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<p>In high-speed fused deposition modeling (FDM) 3D printing, print defects, particularly at sharp angles, are a persistent issue due to dynamic variations and instability in stepper motor control. These defects, such as surface waviness, rough edges, and dimensional inaccuracies, are primarily caused by the inability of conventional control methods to adapt to the rapid changes in motor dynamics during high-speed printing. This paper presents an advanced composite control strategy that integrates fuzzy PI and sliding mode control (SMC) to address these challenges. By leveraging the strengths of both control strategies, this method ensures a balance between precision and robustness. A key innovation introduced in this study is the automatic weight adjustment mechanism, which dynamically modulates the contributions of fuzzy PI and SMC in real-time, based on the system’s operating conditions. This adaptive mechanism allows the system to switch seamlessly between control modes, providing high stability during transient states and high accuracy during steady-state operations. Furthermore, the experimental results highlight its ability to reduce surface defects, such as edge irregularities and roughness, by over 20% compared to conventional methods, showcasing its effectiveness in producing high-quality prints at sharp angles.</p>

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Optimized compound control strategy for high-speed 3D printing: enhancing surface quality and printing precision

  • 期刊论文

  • 发表日期：

    2025年6月11日

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  • Rui Zhou,
  • Junchi Jiang,
  • Penglong Li,
  • Shuaiyuan Lu,
  • Biao Li,
  • Chunzhi Du

摘要

In high-speed fused deposition modeling (FDM) 3D printing, print defects, particularly at sharp angles, are a persistent issue due to dynamic variations and instability in stepper motor control. These defects, such as surface waviness, rough edges, and dimensional inaccuracies, are primarily caused by the inability of conventional control methods to adapt to the rapid changes in motor dynamics during high-speed printing. This paper presents an advanced composite control strategy that integrates fuzzy PI and sliding mode control (SMC) to address these challenges. By leveraging the strengths of both control strategies, this method ensures a balance between precision and robustness. A key innovation introduced in this study is the automatic weight adjustment mechanism, which dynamically modulates the contributions of fuzzy PI and SMC in real-time, based on the system’s operating conditions. This adaptive mechanism allows the system to switch seamlessly between control modes, providing high stability during transient states and high accuracy during steady-state operations. Furthermore, the experimental results highlight its ability to reduce surface defects, such as edge irregularities and roughness, by over 20% compared to conventional methods, showcasing its effectiveness in producing high-quality prints at sharp angles.