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Abstract
Abstract
Abstract
Quality monitoring is still a big challenge in additive manufacturing, popularly known as 3D printing. Detection of
Quality
defectsthe
Under monitoring
during is
ofstill
the printing
concept aprocess
big challenge
"Industry will help
4.0", ineliminate
additiveprocesses
production manufacturing,
waste ofwill bepopularly
material and time.
pushed known
to Defect asdetection
3D printing.
be increasingly Detection
during of
the initial
interconnected,
defects
stages during
of the
printing printing
may process
generate an will
alert help
to eliminate
either pause waste
or stopof material
the printing and time.
process Defect
so that detection
corrective
information based on a real time basis and, necessarily, much more efficient. In this context, capacity optimization during
measuresthe initial
can be
stages ofprevent
takenbeyond
to printingthe may generate
need toaim an alert
reprint to either
the parts. pause
This paperorproposes
stop the printing
a method process so that corrective
to organization’s
automatically assess measures
the quality can be
of 3D
goes the traditional of capacity maximization, contributing also for profitability and value.
taken
printedtoparts
prevent
with thetheneed to reprintofthe
integration a parts. This
camera, paper
image proposes and
processing, a method to automatically
supervised machine assess the
learning. quality
Images of of 3D
semi-
Indeed, lean management and continuous improvement approaches suggest capacity optimization instead of
printed
finishedparts
partswith
are the integration
taken atofseveral ofcritical
a camera,
stagesimage
ofand processing,
the and supervised
printingmodels
process machine learning. Images machine
of semi-
maximization.
finished
Thetaken
studyat capacity optimization costing isaccording
an importantto the part
research geometry.
topic thatA deserves
learning parts are support
method, severalmachine
vector critical (SVM),
stages ofisthe printingtoprocess
proposed classifyaccording
the parts to theeither
into part geometry.
‘good’ or A machine
‘defective’
contributions
learning fromsupport
both thevector
practical and theoretical isperspectives. This paper presents andeither
discusses
‘good’a mathematical
orA‘defective’
category.method,
Parts using ABS and PLA machine (SVM),
materials were proposed
printed totodemonstrate
classify thethe
parts into
proposed framework. numerical
model for
category. capacity
Parts usingmanagement
ABS and based
PLA on different
materials werecosting
printed models
to (ABC
demonstrate and TDABC).
the proposed A generic
framework.model has been
A numerical
example is provided to demonstrate how the proposed method works.
developed and it was used to analyze idle capacity and
example is provided to demonstrate how the proposed method works. to design strategies towards the maximization of organization’s
value.
© 2018TheThe trade-off capacitybymaximization
Authors. Published Elsevier B.V. vs operational efficiency is highlighted and it is shown that capacity
© 2018 The Authors.
optimization might Published
hide by Elsevier
operational B.V.
inefficiency.
© 2018 The under
Peer-review Authors. Published by
responsibility of Elsevier B.V. committee of NAMRI/SME.
the scientific
Peer-review
© under responsibility
2017 The Authors. of Elsevier
Published by the scientific
B.V.committee of the 4th International Conference on System-Integrated Intelligence.
Peer-review under responsibility of the scientific committee of NAMRI/SME.
Peer-review
Keywords: 3Dunder responsibility
printing, of theSupervised
Image processing, scientific machine
committee of theSVM
learning, Manufacturing Engineering Society International Conference
2017.
Keywords: 3D printing, Image processing, Supervised machine learning, SVM
1. Introduction
Keywords: Cost Models; ABC; TDABC; Capacity Management; Idle Capacity;as
Operational Efficiency
3D printing allows for more manufacturing options
1. Introduction as 3D printing
because allows
it has theforability
more manufacturing options
to create complex
Additive manufacturing (AM) has become a viable because it shapes
geometrical has thewithability
the helptoof create complex
design software.
1. Introduction
Additive
option formanufacturing (AM)years.
production in recent has become
AM oftena knownviable geometrical shapesofwith
Other advantages AMthe help ofrapid
include design software.
prototyping,
option for production in recent years. AM often known Other advantages of AM include rapid prototyping,
The cost of idle capacity is a fundamental information for companies and their management of extreme importance
in modern©production
2351-9789 systems.
2018 The Authors. In general,
Published it isB.V.
by Elsevier defined as unused capacity or production potential and can be measured
in several©under
2351-9789
Peer-review ways: tons of production,
2018responsibility
The Authors. Published
of available
by Elsevier
the scientific B.V.hours
committee of manufacturing, etc. The management of the idle capacity
of NAMRI/SME.
Peer-review underTel.:
* Paulo Afonso. responsibility
+351 253 of the761;
510 scientific committee
fax: +351 253 604of741
NAMRI/SME.
E-mail address: psafonso@dps.uminho.pt
inventory reduction, and decentralized production. 3D Wuest et al. [3] proposed a method to deal with the
printing has already contributed significantly to large amounts of complex and high-dimensional data
several technological advances in medicine and is in conventional manufacturing. First, they described
emerging in many other fields like fashion design, and the concept of individual product states along the
architecture and even Nike recently launched the first entire manufacturing line including all sorts of
athletic shoe including 3D printed components [1]. information which could be utilized during the
process. Then, application of a combination of Cluster
Many 3D printing machines do not have a Analysis and SVM on product state data has been
designated system to track and monitor the progress of presented as a potential way for improved quality
printing process. 3D printers may continue to print the monitoring. Fastowicz and Okarma [4] proposed a
method for live monitoring of the progress of 3D
part until all the layers have been completed even if
printing process based on texture analysis using the
the filament ran out or there are any potential defects
Gray-Level Co-occurrence Matrix (GLCM) and
in the print. Detecting defects by performing quality
chosen Haralick features. Images obtained by
check at various (critical) stages of the printing scanning the 3D printed plates have been used to
process not only help in assuring corrective measures verify the approach. Also, taking the influence of
but also eliminate waste of printing bad parts. lighting conditions into consideration, several
Automatic process monitoring is especially important experiments have been performed by taking pictures
for production scale 3D printing operation in which with the help of a camera mounted on a 3D printer.
hundreds of 3D printing machines are used in mass Due to the influence of lighting conditions on the
production of the same part. images obtained when compared to the scanned
images, several modifications have been made to the
A method has been proposed to monitor the 3D proposed method to achieve better results.
printing process by pausing the printer at various
checkpoints to detect any possible defects and take Vaezi and Chua [5] studied the effects of two
proper corrective actions such as stopping the print if parameters of layer thickness and binder saturation
a potential defect is detected. level on the mechanical strength, surface quality and
dimensional accuracy in the 3D printing process.
2. Literature review Experimental results show that under the same layer
thickness, increasing the binder saturation level from
Given the fact that 3D printing is still a relatively 90% to 125% would result in an increase of tensile and
modern technology in the manufacturing field, the flexural strengths of the specimens and decrease of
amount of literature available addressing the quality dimensional accuracy and surface uniformity of the
aspects in 3D printing is limited. Straub [2] proposed specimens. On the other hand, under the same binder
a method to detect completion failure defects during saturation level, increase in layer thickness from 0.087
the 3D printing process. A multi-camera system to 0.1 mm would decrease tensile strength and increase
comprised of five camera units (each unit consisted of flexural strength. Also, it yields better surface
a Raspberry Pi and a Raspberry Pi camera) and image uniformity. Other work related to 3D printing quality
processing software created using C# and Dot Net can be found in [7] and [8]. Besides the efficient use
framework was used to assess the quality of the parts of supervised machine learning to monitor quality in
produced. Images (of the in-process object) were taken 3D printing which is first of its kind, our research
at eight positions by each of five cameras placed at five focuses on some of the key issues in 3D printing that
different angles (to make a total of 40 images) and they were not addressed in the previous research like
were compared against a final object image. The detection of structural defects.
comparison was done on a pixel-by-pixel basis. The
author affirmed that the comparison in his method
could detect two types of errors: when a part has been 3. Implementation strategy
stopped during the progress of printing which results
in an incomplete part and when there are issues with Conventionally, the quality of 3D printed parts is
the printer which results in a failure of injection of being checked after the printing is done. Detecting
filament into the nozzle. However, this method cannot defects during the printing process not only help to
detect geometrical or structural defects which are eliminate waste of material and time but also prevent
common in any manufacturing process.
Ugandhar Delli et al. / Procedia Manufacturing 26 (2018) 865–870 867
Delli, Chang/ Procedia Manufacturing 00 (2018) 000–000 3
References