| Abstract Scope |
Fused Filament Fabrication (FFF) is a widely used additive manufacturing technique, but printing, especially with demanding materials, often requires extensive, filament-specific tuning. To reduce manual optimization and improve reliability, this study introduces a novel method for force-based process monitoring and closed-loop control in FFF. Forces acting on the hotend, extruder, and build plate are measured in real time and synchronized with the G-code. By analyzing these forces across various printing scenarios, the impact of specific print defects is characterized, and defect types are differentiated based on their force signatures. Building on this analysis, a closed-loop control system for the extrusion multiplier is implemented and demonstrated. The system achieves at least three times higher detection accuracy than current image-based methods. This work advances the state of FFF by enabling adaptive, force-aware control strategies, laying the foundation for more robust, automated printing workflows and expanding the use of FFF in high-performance applications. |