Cost-effective sensor-based digital twin for fused deposition modeling 3D printers

Shomenov K. Ali M.H. Jyeniskhan N. Al-Ashaab A. Shehab E.
2025 Taylor and Francis Ltd.

International Journal of Computer Integrated Manufacturing
2025

In a highly digitalized world, Digital Twin (DT) technology is becoming vital in manufacturing, especially in additive manufacturing. This research work presents cost-effective digital twin development and implementation for Fused Deposition Modeling (FDM) 3D printers. This developed system enhances real-time process monitoring, anomaly detection, and autonomous control through a logical approach. Sensor data that measures and tracks filament flow, vibrations, and nozzle position are processed in real-time for the detection of anomalies such as layer shifting, under- and over-extrusion, and excessive vibrations. Magnetic encoders enable monitoring the filament flow with 0.73% error, position sensors identify nozzle displacement to monitor layer shifts. The sensor data are stored in the Firebase and visualized in the Unity interface with a 500- 700 ms data lag. In contrast to traditional systems, this developed system works independently without the need for external hosts, providing a very low-cost, modular solution (less than $50) appropriate for small-scale applications. This research also addresses the gap in FDM 3D printers and sensor-based DT by demonstrating practical, real-time interventions for quality assurance in FDM processes.

3D printing , digital twin , fused deposition modeling , material extrusion , sensors

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Department of Mechanical and Aerospace Engineering, School of Engineering and Digital Sciences, Nazarbayev University, Astana, Kazakhstan
School of Aerospace, Transport and Manufacturing, Cranfield University, Cranfield, United Kingdom

Department of Mechanical and Aerospace Engineering
School of Aerospace

10 лет помогаем публиковать статьи Международный издатель

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