A simple object was drawn as a test target for the experiments: a wall with ridges on the back, two windows, and a large hole (Figure 1). The object was sliced with the printer settings and properties listed in Table 1.
The LSI instrument was aligned with the 3D printer, and the experiment was performed. The user-friendly setup features an additional brightfield camera, which helps during alignment and allows for an easy comparison between the plastic extrusion and the measured polymer motion. The speckle and the brightfield cameras are both equipped with optical filters that prevent interference from the other channel. More technical details about the setup can be found in Supplementary File 1, and an explanation of the analysis routine is presented in Supplementary File 2. Highlights of the results of this experiment are shown in Figure 2, and the full movie can be found in Supplementary Movie 1. As shown before, the experiment can be performed just as well with a home-built instrument17.

Figure 2: Time-lapse of printing with a 100% cooling fan speed. Left: Brightfield, front-view image of the object when the printer is almost finished. The quality of the print looks good upon inspection; although the surface shows the layer lines, the overall designed geometry has been produced. Right: Four LSI snapshots from the white delineated region during the printing process; the blue arrows indicate the print head position at the time of the snapshot, as the LSI images do not correspond in time with the brightfield image. The lighter colors in each snapshot indicate increased polymer motion, which is observed in the most recently printed layers. Note that the region with enhanced motion (the welding zone) is multiple layers thick. The full detailed movie of the experiment is available in Supplementary Movie 1. Please click here to view a larger version of this figure.
Complementary to these results, the print was visually inspected; as expected for these commonly used polymer filaments and print settings, the quality was good. The designed geometry was, indeed, reproduced, and the surface was even, with a small line visible on each layer. With the LSI data, it was possible to gain in-depth insight into the printing process. The freshly extruded plastic was visible as highly mobile, and the mobility decreased gradually as it cooled down. The height of the area with high mobility (i.e., the welding zone) was four to five layers thick throughout the printing procedure, indicating a well-defined duration of layer fusion.
The experiment was repeated with the cooling fan speed manually adjusted to 0%. With this setting, the plastic did not cool down fast enough, which affected the print quality. Highlights of the results are shown in Figure 3, and the full detailed movie can be found in Supplementary Movie 2.
![figure-results-2 Microscopy setup with heat map analysis diagram for surface texture measurement; power scale [dB].](/files/ftp_upload/65415/65415fig03.jpg)
Figure 3: Time-lapse of printing with a 0% cooling fan speed. Left: Brightfield, front-view image of the object when the printer is almost finished. The visual quality of the print looks poor; the surface shows irregular layer lines and big blobs. Additionally, the overall designed geometry has been imperfectly reproduced; notably, the windows and holes are deformed. Right: Four LSI snapshots from the white delineated region during the printing process; the blue arrows indicate the print head position at the time of the snapshot, as the LSI images do not correspond in time with the brightfield image. The lighter colors in each snapshot indicate increased polymer motion, which can be observed throughout the whole object. The full detailed movie of the experiment is available in Supplementary Movie 2. Please click here to view a larger version of this figure.
In line with expectations, visual inspection of the 3D-printed construct indeed showed poor print quality. The layers were unevenly distributed, and the designed geometry was reproduced with deformations. A comparison of the brightfield images in Figure 2 and Figure 3 shows the major effect of the cooling fan on the surface quality and shape of the print result. The origin of this effect was determined by comparing the LSI results from Figure 2 and Figure 3. With a 100% cooling fan speed, enhanced polymer motion was observed in a region only a few layers below the extruded plastic. Therefore, each layer was liquified moderately a few times to achieve layer bonding without plastic flow. With the 0% cooling fan speed, enhanced polymer motion was observed through the whole object. Thus, each layer was liquified many times and extremely close to the freshly extruded plastic, resulting in a loss of geometric accuracy through plastic flow.
To gain a more quantitative view of the cooling fan effect in more moderate situations, the cooling fan speed was systematically varied. The object design was simplified to a wall of 25 mm x 12 mm x 0.8 mm (width x height x depth) without holes or ridges. The same print settings as in Table 1 were used. The experiment was performed 12 times, with cooling fan speeds of 0%, 20%, 40%, 60%, 80%, and 100%, each in duplicate. The resulting movies can be found in Supplementary Movies 3, Supplementary Movie 4, Supplementary Movie 5, Supplementary Movie 6, Supplementary Movie 7, and Supplementary Movie 8, as well as Supplementary Coding File 6, Supplementary Coding File 7, Supplementary Coding File 8, Supplementary Coding File 9, Supplementary Coding File 10, and Supplementary Coding File 11.
To quantitatively compare the welding zones for different fan speeds, advanced data analysis was performed on the LSI results. The goal of this data analysis was to obtain a height profile of the extent of the polymer motion in the welding zone. The associated fully commented MATLAB script can be found in Supplementary Coding File 4 and is described briefly. For every LSI image in the movie, a height profile is computed by taking the mean along the horizontal direction. The profiles of the images where the print head is in the ROI show a distinct peak around the welding zone. To exclusively select those profiles, only profiles with a peak above 8 dB are taken into account. Profiles in which this peak is too close to the edge of the ROI are also discarded. The peak positions of all profiles are subsequently aligned to give an average profile relative to the height at which the polymers are most mobile. The resulting profiles for the six different cooling fan speeds are plotted in Figure 4.

Figure 4: Height profiles for the systematic variation of the cooling fan speed. Left: The welding zone profiles for cooling fan speeds of 100% (black), 80% (blue), 60% (purple), 40% (red), 20% (orange), and 0% (yellow), obtained from the advanced data analysis script in Supplementary Coding File 4. The shaded region is the standard deviation between duplicate experiments. The right schematic explains the averaging procedure to obtain the profile of a typical LSI image. By aligning the maximums of the peaks of all the obtained profiles, the welding zone is obtained. The maximum of the welding zone (relative height = 0) is the height at which the polymers are most mobile. Full detailed LSI and brightfield movies of each experiment are available in Supplementary Movie 3, Supplementary Movie 4, Supplementary Movie 5, Supplementary Movie 6, Supplementary Movie 7,and Supplementary Movie 8. The objectprinted for this figure can be found in Supplementary Coding File 5, with corresponding G-code files in Supplementary Coding File 6. Please click here to view a larger version of this figure.
The welding zone profiles for 40%-100% cooling were nearly identical. The welding zone for 20% cooling had a shoulder reaching into several deeper layers. The welding zone for 0% cooling extended over the entire measured area. The height at which the polymers were most mobile lay in or slightly below the most recently printed layer. This phenomenon explains the presence of an LSI signal at positive relative heights, as there is printed material above the mobility peak. In all cases, the welding zone reached much deeper than the 0.2 mm layer thickness.
Supplementary File 1: LSI setup.xls. Hardware parameters of the LSI instrument used here. Please click here to download this File.
Supplementary File 2: LSI analysis.docx. Explanation of the conversion of the raw speckle images into LSI images. Please click here to download this File.
Supplementary Movie 1: LSI and brightfield movie of the experiment described in Figure 2. The movie is played at 12.5x real-time speed. The upper part is the LSI result, and the lower part is the synchronized brightfield view with the LSI ROI indicated. Please click here to download this Movie.
Supplementary Movie 2: LSI and brightfield movie of the experiment described in Figure 3. The movie is played at 12.5x real-time speed. The upper part is the LSI result, and the lower part is the synchronized brightfield view with the LSI ROI indicated. Please click here to download this Movie.
Supplementary Movie 3: The 100% cooling fan speed experiment described in Figure 4. The movie is played at 12.5x real-time speed. The upper part is the LSI result, and the lower part is the synchronized brightfield view with the LSI ROI indicated. Please click here to download this Movie.
Supplementary Movie 4: The 80% cooling fan speed experiment described in Figure 4. The movie is played at 12.5x real-time speed. The upper part is the LSI result, and the lower part is the synchronized brightfield view with the LSI ROI indicated. Please click here to download this Movie.
Supplementary Movie 5: The 60% cooling fan speed experiment described in Figure 4. The movie is played at 12.5x real-time speed. The upper part is the LSI result, and the lower part is the synchronized brightfield view with the LSI ROI indicated. Please click here to download this Movie.
Supplementary Movie 6: The 40% cooling fan speed experiment described in Figure 4. The movie is played at 12.5x real-time speed. The upper part is the LSI result, and the lower part is the synchronized brightfield view with the LSI ROI indicated. Please click here to download this Movie.
Supplementary Movie 7: The 20% cooling fan speed experiment described in Figure 4. The movie is played at 12.5x real-time speed. The upper part is the LSI result, and the lower part is the synchronized brightfield view with the LSI ROI indicated. Please click here to download this Movie.
Supplementary Movie 8: The 0% cooling fan speed experiment described in Figure 4. The movie is played at 12.5x real-time speed. The upper part is the LSI result, and the lower part is the synchronized brightfield view with the LSI ROI indicated. Please click here to download this Movie.
Supplementary Coding File 1: wall_with_holes.stl. The 3D design for the object described in Figure 1. Please click here to download this File.
Supplementary Coding File 2: wall_with_holes.gcode. The sliced object wall_with_holes.stl with the settings from Table 1. Please click here to download this File.
Supplementary Coding File 3: config.ini. The configuration file for the slicing software. Please click here to download this File.
Supplementary Coding File 4: AdvancedDataAnalysis_FanSpeed.m. The script to perform the advanced data analysis on the cooling fan sweep data and plot Figure 4. The script is fully commented. Please click here to download this File.
Supplementary Coding File 5: wall.stl. The 3D design of the object used to collect the data in Figure 4. Please click here to download this File.
Supplementary Coding File 6: wall_100%fan.gcode. The sliced object wall.stl with a 100% cooling fan speed. Please click here to download this File.
Supplementary Coding File 7: wall_80%fan.gcode. The sliced object wall.stl with an 80% cooling fan speed. Please click here to download this File.
Supplementary Coding File 8: wall_60%fan.gcode. The sliced object wall.stl with a 60% cooling fan speed. Please click here to download this File.
Supplementary Coding File 9: wall_40%fan.gcode. The sliced object wall.stl with a 40% cooling fan speed. Please click here to download this File.
Supplementary Coding File 10: wall_20%fan.gcode. The sliced object wall.stl with a 20% cooling fan speed. Please click here to download this File.
Supplementary Coding File 11: wall_0%fan.gcode. The sliced object wall.stl with a 0% cooling fan speed. Please click here to download this File.