Laser-Based Volume Measurement System for Optimizing the 3D Printing Process

Abstract

This article presents the development of a volume measurement system for calibrating material flow in the print head of a 3D printer operating with FDM technology, with usage of pellet material. To ensure high printing precision, it was necessary to design a measurement system capable of calibrating material flow by determining the volume of the deposited material path. A laser triangulation method – an optical, non-contact distance measurement technique – was employed for this purpose. In this approach, diffused laser light, focused through a lens, is projected onto a CCD or CMOS sensor. The position of the laser beam on the sensor allows for the precise calculation of the distance to the object. Given the high cost of commercial laser profilometers and the closed architecture of low-cost systems offered by existing 3D printer manufacturers, a custom measurement solution was developed. The system architecture is based on low-cost an widely accessible materials. A dedicated image processing algorithm was developed to analyze the deformation of the laser line and convert the profile data into volumetric measurements. The system interfaces with the printer’s control unit. Experimental validation was conducted using a reference object – a machined plate with a insertion of known dimensions. The results confirmed high measurement accuracy, with errors in the range of tenths of a cubic millimeter, which is considered sufficient for the intended application.