Spectral Features Analysis for Print Quality Prediction in Additive Manufacturing: An Acoustics-Based Approach

Quality prediction in additive manufacturing (AM) processes is crucial, particularly in high-risk manufacturing sectors like aerospace, biomedicals, and automotive. Acoustic sensors have emerged as valuable tools for detecting variations in print patterns by analyzing signatures and extracting distinctive features. This study focuses on the collection, preprocessing, and analysis of acoustic data streams from a Fused Deposition Modeling (FDM) 3D-printed sample cube (10 mm × 10 mm × 5 mm). Time and frequency-domain features were extracted at 10-s intervals at varying layer thicknesses. The audio samples were preprocessed using the Harmonic-Percussive Source Separation (HPSS) method, and the analysis of time and frequency features was performed using the Librosa module. Feature importance analysis was conducted, and machine learning (ML) prediction was implemented using eight different classifier algorithms (K-Nearest Neighbors (KNN), Support Vector Machine (SVM), Gaussian Naive Bayes (GNB), Decision Trees (DT), Logistic Regression (LR), Random Forest (RF), Extreme Gradient Boosting (XGB), and Light Gradient Boosting Machine (LightGBM)) for the classification of print quality based on the labeled datasets. Three-dimensional-printed samples with varying layer thicknesses, representing two print quality levels, were used to generate audio samples. The extracted spectral features from these audio samples served as input variables for the supervised ML algorithms to predict print quality. The investigation revealed that the mean of the spectral flatness, spectral centroid, power spectral density, and RMS energy were the most critical acoustic features. Prediction metrics, including accuracy scores, F-1 scores, recall, precision, and ROC/AUC, were utilized to evaluate the models. The extreme gradient boosting algorithm stood out as the top model, attaining a prediction accuracy of 91.3%, precision of 88.8%, recall of 92.9%, F-1 score of 90.8%, and AUC of 96.3%. This research lays the foundation for acoustic based quality prediction and control of 3D printed parts using Fused Deposition Modeling and can be extended to other additive manufacturing techniques.