Nondestructive evaluation of fused filament fabrication 3D printed structures using optical coherence tomography

Purpose The quality of components under fused filament fabrication (FFF) is related to the correct filament spacing and bonding of successively deposited layers and is evaluated mainly by scanning electron microscopy (SEM). However, it is a destructive technique and real-time evaluation is not possible. Optical coherence tomography (OCT), on the other hand, is an optical method that acquires cross-sectional images non-invasively and in real-time. Therefore, this paper aims to propose and validate the use of OCT as a non-destructive quality evaluation tool for FFF using Polylactic Acid (PLA) filaments. Design/methodology/approach PLA three-dimensional (3D) printed samples were made in a variety of nozzle temperatures and mesh spacing. These samples were fractured in liquid nitrogen and inspected using SEM (as a gold standard) to evaluate dimensions and morphology, then the samples were evaluated by OCT in the same area, allowing the results confrontation. Findings Our results indicate a good correlation between OCT and SEM for the dimensional assessment of layers. When the filament was extruded in lower temperatures, the OCT images presented sharply defined interfaces between layers, in contrary to higher nozzle temperatures, denoting better fusion between them. However, higher extruding temperatures are incurred in greater deviations from nominal dimensions of the mesh. Finally, we demonstrate the advantage of a full 3D tomographic reconstruction to inspect within a FFF sample, which enabled the inspection of “hidden” information, not visible on a single cross-sectional cut. Originality/value This paper proposes OCT as a novel and nondestructive evaluation tool for FFF.