This paper introduces a characterization technique to study 3D-printing of conductors and sensors during fabrication. Currently characterization of 3D-printed sensors is done after fabrication. In our novel method, however, the electrical resistance is monitored in-situ by electrically contacting the part in the beginning of the print process. This way, the effect of every additional layer on the total resistance is determined. Our new experimental method opens up ways to study 3Dprinting of sensors in order to better understand the processes at hand, e.g. it may allow distinguishing between bulk and interlayer resistances. FEM simulations and experiments are used to validate the use of this new method.

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This work demonstrates in-situ monitoring of additive manufacturing through Fused Filament Fabrication with multi-electrode resistance measurements as an alternative to thermal and optical monitoring methods. Measurements are performed through the means of a resistive filament in combination with multiplexed nozzle to bed electrodes. When printing a beam, measurements show the addition of layers as well as nozzle x-position. Furthermore effects of the electrode placement, size and loss of nozzle contact can be measured. Future work will focus on measurements with a higher number of electrodes and more complex sample geometries.