Plate auto-level system for fused deposition modelling (FDM) 3D printers

Purpose - The purpose of this paper is to present a solution for the levelling plate of fused deposition modelling (FDM) additive manufacturing (AM) systems. This automatic levelling system is presented as an evolution of actual systems, which uses a new ultrasound sensing system. Design/methodology/approach - After obtaining a prototype, different tests were conducted for getting a system which solves the level plate problem and can be mounted in any FDM AM machine. Several benchmark models were obtained and compared with current equipment concepts for the validity of the product. Findings - All tests were performed with high accuracy, enabling the production of geometries that could not have been achieved without this novel system. Practical implications - This development will enable experienced users to set aside the problems of calibration and focus on the purpose of this type of machines, making prototypes. Originality/value - A system architecture has been developed and integrated into an open hardware AM system, allowing real-time adjustment of the plate during each layer, thus eliminating the need of levelling the plate, allowing to achieve easier printing, and without increasing the cost significantly.