3D-Printing Setup and Real-Time Imaging of 3D-Printed Layer Bonding

Start by drawing the object using a 3D drawing software of choice and export the object as a dot SDL file. Next, import the dot SDL file into the slicing software and choose the printing settings. Press the slice button in the slicing software to obtain the layers and travel path of the print head.

Save the resulting G-code and send it to the 3D printer. Now start the 3D printer and allow it to warm up. Start the LSI measurement when the plastic starts to extrude to prevent unnecessary data saving.

Once the 3D printer is done printing, stop the LSI measurement. Load the resulting data into an image viewing software and visually inspect the printed object. Print quality of the object appeared good with the surface showing layer lines.

LSI imaging showed increased polymer motion in the recently printed layers. The experiment when repeated with the cooling fan resulted in slower cooling of the plastic at 0%fan speed, causing poor visual print quality with irregular surface layer lines and blobs. The overall designed geometry was imperfectly reproduced with the windows and holes being deformed.

LSI imaging indicated increased polymer motion throughout the whole object. Advanced data analysis for the comparative welding zones of six fan speeds showed peak profile positions at which the polymers were most mobile. The welding zone profiles for 40 to 100%cooling were nearly identical, while the zone for 0%cooling extended over the entire measured area.