Cost-effective sensor-based digital twin for fused deposition modeling 3D printers

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dc.contributor.authorShomenov, Kemel
dc.contributor.authorAli, Md. Hazrat
dc.contributor.authorJyeniskhan, Nursultan
dc.contributor.authorAl-Ashaab, Ahmed
dc.contributor.authorShehab, Essam
dc.date.accessioned2025-07-10T12:51:50Z
dc.date.available2025-07-10T12:51:50Z
dc.date.freetoread2025-07-10
dc.date.issued2025-12-31
dc.date.pubOnline2025-05-13
dc.description.abstractIn a highly digitalized world, Digital Twin (DT) technology is becoming vital in manufacturing, especially in additive manufacturing. This research work presents cost-effective digital twin development and implementation for Fused Deposition Modeling (FDM) 3D printers. This developed system enhances real-time process monitoring, anomaly detection, and autonomous control through a logical approach. Sensor data that measures and tracks filament flow, vibrations, and nozzle position are processed in real-time for the detection of anomalies such as layer shifting, under- and over-extrusion, and excessive vibrations. Magnetic encoders enable monitoring the filament flow with 0.73% error, position sensors identify nozzle displacement to monitor layer shifts. The sensor data are stored in the Firebase and visualized in the Unity interface with a 500- 700 ms data lag. In contrast to traditional systems, this developed system works independently without the need for external hosts, providing a very low-cost, modular solution (less than $50) appropriate for small-scale applications. This research also addresses the gap in FDM 3D printers and sensor-based DT by demonstrating practical, real-time interventions for quality assurance in FDM processes.
dc.description.journalNameInternational Journal of Computer Integrated Manufacturing
dc.description.sponsorshipThe research is funded by Nazarbayev University under the Faculty Development Competitive Research Grant Program (FDCRGP), Grant No. 11022021FD2904.
dc.identifier.citationShomenov K, Ali MH, Jyeniskhan N, et al., (2025) Cost-effective sensor-based digital twin for fused deposition modeling 3D printers. International Journal of Computer Integrated Manufacturing, Available online 13 May 2025en_UK
dc.identifier.eissn1362-3052
dc.identifier.elementsID673363
dc.identifier.issn0951-192X
dc.identifier.issueNoahead-of-print
dc.identifier.urihttps://doi.org/10.1080/0951192x.2025.2504085
dc.identifier.urihttps://dspace.lib.cranfield.ac.uk/handle/1826/24178
dc.identifier.volumeNoahead-of-print
dc.languageEnglish
dc.language.isoen
dc.publisherTaylor & Francisen_UK
dc.publisher.urihttps://www.tandfonline.com/doi/full/10.1080/0951192X.2025.2504085
dc.rightsAttribution 4.0 Internationalen
dc.rights.urihttp://creativecommons.org/licenses/by/4.0/
dc.subject3D printingen_UK
dc.subjectfused deposition modelingen_UK
dc.subjectmaterial extrusionen_UK
dc.subjectdigital twinen_UK
dc.subjectsensorsen_UK
dc.subject4014 Manufacturing Engineeringen_UK
dc.subject40 Engineeringen_UK
dc.subject9 Industry, Innovation and Infrastructureen_UK
dc.subjectIndustrial Engineering & Automationen_UK
dc.titleCost-effective sensor-based digital twin for fused deposition modeling 3D printersen_UK
dc.typeArticle
dc.type.subtypeJournal Article
dcterms.dateAccepted2025-05-06

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