Digital Twin Integration for Enhanced Control in FDM 3D Printing

This study addresses the critical need for precise monitoring and adaptive control systems in 3D printing processes using fused deposition modelling (FDM). The printing process is dynamic and has intrinsic complexity, hence it becomes critical to implement a Digital Twin architecture. Real-time insights into temperature changes and material deposition are necessary for successful control of the intricate relationship between heat transfer and material deposition, as estimated by a realistic MATLAB model. This research utilizes a finite difference technique to update the printing area’s temperature distribution repeatedly. It also seamlessly incorporates an extrusion model to simulate the deposition of material layer by layer. The maximum extrusion rate and increase extrusion rate are two further characteristics that enhance the versatility of the Digital Twin structure. The outcomes demonstrate the effectiveness of integrating Digital Twins to optimise the 3D printing process and highlight the need for this kind of strategy to achieve accuracy and dependability. The study offers a thorough grasp of the thermal dynamics associated with FDM 3D printing, highlighting the critical role that Digital Twins play in reducing difficulties and improving the capabilities of the manufacturing process. This study provides a comprehensive approach to real-time monitoring and control in FDM 3D printing through the essential integration of Digital Twin technology, laying the groundwork for future efforts in smart manufacturing.