A Framework for Modeling and Control for Extrusion-based Additive Manufacturing

Additive manufacturing (AM) processes have experienced a surge in demand, largely driven by the growing need for customization across various industries. This paradigm shift underscores the need for more robust AM processes, where precise customization is vital to meet individual requirements. However, there does not exist a structured framework for deriving models that characterize the relationship between process parameters and pattern characteristics. Additionally, determining critical inputs and outputs, as well as control strategies for in situ AM control, further compounds this challenge. This work addresses these challenges by proposing a structured approach to closing the loop for an extrusion-based AM printing process, demonstrating its transferability across multiple printers within the same AM family. The control framework was tested under scenarios of nozzle clogging and over-extrusion, demonstrating effective error mitigation and rapid convergence with appropriate controller gain designs. Moreover, The framework was successfully transferred to a different extrusion printer, showing its adaptability across varied environments and printers, offering insights into the underlying dynamics of this extrusion-based AM process, and paving the way for enhanced performance and reliability in AM.