Effective thermal management is essential in fused deposition modeling (FDM) 3D printers, where hotend temperature directly affects print quality and reliability. This study develops a MATLAB and Simscape model capturing the coupled thermal dynamics of the hotend, cooling fan, and filament feed, and evaluates system behavior under constant heater and fan operation. The model highlights frequently underexplored factors, including the influence of filament flow on hotend temperature and the interactions between heat conduction and convective cooling. Building on this foundation, a proposed control framework is outlined in which fuzzy logic regulation is applied to the heater, while the fan is maintained using a conventional PID controller. Membership function ranges and tuning logic are conceptually outlined to illustrate potential integration strategies. Assumptions regarding filament flow and thermal properties are based on typical desktop FDM printer configurations. Simulation results reproduce expected thermal trends and provide insight into the challenges of maintaining operational temperature ranges. These findings establish a foundation for future work exploring fuzzy-based thermal control strategies in additive manufacturing.

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MATLAB and Simscape Framework for 3D Printer Hotend Thermal Management with Conceptual Fuzzy Logic Heater and PID Fan Control

  • Rahim Mammadzada

摘要

Effective thermal management is essential in fused deposition modeling (FDM) 3D printers, where hotend temperature directly affects print quality and reliability. This study develops a MATLAB and Simscape model capturing the coupled thermal dynamics of the hotend, cooling fan, and filament feed, and evaluates system behavior under constant heater and fan operation. The model highlights frequently underexplored factors, including the influence of filament flow on hotend temperature and the interactions between heat conduction and convective cooling. Building on this foundation, a proposed control framework is outlined in which fuzzy logic regulation is applied to the heater, while the fan is maintained using a conventional PID controller. Membership function ranges and tuning logic are conceptually outlined to illustrate potential integration strategies. Assumptions regarding filament flow and thermal properties are based on typical desktop FDM printer configurations. Simulation results reproduce expected thermal trends and provide insight into the challenges of maintaining operational temperature ranges. These findings establish a foundation for future work exploring fuzzy-based thermal control strategies in additive manufacturing.