Dimensional Accuracy Evaluation of Single-Layer Prints in Direct Ink Writing Based on Machine Vision

The absence of standardized evaluation methodologies for single-layer dimensional accuracy significantly hinders the broader implementation of direct ink writing (DIW) technology. Addressing the critical need for precision non-contact assessment in DIW fabrication, this study develops a novel machine vision-based framework for dimensional accuracy evaluation. The methodology encompasses three key phases: (1) establishment of an optimized hardware configuration with integrated image processing algorithms; (2) comprehensive investigation of camera calibration protocols, advanced image preprocessing techniques, and high-precision contour extraction methods; and (3) development of an iterative closest point (ICP) algorithm-enhanced evaluation system. The experimental results demonstrate that our machine vision system achieves 0.04 mm × 0.04 mm spatial resolution with the ICP convergence threshold optimized to 0.001 mm. The proposed method shows an 80% improvement in measurement accuracy (0.001 mm) compared to conventional approaches. Process parameter optimization experiments validated the system’s effectiveness, showing at least 76.3% enhancement in printed layer dimensional accuracy. This non-contact evaluation solution establishes a robust framework for quantitative quality control in DIW applications, providing critical insights for process optimization and standardization efforts in additive manufacturing.