Every second for the PRO version (every 5 seconds for the STANDARD version), Filament Control takes diameter measurements in two perpendicular planes and calculates the ovality and average cross-section of the filament.

Simultaneously with the diameter measurements, it queries the Qu3-HT's motherboard to find out what the extruded length was when the diameter was measured.

It then calculates the volume compensation to be sent to the Qu3-HT and at what extruded length it should send this compensation (depending on the distance between the measurement point and the extruder drive rollers).

When the extruded length reaches this value, it sends the compensation via a G-code, which is executed immediately by the machine... Adjusting the material flow according to the actual filament cross-section.
ENSURE THE QUALITY OF YOUR 3D PRINTS WITH OUR FILAMENT MEASUREMENT AND VOLUME COMPENSATION SYSTEM DURING PRINTING

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

 

Filament manufacturing tolerances can vary by +/-0.05mm, resulting in a 12% variation in volume between the maximum and minimum tolerances.

 

For technical filaments such as PEEK, PEKK, PEI, PPSU, some manufacturers even claim  tolerances of +/- 0.10mm, which means that the filament can vary by 24% in volume!

 

Although these volume variations 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 in "mm equivalent", which makes it impossible to achieve consistent, reproducible quality prints with such volume variations.

 

The figure on the right shows the variation in extruded volume for 1mm of filament, with minimum and maximum tolerances.

 

A simple percentage calculation shows that the volume variation is 12% (varies between 2.5446 and 2.2698mm3) between 1.80mm and 1.70mm (+/- 0.05mm) and 24% (varies between 2.688 and 2.1382mm3) between 1.85mm and 1.65mm (+/- 0.10mm)

 

These volume variations can 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.

CERTIFY THE QUALITY OF YOUR PRINTED PARTS
Our Qu3-HT with Filament Control guarantees the quality of your 3D printed parts, regardless of variations in filament diameter.

With our system, you can ensure the reproducibility of 3D printed parts.

Once you have achieved the desired properties of 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 printing parameters such as nozzle temperature, chamber temperature, bed temperature, volume flow, 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.
HOW DOES OUR FILAMENT MEASUREMENT AND VOLUME COMPENSATION SYSTEM WORK?
The Filament Control is a device that measures the diameter of the filament continuously during 3D printing.

It does this by measuring the diameter in two perpendicular planes every second for the PRO version or every 5 seconds for the STANDARD version.

From these measurements, it calculates the ovality and the average cross-section of the filament.

Simultaneously with the diameter measurements, the Filament Control queries the Qu3-HT motherboard to find out what length was extruded when the diameter was measured.

From this information it calculates the volume compensation to be sent to the Qu3-HT and determines at what extruded length it should send this compensation based on the distance from the measurement point to the extruder drive rollers.

When the extruded length reaches this value, the Filament Control sends the compensation via a G-code, which is immediately executed by the machine, thus adjusting the material flow to the actual filament cross-section.

In short, Filament Control allows the amount of material extruded to be adjusted in real time to ensure consistent quality 3D printing.
Standard 3D Printer
Without Filament
Control
Variations in filament diameter have been exaggerated for better understanding
Qu3-HT
With Filament
Control
2 ACCURACY CLASSES : +/- 0.01 mm or +/-0.0008 mm
Depending on your budget it is possible to obtain a filament measurement to +/- 10µm for the STANDARD version or an accuracy of +/- 0.8µm for the PRO version.
GENERATION OF A PRINT REPORT AT EACH PRINT RUN

By using Filament Control, you can effectively certify the printed parts or production batch, by providing a pdf document with the parts to show that variations in filament diameter have been compensated.

 

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

 

In addition, full and true traceability of the printed parts is provided as all printing parameters have been recorded.

 

This also improves the reliability of the printed parts as the interlayer bonds are constant, the dimensions are constant, the fill rate is constant and guaranteed, the mass is constant, etc.

IN SUMMARY, THE FOUR KEY BENEFITS OF FILAMENT CONTROL

1 - Certification of the printed part and provision of a document attesting to the compensation of filament diameter variations.

 

2 - Guarantee of optimal printing without variations that could affect the mechanical properties of the printed part.

 

3 - Complete traceability of printing parameters for each part.

 

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

TECHNICAL SPECIFICATIONS

Designation

Standard Version

PRO Version

Measuring range

Ø1.60 / Ø1,90mm

Ø1.50 / Ø2,0mm

Number of measurement axes

2  (perpendicular)

2  (perpendicular)

Number of measurements made simultaneously (per axis)

7 to 50

Measurements at a frequency of 500 Hz

Calculation of the average cross-section

Yes

Yes

Ovality control

Yes

Yes

Resolution

0.8 µm

< 0.1 µm

Repeatability (3Sigma)

(in progress)

+/-0.07µm (Mean Time : 1 second)

Measurement accuracy

+/- 10µm

Better than +/- 0.8µm

Calibration

Calibration rods supplied

At the factory

Automatic dust detection

Yes

Yes

Automatic detection of erroneous measurements

Yes

Yes

Maximum measurement frequency

0,2Hz

50 Hz

Operating temperature

15 to 60°C

15 to 45°C

Control and calculation software

Windows / Linux

Windows / Linux

Internet Of Thing

Static IP or DHCP

RJ45

Control interface accessible on the network

WEB Browser

WEB Browser

Recording of measurements during printing

Excel compatible print report

Excel compatible print report

Connection to the machine: Bayonet connector

PTFE Tube OD. 4.0, 5.0, 6.0

PTFE Tube OD. 4.0, 5.0, 6.0

Power supply

5V - 650mA (USB 3.0 possible)

220V – 2A
ANY QUESTIONS ? CONTACT US...

Copyright © 2011-2023 QUALUP SAS

Specialist in 3D printing. We have been designing 3D printers since 2011. Our expertise has led us to make custom machines for industry and research, our specialty is printing high temperature polymer materials.
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