Qu-Control - Filament Control

Compensating for variations in filament diameter is essential to guarantee the quality and reproducibility of 3D parts.

The manufacturing tolerances of filaments can vary by +/-0.05mm, resulting in a 12% variation in volume between the maximum and minimum of these tolerances.
For technical filaments such as PEEK, PEKK, PEI, PPSU,... some manufacturers even advertise tolerances of +/- 0.10mm, which means that the filament can vary by 24% in volume!

Although these variations in volume are generally well tolerated when using standard filaments such as PLA or PETG, they can cause considerable problems with technical filaments.

Filament extruders control the flow rate based on "equivalent mm," which makes it difficult to achieve consistent, high-quality prints due to variations in filament volume.

The diagram below illustrates the difference in extruded volume for 1 mm of filament, accounting for minimum and maximum tolerances.

A simple percentage calculation shows that the volume can vary by 12% (ranging from 2.5446 to 2.2698 mm³) when the filament diameter fluctuates between 1.70 mm and 1.80 mm (+/- 0.05 mm). This variation increases to 24% (ranging from 2.688 to 2.1382 mm³) when the diameter changes between 1.65 mm and 1.85 mm (+/- 0.10 mm).

These variations in volume cause under-extrusions or over-extrusions which affect the quality of the part by systematically degrading the inter-layer bonds, strength, dimensions, fill ratio, surface finish, mass, etc.

A Qu4-HT equipped with QU-CONTROL guarantees the quality of your 3D printed parts, regardless of variations in filament diameter.
Thanks to our system, you can ensure the reproducibility of 3D printed parts.

Once you have achieved the desired properties for the part in the pilot phase, you can be sure that subsequent parts will be absolutely identical (same strength, same mass, same adhesion between layers, etc.).
Indeed, even if a machine records all the printing parameters such as nozzle temperature, chamber temperature, bed temperature, volume flow rate, etc. and generates complete and documented print reports, it is impossible to guarantee the print quality of two identical parts if you do not control the extruded volume.

Qu-CONTROL is a device that continuously monitors the diameter of the filament during 3D printing. It measures the filament’s diameter in two perpendicular planes every second with an accuracy of 0.8µm. Using these measurements, it calculates the ovality and average cross-sectional area of the filament.

At the same time, Qu-CONTROL communicates with the Qu4-HT’s motherboard to determine the exact length of filament that has been extruded at the moment of measurement. Based on this data, it calculates the necessary volume compensation and determines when this adjustment should be applied, considering the distance between the measurement point and the extruder’s drive rollers.

Once the extruded length reaches the calculated point, Qu-CONTROL sends a compensation command via G-code to the Qu4-HT, which is executed immediately. This process adjusts the material flow in real-time to match the actual filament cross-section.

In summary, Qu-CONTROL ensures consistent quality in 3D printing by dynamically adjusting the amount of extruded material based on real-time filament measurements.

PRODUCTION OF A PRINT REPORT EACH TIME A PRINT JOB IS LAUNCHED

By using QU-CONTROL, you can actually validate the printed parts or the production batch, by providing a HTML document with the parts certifying that the variations in filament diameter have been compensated for.

This allows you to ensure that 3D printing is carried out in the best possible way and that there are no variations in the process that could weaken the mechanical properties of the printed part.

What's more, complete and true traceability of the printed parts is provided because all the printing parameters have been recorded.

This also improves the reliability of the printed parts because the inter-layer bonds are constant, the dimensions are constant, the fill rate is constant and guaranteed, the mass is constant, etc.

1 - Validation of the printed part and supply of a document certifying compensation for variations in filament diameter.

2 - Guarantee of optimum printing with no variations that could affect the mechanical properties of the printed part.

3 - Complete traceability of printing parameters for each part.

4 - Increased reliability of printed parts, with constant interlayer bonds, guaranteed dimensions and fill rate, and constant mass.

Designation	Values
Measuring range	Ø1.50 / Ø2,0mm
Number of measurement axes	2 (perpendicular)
Number of measurements made simultaneously (per axis)	Measurements at a frequency of 500 Hz
Calculation of the average cross-section	Yes
Ovality control	Yes
Resolution	< 0.1 µm
Repeatability (3Sigma)	+/-0.07µm (Mean Time : 1 second)
Measurement accuracy	Better than +/- 0.8µm
Calibration	At the factory
Automatic dust detection	Yes
Automatic detection of erroneous measurements	Yes
Maximum measurement frequency	50 Hz
Operating temperature	15 to 45°C
Control and calculation software	Windows / Linux
Internet Of Thing	RJ45
Control interface accessible on the network	WEB Browser
Recording of measurements during printing	HTML & Excel compatible print report
Connection to the machine: Bayonet connector	PTFE Tube OD. 4.0, 5.0, 6.0
Power supply	220V – 2A

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