Nondestructive ultrasonic evaluation of fused deposition modeling based additively manufactured 3D-printed structures

The quality control of 3D printed structures is significant for the reliability of additively manufactured objects. A novel remote sensing technique for characterizing 3D printed structures was developed by non-destructive ultrasonic imaging of a commonly used thermoplastic object such as acrylonitrile butadiene syrene (ABS). The quality of the additively manufactured ABS slab printed by fused deposition modeling (FDM) technique was evaluated by imaging effective density technique. The infill density of the FDM printed structures were modified by varying the motor speed of the printing extruder. An ultrasonic raster scan of the 3D printed structure using the novel effective density imaging technique distinguished the contrast in density with a very high resolution in the density variation. In addition to the lateral scanning, the density characterization was also effective when applied axially and can probe deep inside the additively manufactured object. The experimentally measured density variation agrees well with the theoretically calculated density values as a function of flow rate. The combined lateral and axial capabilities of the imaging technique make it a promising diagnostic tool for an in-situ inspection method of optimizing FDM printing and quality control of 3D printed objects.