Real time fault detection in 3D printers using Convolutional Neural Networks and acoustic signals
This study addresses the challenge of low-cost, real-time detection of mechanical faults in fused deposition modeling (FDM) 3D printing—such as nozzle clogging and filament breakage—which significantly compromise print quality and system reliability. To this end, the authors propose a non-intrusive monitoring approach that leverages acoustic signals and a convolutional neural network (CNN) to classify multiple common printing anomalies in real time. By collecting operational audio from the printer and constructing a dedicated fault dataset, the method eliminates the need for expensive sensors or manual intervention. Experimental results demonstrate that the proposed framework achieves high classification accuracy and robustness across diverse fault scenarios, offering an efficient, scalable, and cost-effective solution for real-time process monitoring in 3D printing.