Machinery & Energetics

Comparative research of 3D printer main control parameters and characteristics utilising Klipper firmware

Volodymyr Nazarenko, Bohdan Ostroushko
Download article
Abstract

3D printing is replacing traditional machine design methods, providing manufacturers with flexibility, ease of operation, and the ability to adjust process parameters in real-time. This study focused on determining the print speed to produce high-quality models in two scenarios: without Klipper firmware and using Klipper firmware for control parameters during printing. The 3D printer used in study used a Creality Ender 3 V3 SE printer with two sample 3D models. The authors conducted the testing process with three presets of print speed: medium speed, above-average speed, and maximum possible speed (maximum print speed 345 mm/s; above-average speed 180 mm/s; average 150 mm/s). As a result of the study, it was found that the most critical problem is that the stepper motor only sometimes has time to move the table by the required number of steps. The standard acceleration values were set at the level the original equipment manufacturer recommended, and the optimal printing speed was up to 120 mm/s. During the experiments, the standard acceleration values were increased, which showed positive changes and led to better print quality and stability of this process. It has been determined that it is best to keep the default settings and settings in the case of a standard (ready-to-pack) printer, as the printer will not be able to print faster due to its hardware limitations. In contrast, special hardware firmware can help dynamically adjust print parameters while maintaining maximum quality and optimising job performance. The study results can be used in industrial production to optimise 3D printing processes, improve product quality, and reduce manufacturing costs

Keywords

printing technologies, embedded systems, automated systems, iterative system evaluation, control systems

Suggested citation
Nazarenko, V., & Ostroushko, B. (2025). Comparative research of 3D printer main control parameters and characteristics utilising Klipper firmware. Machinery & Energetics, 16(1), 81-90. https://doi.org/10.31548/machinery/1.2025.81
References

[1] Afshar, R., Jeanne, S., & Abali, B.E. (2023). Nonlinear material modeling for mechanical characterization of 3-D printed PLA polymer with different infill densities. Applied Composite Materials, 30(3), 987-1001. doi: 10.1007/s10443-023-10122-y.

[2] Albar, A., Swash, M.R., & Ghaffar, S. (2019). The design and development of an extrusion system for 3d printing cementitious materials. In 2019 3rd International Symposium on Multidisciplinary Studies and Innovative Technologies (ISMSIT) (pp. 1-5). Ankara: IEEE. doi: 10.1109/ISMSIT.2019.8932771.

[3] Arnold, C., Monsees, D., Hey, J., & Schweyen, R. (2019). Surface quality of 3D-printed models as a function of various printing parameters. Materials, 12(12), article number 1970. doi: 10.3390/ma12121970.

[4] Chen, D., Levin, D.I., Didyk, P., Sitthi-Amorn, P., & Matusik, W. (2013). Spec2Fab: A reducer-tuner model for translating specifications to 3D prints. ACM Transactions on Graphics (TOG), 32(4), article number 135. doi: 10.1145/2461912.2461994.

[5] Christodoulou, I., Alexopoulou, V., & Markopoulos, A.P. (2023). Study and development of a high-speed fused filament fabrication 3D printer. In 2023 8th South-East Europe design automation, computer engineering, computer networks and social media conference (SEEDA-CECNSM) (pp. 1-6). Piraeus: IEEE. doi: 10.1109/SEEDA-CECNSM61561.2023.10470706.

[6] Geng, P., Zhao, J., Wu, W., Ye, W., Wang, Y., Wang, S., & Zhang, S. (2019). Effects of extrusion speed and printing speed on the 3D printing stability of extruded PEEK filament. Journal of Manufacturing Processes, 37, 266-273. doi: 10.1016/j.jmapro.2018.11.023.

[7] Gokhare, V.G., Raut, D.N., & Shinde, D.K. (2017). A review paper on 3D-printing aspects and various processes used in the 3D-printing. International Journal of Engineering Research & Technology, 6(06), 953-958.

[8] Gomathi, K., Ganesh, T., Bharanidharan, J., Prajathkar, A.A., & Aravinthan, R. (2021). Condition monitoring of 3D printer using micro accelerometer. IOP Conference Series: Materials Science and Engineering, 1055(1), article number 012035. doi: 10.1088/1757-899X/1055/1/012035.

[9] Hemminger, H.A. (2022). Improvements and characterization of error, speed, and capabilities in low-cost additive manufacturing systems. (Master of Science thesis, University of California, Los Angeles, United States of America).

[10] Jandyal, A., Chaturvedi, I., Wazir, I., Raina, A., & Haq, M.I.U. (2022). 3D printing – a review of processes, materials, and applications in Industry 4.0. Sustainable Operations and Computers, 3, 33-42. doi: 10.1016/j.susoc.2021.09.004.

[11] Kaman, A., Balogh, L., Jakab, M., Meszlenyi, A., Tarcsay, B.L., & Egedy, A. (2023). The effect of 3D printing process parameters on nylon based composite filaments: Experimental and modelling study. Chemical Engineering Transactions, 100, 481-486. doi: 10.3303/CET23100081.

[12] Kantaros, A., & Piromalis, D. (2021). Employing a low-cost desktop 3D printer: Challenges, and how to overcome them by tuning key process parameters. International Journal of Mechanics and Applications, 10(1), 11-19. doi: 10.5923/j.mechanics.20211001.02.

[13] Kentzer, J., Koch, B., Thiim, M., Jones, R.W., & Villumsen, E. (2011). An open source hardware-based mechatronics project: The replicating rapid 3-D printer. In 2011 4th International conference on mechatronics (ICOM) (pp. 1-8). Kuala Lumpur: IEEE. doi: 10.1109/ICOM.2011.5937174.

[14] Khosravani, M.R., & Reinicke, T. (2020). Effects of raster layup and printing speed on strength of 3D-printed structural components. Procedia Structural Integrity, 28, 720-725. doi: 10.1016/j.prostr.2020.10.083.

[15] Kluska, E., Gruda, P., & Majca-Nowak, N. (2018). The accuracy and the printing resolution comparison of different 3D printing technologies. Transactions on Aerospace Research, 2018(3), 69-86. doi: 10.2478/tar-2018-0023.

[16] Lanzotti, A., Grasso, M., Staiano, G., & Martorelli, M. (2015). The impact of process parameters on mechanical properties of parts fabricated in PLA with an open-source 3-D printer. Rapid Prototyping Journal, 21(5), 604-617. doi: 10.1108/RPJ-09-2014-0135.

[17] Pivar, M., Gregor-Svetec, D., & Muck, D. (2021). Effect of printing process parameters on the shape transformation capability of 3D printed structures. Polymers, 14(1), article number 117. doi: 10.3390/polym14010117.

[18] Stănciulescu, Ş., Schulze, S., & Wąsowski, A. (2015). Forked and integrated variants in an open-source firmware project. In 2015 IEEE International conference on software maintenance and evolution (ICSME) (pp. 151-160). Bremen: IEEE. doi: 10.1109/ICSM.2015.7332461.

[19] Suiker, A.S. (2022). Effect of accelerated curing and layer deformations on structural failure during extrusion-based 3D printing. Cement and Concrete Research, 151, article number 106586. doi: 10.1016/j.cemconres.2021.106586.

[20] Wu, J. (2018). Study on optimization of 3D printing parameters. IOP Conference Series: Materials Science and Engineering, 392, article number 062050. doi: 10.1088/1757-899X/392/6/062050.

[21] Zucca, R., Santos, R. C., Lovatto, J., Cesca, R.S., & Lovatto, F. (2019). Development of a low cost 3D printer indicated to prototyping objects. Semina: Exact and Technological Sciences, 40(1), 47-54. doi: 10.5433/1679-0375.2019v40n1p47.