeds, and the results showed increased polymer motion with lower fan speeds and, thus, explained the poor printing quality when the cooling fan was turned off. These findings show that this methodology allows for optimizing the printing settings and understanding the material behavior. This information can be used for the development and testing of novel printing materials or advanced slicing procedures. With this approach, a deeper understanding of extrusion can be built to take 3D printing to the next level.

With a non-invasive and real-time technique, nanoscopic polymer motion inside a polymer filament is imaged during 3D printing. Fine-tuning this motion is crucial for producing constructs with optimal performance and appearance. This method reaches the core of plastic layer fusion, thus offering insights into optimal printing conditions and material design criteria.

In recent times, 3D printing technology has revolutionized our ability to design and produce products, but optimizing the print quality can be ...

Setup and Alignment of the Laser Speckle Imaging (LSI) Instrument with the 3D Printer

Begin by placing the 3D printer on a steady surface to minimize vibrations. Place the LSI instrument next to the printer so that the camera has a clear view of the printing area. Position the LSI slightly higher than the camera build plate and tilt it downward slightly to prevent view obstruction.Next, turn on the laser and bright-field illumination and ensure that they are aligned with the imaging area. Start with a test print, making sure that the LSI camera is focused on the printing area. During the test print, optimally align the lighting and the digital camera and adjust the laser direction to illuminate the whole imaging area homogenously.Adjust the diaphragm so that the speckle size is slightly larger than the pixel size. Select the parameters for the live LSI data analysis, being sure to choose the frequency that produces the best imaging contrast between molten and solidified plastic. Choose the frequency and length of image saving to prepare the LSI instrument to capture images.