Last Update : 18-07-2022

New Dec 2023

Compensate for variations in filament diameter to ensure part quality...

The manufacturing tolerances of filaments generally vary by +/-0.05mm, which in reality gives a variation of 12% in volume between the maximum and minimum tolerances.

For technical filaments: PEEK, PEKK, PEI, PPSU...  Some manufacturers even announce tolerances of +/- 0.10mm, which means that the filament can vary by 24% in volume.

 

These volume variations are generally well supported when using standard filaments (PLA, ABS, PETG,...), but pose significant problems with technical filaments.

All filament extruders control the flow in "mm equivalent", it is therefore impossible to obtain reproducible and constant quality prints with such volume variations.

The sketch on the right shows the extruded volume for 1mm of filament at min/max tolerances. A simple percentage calculation shows that between 1.80 and 1.70mm (+/- 0.05mm) the volume variation is 12% (varies between 2.5446 and 2.2698mm3)

 Between 1.85 and 1.65mm (+/- 0.10mm) the volume variation is 24% (varies between 2.688 and 2.1382mm3)

 

The variation of the printed volume causes under- or over-extrusions systematically degrading the :

- Inter-layer bonds, and therefore the strength of the parts

- Part dimensions

- Filling rate

- Surface finish

- Mass of the part

-...

Certify the quality of your printed parts

With a Qu3-HT equipped with Filament Control, you can be sure that the quality of your parts will be the same regardless of filament variations.
This makes it easy to ensure the reproducibility of 3D printed parts. Once you have achieved the desired part properties in the pilot phase, you can be sure that subsequent parts will be absolutely identical.
Even if a machine records  printing parameters (nozzle temperature, chamber temperature, bed temperature, volume flow, etc.) and generates complete and documented print reports.
It is impossible to guarantee the quality of the same 2 parts if you do not control the extruded volume.

Operating principles

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.

Variations in filament diameter have been deliberately exaggerated for better understanding

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.

Generates a Print Report files at each print launch

The Excel-compatible File is automatically generated at each print launch, it contains:

⦁ All temperature parameters (nozzle[s], chamber, bed...)

⦁ All filament diameter measurements (according to X, according to Y, average diameter, average section, as well as the extruded length corresponding to these measurements)

⦁ All diameter compensations sent to the machine and the extrusion lengths when sent

⦁ Other generic print information parameters (print speeds, safety status,...)

As well as a print report containing a summary of the printing with graphics.

This report is customisable and adaptable to your needs, with an editing tool that we provide.

Benefits of Filament Control

1. Possibility to actually certify the printed part or the production batch, and to provide, together with the printed parts, a document attesting that the variations in filament diameter have been compensated.

 

2. Ensure that the 3D printing is carried out in an optimal way and that there are no variations in the process that could weaken the mechanical properties of the printed part.

 

3. Provide complete and true traceability of the printed parts, as all printing parameters have been recorded.

 

4. Improved reliability of the printed parts: constant interlayer bonds, constant dimensions, constant and guaranteed fill rate.

Adaptable to all Qu3-HT versions

Whether your machine is from 2020, 2021 or 2022, it is possible to install and use a Filament Control, contact us...

Technical Specifications

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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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