Fault detection in fused filament fabrication 3D printers via continuous monitoring of the feeding system

Abstract

A device for real-time monitoring of 3D printer feeding systems was designed and evaluated. The device detects faults by measuring filament flow using rotary encoders at two points in the system: one measures the actual amount of filament fed, and the other measures the expected amount. The percentage discrepancy between these two measurements is then calculated; a significant discrepancy indicates an anomaly in the feeding system that requires correction. The device can be used with any type of 3D printer that employs fused filament fabrication (FFF) technology. The main faults detected are those that prevent the filament from flowing freely, such as low extrusion temperature, heating element failure, roller misalignment, or worn components. The system alerts the user to correct the problem, pause printing, or continue if the fault does not affect model quality. To validate the device’s functionality, the monitoring system was installed on a commercial 3D printer, where several faults were intentionally induced. The system successfully detected common failures such as filament runout, nozzle clogging, and extruder temperature faults, confirming its effectiveness even though its diagnostic capability covers a wider range of possible anomalies