Applied metrology in additive manufacturing

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The fabrication of products through layer-by-layer additive manufacturing presents exciting opportunities, including advancements in Industry 4.0, sustainability, and local manufacturing. To fully realize these benefits, effective measurement methodologies are essential. Fused Filament Fabrication (FFF), a cost-effective additive manufacturing technique, offers a solution to global plastic pollution and is particularly suited for developing economies. However, measurement approaches are necessary to elevate this technology from rapid prototyping to functional production. This thesis focuses on developing accessible solutions to enhance the critical material feed mechanism. It begins with a comprehensive review of the process steps, including the motion tool chain from stepper motor actuation to firmware implementation. The study presents the feedstock materials and liquefier design, followed by five experimental methods for process optimization. These include optical monitoring of the feed mechanism for volumetric flow rate measurement, exit flow rate measurement, and a pressure sensor for liquefier state assessment. Additionally, the thesis introduces the Vapour Deposition Fabrication concept, akin to Dynamic Stencil Lithography, utilizing FFF electronics and firmware. It details the design and construction of the first Vapour Deposition Fabrication micro-printer. The findings emphasize the importance of monitoring material a