Leveraging Machine Learning for Porosity Prediction in AM Using FDM for Pretrained Models and Process Development

Additive manufacturing involves numerous independent parameters, often leading to inconsistent print quality and necessitating costly trial-and-error approaches to optimize input variables. Machine learning offers a solution to this non-linear problem by predicting optimal printing parameters from a minimal set of experiments. Using Fused Deposition Modeling (FDM) as a case study, this work develops a machine learning-powered process to predict porosity defects. Specimens in two geometrical scales were 3D-printed and CT-scanned, yielding raw datasets of grayscale images. A machine learning image classifier was trained on the small-cube dataset (~2200 images) to distinguish exploitable images from defective ones, averaging over 97% accuracy and correctly classifying more than 90% of the large-cube exploitable images. The developed preprocessing scripts extracted porosity features from the exploitable images. A repeatability study analyzed three replicate specimens printed under identical conditions, and quantified the intrinsic process variability, showing an average porosity standard deviation of 0.47% and defining an uncertainty zone for quality control. A multi-layer perceptron (MLP) was independently trained on 1709 data points derived from the small-cube dataset and 3746 data points derived from the large-cube dataset. Its accuracy was 54.4% for the small cube and increased to 77.6% with the large-cube dataset, due to the larger sample size. A rigorous grouped k-fold cross-validation protocol, relying on splitting data per cube, strengthened the ML algorithms against data leakage and overfitting. Finally, a dimensional scalability study further assessed the use of the pipeline for the large-cube dataset and established the impact of geometrical scaling on defect formation and prediction in 3D-printed parts.