Control-Oriented Modeling and Layer-to-Layer Stability for Fused Deposition Modeling: A Kernel Basis Approach

Additive manufacturing (AM) is an increasingly important enabler of smart manufacturing systems. Fused deposition modeling (FDM) is an AM technology that uses layer-wise extrusion to deposit material in 3D and most FDM machines run in open-loop. Due to the lack of feedback controllers, disturbances in the process cause failures. Although there are some spatial models for the FDM process, there are no layer-to-layer spatial dynamics models to enable control applications. This work proposes a novel modeling framework to capture the in-layer and layer-to-layer spatial dynamics of the FDM process utilizing a kernel basis approach. Individual kernels represent the deposition cross-sections and the orientation of the deposition. Layer-wise and layer-to-layer performance measures and stability definitions are proposed for the layer-to-layer spatial model. A simulation example is provided to demonstrate the validity of the stability criteria.