Height error mapping and compensation for a fused filament fabrication machine

Abstract

An artifact-based height error mapping and compensation method for fused lament fabrication machines ("3D printers") is developed. In the proposed method, an error mapping artifact is produced and inspected using a coordinate measuring machine to determine height errors at 81 discrete points in the machine's work envelope. A polynomial regression model is fitted to this measured data and used to generate height error predictions at each point in the volume of novel parts. Finally, height error compensation based on the aforementioned model is applied by modifying G-code sequences used to drive the machine. Preliminary experimental validation of the proposed method's efficacy was carried out on NVPro fused lament fabrication machines manufactured by New Valence Robotics Corporation. Results suggest the proposed method is capable of reducing systematic height errors and spatial dependence of height errors over the work volume studied. However, these improvements are attenuated by an accompanying increase in random height variation resulting from the intervention. Recommendations for further testing, refinement, and application of the proposed error mapping and compensation method are presented.