Real-time Monitoring of 3D Printing Using Between-layer Structural Similarity (BLSS)

This research introduces an innovative method specifically designed for comprehensive error detection in the 3D printing process. The Between-layer Structural Similarity (BLSS) technique gauges the similarity between displacement maps, which are generated using the Structural Similarity Index Measure (SSIM). This allows for the differentiation between consecutive layers in both simulated and actual prints. Utilising the Fast Fourier Transform (FFT), the displacement maps can be converted to the frequency domain and assessed for similarity. The proposed approach involves three key processing stages: print simulation and processing, print capture and processing, and BLSS-based structural analysis and evaluation. This methodology not only reduces material wastage but also lays the foundation for automated systems capable of halting or terminating live printing processes upon error detection. Experimental results reveal that printing defects occur below 97.5 % of the similarity value, establishing this threshold as appropriate. This underscores the effectiveness of the system in error detection and its potential for real-time quality control in 3D printing.