Enhancing 3D printing quality: active vibration control for FDM in challenging environments

Fused deposition modelling (FDM) is a widely used 3D printing technique valued for its versatility and rapid prototyping capabilities. Its compact and portable design makes it well-suited for on-site or field-based applications. However, inevitable inherent mechanical vibration from print head and build plate motion often degrade printed component geometry or surface quality, especially when printing in dynamic or vibration-prone environments. To address this limitation, we implement active vibration control (AVC) using the filtered-x least mean square (FxLMS) algorithm to actively suppress vibration during the 3D printing process. The algorithm performance is systematically evaluated under commonly encountered vibrating conditions, simulated in the laboratory using an electrodynamic shaker. Experimental results demonstrate that AVC reduces the print head overall vibration by over 1.6 dB and peak harmonic vibration amplitudes by more than 3 dB, as measured by a monitor sensor located on the print head. The AVC performance is further evaluated by assessing the surface roughness of the printed components, revealing around 30% improvement when AVC is applied. These preliminary findings demonstrate that more precise and reliable FDM printing in challenging environments is possible, expanding the applicability of this additive manufacturing process across industries requiring high-quality, on-demand fabrication directly on-site.