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April 29, 2024

Methods of improving rapid FDM prototyping solutions in industrial systems using strategies of Industry 4.0

Ghinea Mihalache, Niculescu Alex Cosmin, Rosca Bogdan

National University of Science and Technology Politehnica Bucharest

Abstract

Modern production relies on technologies introduced by Industry 4.0 (known as Smart Manufacturing in the USA). As one of the nine pillars of this concept, additive manufacturing plays a crucial role, spanning from rapid prototyping to creating custom final products in the shortest and most cost-effective time.  Advances in this field have led to the development of various advanced manufacturing technologies such as Fused Deposition Modeling (FDM), Stereolithography (SLA), and Selective Laser Sintering (SLS), enabling the utilization of a wide range of metallic, plastic, and/or composite materials. Klipper is open-source software designed for 3D printers, providing capabilities for faster and more precise printing. The technique employed involves offloading computationally intensive processes to a separate microcontroller from that of the printer, resulting in performance, versatility, and customization benefits, significantly reducing the time of the prototyping process. The purpose of this article is to analyze the weaknesses of common/affordable printers with average performance using the software tools integrated into Klipper. Additionally, the study focuses on enhancing the performance of the printer Tevo Black Widow. As an additional outcome, it also focuses on improving the quality of printed parts (surface quality and dimensional accuracy). The study is comparative, analyzing the standard performance of a Tevo Black Widow printer with those offered by the same system while using the Klipper firmware.

1. Introduction

Various additive manufacturing techniques have been devised to fulfill the need for producing intricate structures with low waste (Hui et al., 2018). The advancement of these technologies has been primarily motivated by the desire for rapid prototyping, mitigating printing imperfections, and enhanc...

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