Design of a Real-Time Tracking System to Eliminate 3D Printing Errors Caused by Thermoplastic Materials

Material-related printing errors are frequently encountered in 3D printers based on the Fused Filament Fabrication (FFF) technology. When the materials used are investigated, materials such as PLA, ABS, and Nylon are generally preferred at affordable prices. However, printing problems may occur due to the mechanical characteristics difference between the materials. Among the main reasons for this are parameters such as material characters, melting temperature, and extrusion speed. These errors cause problems such as filament breaking, nozzle clogging, and filament falling out of the holder. As a result, the filament flow is interrupted, and the printing process continues without extrusion of the filament because the 3D printer cannot detect this flow. 3D printers on the market do not have a system to detect possible printing errors. Therefore, in this study, a system design measures the filament weight via a load sensor and informs the user has been performed. 3D printers could stop the printing process since they can detect possible errors in advance with the developed system and prevent electricity consumption and time loss. In addition, the amount of used and remaining filaments, which are not yet common in 3D printers, can be followed by the user.