Rapid Prototyping (PST) at a glance
Rapid prototyping using additive manufacturing enables components to be produced quickly and flexibly – from concept models to small series. The project was funded by ZIM, grant number 16KN095327. A process control tool (PST) complements this approach with digital monitoring, simulation, and documentation of all relevant printing parameters. This enables construction errors to be detected at an early stage, reduces rework, and ensures consistent quality across all print runs.
PST enables stable process control, especially for complex geometries or demanding materials, avoiding costly misprints and saving time and material resources. As part of a ZIM cooperation project, PST was developed specifically for components based on the bioplastic polyactide (PLA).
Why is a process control tool for additive manufacturing relevant for companies?
A process control tool for additive manufacturing is essential for companies because it enables continuous assurance of component quality by compensating for fluctuations in temperatures or material properties in real time. Automated monitoring and adjustment of printing parameters significantly reduces waste, which lowers both material and cost expenditure and minimizes post-processing.
At the same time, the development and validation phase for new components is shortened, allowing products to reach market maturity faster. Whether for single parts or small series, the tool ensures that proven settings are reliably reproduced, which supports the scalability of production. In addition, the avoidance of misprints and optimized energy use contribute to the sustainable conservation of resources and fit seamlessly into a holistic sustainability strategy.
The main advantages of rapid prototyping
Our services
Our 3D printing optimization services offer you targeted support in the introduction and continuous improvement of your additive manufacturing process. We ensure that you benefit optimally from our process control tool (PST) right from the start – with solutions that are precisely tailored to your production requirements:
- Setup and maintenance of the PST system
- Technical support and user training
- Visualization and evaluation of process data
- Support with data collection during the printing process
- Optimization approaches even before printing, such as thin wall thickness, structures, etc.
- Development of individual optimization strategies and recommendations for action
Unique advantages with PPP
Working with PPP offers unique advantages for your 3D printing optimization with our process control tool (PST). We not only support you in the implementation and maintenance of your additive manufacturing processes, but also in the continuous improvement of quality, efficiency, and sustainability.
- Fast processing: Using state-of-the-art software technology, we deliver fast and accurate results.
- International team: Our global team is available to assist you with all your questions and challenges.
- Industry expertise: Our team has extensive knowledge in the field of additive manufacturing and can draw on many years of experience in various industries.
- Tailor-made solutions: We offer customized consulting and service packages that are precisely tailored to the requirements of your production environment.
- Measurable improvements: Our services enable concrete progress in quality, throughput time, and resource efficiency.
- Continuous support: We accompany you over the long term and support you in the sustainable optimization of your 3D printing processes.
- Improved corporate image: With a data-driven, reliable 3D printing process, you position yourself as a future-oriented and quality-conscious company.
Free initial consultation
Would you like to learn more about 3D printing optimization with our Process Control Tool (PST)? Contact us for a free initial consultation or schedule a no-obligation web session. Our experts are ready to discuss your individual requirements and offer you tailor-made solutions for more efficient and reliable additive manufacturing.
Patrick Wortner
CEO | MBA and Eng., Dipl.-Ing. (FH)
What does 3D printing optimization mean?
At PeoplePlanetProfit (PPP), 3D printing optimization refers to the strategic use of digital control technologies to increase efficiency, quality, and sustainability in additive manufacturing. This comprehensive approach transforms traditional printing processes through precise monitoring and control of all manufacturing parameters. At its core, it is about minimizing material waste, optimizing energy consumption, and ensuring consistent component quality across all production runs—especially for demanding applications in medical technology, aviation, or the automotive industry.
How does the process control tool (PST) work?
The PST forms the technological heart of our solution as a closed control loop and operates in three synchronized phases: Before printing begins, it simulates the computer-aided design (CAD) model for thermal warping risks and structural weaknesses, with virtual pre-tests reducing errors by up to 85%. During printing, high-resolution industrial cameras continuously detect layer thickness deviations and filament application irregularities, with deviations triggering automatic corrections. At the same time, artificial intelligence (AI) algorithms interpret the data streams and adjust the printing speed, nozzle temperature, and cooling profiles in real time.
Process control in 3D printing for precise results
The particular strength of PST lies in its ability to synchronize digital twins with live process data. This integration enables unprecedented precision, as demonstrated by a use case in medical technology: The system reduced dimensional tolerances from ±0.3 mm to ±0.05 mm, while post-processing hours were reduced by 92% and material savings of 28% were achieved through optimized support structures. Especially for hybrid components made of multiple materials, PST achieves reproducibility where manual control fails.
Why is consistent quality crucial in 3D printing?
In regulated industries, micrometers determine component approval or costly rejects. Our PST addresses four key challenges: Geometric distortions are compensated for by real-time thermal modeling, and layer adhesion errors are avoided by infrared temperature monitoring with automatic reheating. The system compensates for material inconsistencies through AI-supported parameter tuning for batch variations, while digital print profiles with 100% reproducibility eliminate series variance. This has been proven to reduce scrap rates by up to 68%.
Digital simulation of the printing process before each component
Each print job begins with a computational fluid dynamics (CFD)-based heat distribution analysis that predicts thermal stresses and warping risks. The software calculates topology-optimized, weight-reduced component structures and automatically generates support-free printing strategies. This predictive approach identifies potential sources of error as early as the planning phase and adjusts printing parameters preventively, which not only saves material and energy but also significantly increases the success rate for novel geometries.
Real-time monitoring of filament application with industrial camera
High-frequency thermographic images combined with laser triangulation measurements continuously monitor layer thicknesses and filament application. Spectral analysis of the melt pool immediately detects material inhomogeneities, while the 5 µm pixel resolution identifies even the smallest irregularities. In the event of critical anomalies, printing is immediately interrupted, which contributes significantly to quality assurance, especially for medical implants or aerodynamic components.
Avoiding misprints with complex geometries
Patented Adaptive Slicing Technology enables even undercuts and ultra-thin wall structures with a wall thickness of less than 0.4 mm to be precisely reproduced. The system dynamically calculates optimized print paths, continuously adjusts layer thicknesses between 20-200 µm, and controls local cooling zones. In multi-axis printers, integrated collision detection prevents machine damage, while material-adaptive speed controls prevent filament breakage at curve radii—crucial for lightweight structures in aviation.
Digital twins for optimizing materials and parameters
Our virtual material library with over 500 material profiles simulates crystallization behavior and mechanical properties under operating loads. Machine learning algorithms compare new geometries with historical print data and generate precise parameter recommendations. What-if scenarios also enable virtual testing of exotic material combinations before real resources are used—a decisive advantage in the development of sustainable composite materials.
Central process database as the link between all technologies
As an integrating platform, the versioned database stores all printing parameters, sensor measurements, and quality logs. AI-supported pattern recognition identifies hidden correlations between environmental conditions and component defects, while predictive algorithms forecast tool wear. Application programming interface (API) interfaces to ERP systems also enable seamless integration into existing production ecosystems and quality management systems.
Use of artificial intelligence for data-based control
The self-learning algorithms process empirical values from over 15 million printing hours. They continuously optimize printing profiles by anticipating thermal inertia effects and dynamically balancing material flow properties. This intelligent control approach reduces manual intervention to a minimum and ensures reproducible quality even during long production runs.
Free initial consultation
Would you like to learn more about 3D printing optimization with our Process Control Tool (PST)? Contact us for a free initial consultation or schedule a no-obligation web session. Our experts are ready to discuss your individual requirements and offer you tailor-made solutions for more efficient and reliable additive manufacturing.
Patrick Wortner
CEO | MBA and Eng., Dipl.-Ing. (FH)
Frequently asked questions
What is meant by 3D printing optimization?
3D printing optimization refers to the strategic use of digital control technologies to increase efficiency, quality consistency, and sustainability in additive manufacturing. At its core is the integration of a process control tool (PST) that uses predictive simulation, real-time monitoring, and AI-supported control to reduce material consumption, increase energy efficiency, and ensure component quality across all production runs—which is particularly critical for medical or aerospace components.
How does the process control tool (PST) work?
The PST operates as a closed cyber-physical control loop: Before printing begins, it simulates thermomechanical stresses on the digital twin and generates optimized printing parameters. During printing, industrial cameras (5 µm/pixel) monitor the filament application and sensors detect temperature gradients. Deviations >0.2 mm trigger automatic corrections via AI algorithms, which adaptively control the printing speed, nozzle temperature, and cooling in real time. All data is documented in a central process database with versioning.
What advantages does the software offer companies?
- Quality improvement: Reduction of dimensional tolerances to ±0.05 mm (medical technology reference)
- Cost reduction: Up to 92% less rework, 28% material savings
- Resource efficiency: Up to 17 kWh energy savings per avoided misprint
- Scalability: 100% reproducible print profiles for series production
- Sustainability: Transparent life cycle assessment via TransPPParent integration
What technologies are used in PST?
- Digital simulation: CFD-based heat distribution analysis and topology optimization
- Multisensor technology: High-frequency thermography + laser triangulation
- Adaptive slicing: Dynamic layer thickness adjustment for complex geometries
- Material digitization: Virtual library with 500+ material profiles
- AI control: Self-learning algorithms from 15M+ printing hours