New control technology for 3D printing improves speed and precision

A research team at the Whiting School of Engineering has developed a new control method for 3D printers that aims to improve the speed and precision of the printing process. The method, called Time Code (T-Code), replaces the Geometry Code (G-Code) that has been used for decades and enables an uninterrupted printing process. This allows complex printing operations to be carried out more efficiently.

“3D printing technology has advanced, but G-Code has struggled to keep up. It’s like asking a car to stop every time you want to change the song on the radio,” said Jochen Mueller. “G-code limits the use of multifunctional printheads, which allow users to mix materials or change the nozzle shape. Each additional function requires more commands in the programming language, causing more interruptions and defects in printed objects.”

The control of 3D printers is traditionally based on G-code, a language originally developed for CNC milling. This system forces the printer to stop before each new instruction, which leads to bottlenecks in the printing process and can leave visible defects. T-Code, on the other hand, synchronizes additional printing functions with the movement of the printer, enabling continuous printing. This could be particularly advantageous in the production of individual components.

The researchers led by additive manufacturing expert Jochen Mueller published their findings in the journal Nature Communications. The team has developed a Python-based solution that divides G-code commands into two separate tracks: one for the core movements of the printer and one for additional functions of the print head. This allows material changes or structural adjustments to be made without interrupting the printing process. This not only leads to faster completion, but also to higher print quality.

“We wanted to overcome the limitations that line-by-line printing controls impose on speed and precision,” said study co-leader, Sarah Propst, a doctoral student in civil and systems engineering. “With T-Code, we’re able to achieve a level of sophistication that wasn’t possible before.”

“There’s already a broad array of printhead functionalities, and the demands on printhead controls are only expected to grow as 3D printing capabilities advance,” said Mueller. “These advancements will enable the creation of unprecedented structures with integrated functionalities, such as wearable electronic devices, smart prosthetics, and customized implants—but achieving this is contingent on sophisticated printhead control systems.”

The new method is compatible with existing 3D printers and can be used as a supplement to G-code without the need for complex hardware customization. T-code could open up new possibilities, particularly in areas such as medical technology, robotics or product development, where customized solutions are required. The researchers assume that this technology will help to further optimize 3D printing and facilitate the production of complex structures.