Non-contact microwave sensor for FDM 3D printing quality control

Abstract

In recent years, 3D printing has undergone a transformational journey–from prototyping technology, limited to laboratories, to a production method used in industry–becoming a powerful tool for creating functional objects. Despite this progress, 3D printing faces ongoing challenges related to defect detection and print quality control. We present an innovative, non-contact, fast and cheap microwave sensor for detecting defects in printed components, related to both mechanical errors and conductivity inhomogeneities. We discuss in detail the methodology of the microwave surface mapping technique and the results obtained for several samples printed with popular filaments. Tests show the ability to detect faults with millimetre precision. The simple design of the entire quality control module allows for easy integration with various types of 3D printers, from popular ones used by hobbyists to professional, highly specialised ones.