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Related Experiment Video

Updated: Jul 26, 2025

Fused Filament Fabrication FFF of Metal-Ceramic Components
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Anomaly Detection in Fused Filament Fabrication Using Machine Learning.

Guo Dong Goh1, Nur Muizzu Bin Hamzah1, Wai Yee Yeong1,2,3

  • 1Singapore Centre for 3D Printing, School of Mechanical & Aerospace Engineering, Nanyang Technological University Singapore, Singapore, Singapore.

3D Printing and Additive Manufacturing
|June 22, 2023
PubMed
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This study introduces an on-site monitoring system for fused filament fabrication (FFF) 3D printing, using computer vision to detect and correct defects in real-time. The system enhances part quality and print repeatability in additive manufacturing.

Area of Science:

  • Additive Manufacturing
  • Computer Vision
  • Artificial Intelligence

Background:

  • Fused filament fabrication (FFF) is a widely adopted 3D printing technology with growing industrial use.
  • Key limitations include inconsistent part quality and print repeatability due to manufacturing-induced defects.
  • Existing FFF processes lack real-time defect detection and correction mechanisms.

Purpose of the Study:

  • To develop and implement an on-site monitoring system for extrusion-based 3D printers.
  • To integrate computer vision and object detection for real-time defect identification and correction.
  • To improve the quality and repeatability of FFF 3D printed parts.

Main Methods:

  • A monitoring system with a print-head-attached camera and a laptop for video feed processing was developed.
Keywords:
3D printingartificial intelligentfused deposition modelingin situ monitoringsupervised learning

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  • Various YOLO (You Only Look Once) architectures were evaluated for detecting under-extrusion and over-extrusion defects.
  • Optimized YOLO models (YOLOv3-Tiny) using ONNX for improved inference speed and implemented a G-code based correction algorithm.
  • Main Results:

    • YOLOv3 and YOLOv4 Tiny models achieved >80% mean average precision (AP50) in defect detection.
    • Optimized models achieved 89.8% classification accuracy and 70 frames per second inference speed.
    • Demonstrated successful real-time monitoring and autonomous correction of defects during the FFF process.

    Conclusions:

    • The developed on-site monitoring system effectively detects and corrects defects in FFF 3D printing in real-time.
    • This closed-loop feedback system significantly enhances part quality and print repeatability.
    • The approach provides a foundation for advanced monitoring and correction in various additive manufacturing processes.