The agenda of Industry 4.0 highlights smart manufacturing by making machines smart enough to make data-driven decisions. Large-scale 3D printers, being one of the important pillars in Industry 4.0, are equipped with smart sensors to continuously monitor print processes and make automated decisions. One of the biggest challenges in decision autonomy is to consume data quickly along the process and extract knowledge from the printer, suitable for improving the printing process. This paper presents the innovative unsupervised learning approach, bootstrap–CURE, to decode the sensor patterns and operation modes of 3D printers by analyzing multivariate sensor data. An automatic technique to detect the suitable number of clusters using the dendrogram is developed. The proposed methodology is scalable and significantly reduces computational cost as compared to classical CURE. A distinct combination of the 3D printer’s sensors is found, and its impact on the printing process is also discussed. A real application is presented to illustrate the performance and usefulness of the proposal. In addition, a new state of the art for sensor data analysis is presented.

Hierarchical clustering is one of the most preferred choices to understand the underlying structure of a dataset and defining typologies, with multiple applications in real life. Among the existing clustering algorithms, the hierarchical family is one of the most popular, as it permits to understand the inner structure of the dataset and find the number of clusters as an output, unlike popular methods, like k-means. One can adjust the granularity of final clustering to the goals of the analysis themselves. The number of clusters in a hierarchical method relies on the analysis of the resulting dendrogram itself. Experts have criteria to visually inspect the dendrogram and determine the number of clusters. Finding automatic criteria to imitate experts in this task is still an open problem. But, dependence on the expert to cut the tree represents a limitation in real applications like the fields industry 4.0 and additive manufacturing. This paper analyses several cluster validity indexes in the context of determining the suitable number of clusters in hierarchical clustering. A new Cluster Validity Index (CVI) is proposed such that it properly catches the implicit criteria used by experts when analyzing dendrograms. The proposal has been applied on a range of datasets and validated against experts ground-truth overcoming the results obtained by the State of the Art and also significantly reduces the computational cost.