Fused deposition modeling (FDM) has emerged as one of the most accessible and versatile additive manufacturing processes. However, non-uniform thermal distribution on the printing bed remains a critical challenge, as it can lead to warping, dimensional inaccuracies, and compromised mechanical properties in printed parts. These issues highlight the need for more effective thermal management strategies to ensure improved part quality and process reliability. This study addresses these limitations by developing and implementing a segmented thermal bed composed of a matrix of individually controlled resistive elements. A closed-loop control circuit was designed to deliver precise thermal regulation, minimizing temperature gradients across the bed surface. The research was conducted in three stages: (1) design and fabrication of the segmented resistive-element bed, (2) development and optimization of an AC-based control circuit, and (3) integration of the system with an FDM 3D printer. Electrical, thermographic, and mechanical evaluations demonstrated a more uniform temperature distribution, a modest (approximately 3%) improvement in tensile strength of printed specimens compared to those produced on a conventional bed, and potential energy savings of up to 20% for fully heated areas and 95% when only a single segment is activated. Furthermore, cross-sectional optical microscopy revealed enhanced interlayer adhesion, more uniform layer thickness, and improved surface quality. While these findings are promising, future work will focus on automating element selection, applying statistical analyses to reinforce mechanical property improvements, and conducting long-term stability and cost–benefit studies. Such advancements aim to facilitate industrial-scale adoption of this technology, ultimately leading to higher-quality, more energy-efficient FDM printing processes.

Control of temperature distribution of a thermal bed divided into resistive elements for FDM 3D printers / Santos, Emerson Costa; Munõz, Segundo Nilo Mestanza. - In: INTERNATIONAL JOURNAL, ADVANCED MANUFACTURING TECHNOLOGY. - ISSN 0268-3768. - (2025). [10.1007/s00170-025-15048-2]

Control of temperature distribution of a thermal bed divided into resistive elements for FDM 3D printers

Santos, Emerson Costa
Writing – Review & Editing
;
2025

Abstract

Fused deposition modeling (FDM) has emerged as one of the most accessible and versatile additive manufacturing processes. However, non-uniform thermal distribution on the printing bed remains a critical challenge, as it can lead to warping, dimensional inaccuracies, and compromised mechanical properties in printed parts. These issues highlight the need for more effective thermal management strategies to ensure improved part quality and process reliability. This study addresses these limitations by developing and implementing a segmented thermal bed composed of a matrix of individually controlled resistive elements. A closed-loop control circuit was designed to deliver precise thermal regulation, minimizing temperature gradients across the bed surface. The research was conducted in three stages: (1) design and fabrication of the segmented resistive-element bed, (2) development and optimization of an AC-based control circuit, and (3) integration of the system with an FDM 3D printer. Electrical, thermographic, and mechanical evaluations demonstrated a more uniform temperature distribution, a modest (approximately 3%) improvement in tensile strength of printed specimens compared to those produced on a conventional bed, and potential energy savings of up to 20% for fully heated areas and 95% when only a single segment is activated. Furthermore, cross-sectional optical microscopy revealed enhanced interlayer adhesion, more uniform layer thickness, and improved surface quality. While these findings are promising, future work will focus on automating element selection, applying statistical analyses to reinforce mechanical property improvements, and conducting long-term stability and cost–benefit studies. Such advancements aim to facilitate industrial-scale adoption of this technology, ultimately leading to higher-quality, more energy-efficient FDM printing processes.
2025
Additive manufacturing, FDM printer, Temperature control, Thermal bed, Thermal damage, Thermography
01 Pubblicazione su rivista::01a Articolo in rivista
Control of temperature distribution of a thermal bed divided into resistive elements for FDM 3D printers / Santos, Emerson Costa; Munõz, Segundo Nilo Mestanza. - In: INTERNATIONAL JOURNAL, ADVANCED MANUFACTURING TECHNOLOGY. - ISSN 0268-3768. - (2025). [10.1007/s00170-025-15048-2]
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Utilizza questo identificativo per citare o creare un link a questo documento: https://hdl.handle.net/11573/1732408
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