For more than 20 years, material extrusion 3D printing has been widely used and it has been one of the most accessible processes. And yet, for all its popularity, it still has a fundamental weakness: the lack of process control. The process is still a black box. The system operates “blind,” assuming that all parameters, like extrusion rate, temperature, and motion perform as programmed in the G-code. As a result, deviations such as under- or over-extrusion often go undetected until post-production inspection. In industrial environments, such as in aerospace and medical/life science where dimensional accuracy, repeatability, and traceability are critical, this open-loop approach is no longer sufficient. True industrialisation of the material extrusion process requires real-time process monitoring, adaptive correction according to needs and a closed-loop feedback. Our closed-loop process with our 3D printer TrueFormer 600 powered by SituGuard is the cornerstone of what we do at TRACK3D.

Understanding the Challenge and the real pain point in Material Extrusion 3D printing:

Material extrusion 3D printing might be the widest used type of technology, but it still has plenty of challenges in front of it:

1. Repeatability: One of the major challenges in industrial 3D printing particularly in material extrusion processes is achieving true repeatability. While individual parts may meet dimensional expectations, reproducing the same geometry with identical precision across multiple prints remains difficult. This inconsistency stems from the open-loop nature of 3D printer systems. Even minor variations in extrusion flow, temperature, or layer adhesion can accumulate over time, leading to deviations between prints. Without feedback and controlled layer adhesion, the 3D printer cannot detect or compensate for these drifts, resulting in parts that differ in dimensions, surface quality, or mechanical stability. In industrial manufacturing, where process validation and certification demand consistent, reproducible results, the lack of controlled layer adhesion and process feedback represents a critical limitation.
2. Geometric Errors and Dimensional Deviations: Material behaviour in extrusion processes is highly sensitive to temperature and humidity. Even minor deviations in filament diameter can affect extrusion volume, leading to under- or over-extrusion and surface irregularities.
3. Limited Traceability and Quality Assurance: Industrial users require process traceability and documented quality assurance for certification and compliance (e.g., aerospace, medical and Railway industries). Extrusion processes currently provide little to no data about what occurred during printing. The result is a black box process, quality issues can only be detected after the part is completed, often through destructive testing or manual inspection.

The Closed-Loop Concept

The Closed-Loop Concept is built on the principle that sensor-based feedback becomes more reliable than human intervention. Instead of relying on post-process inspection or manual adjustments, the system performs self-regulation through continuous sensor data and automated feedback control. This data is continuously compared to the target geometry. When deviations are detected, the system generates a control command, which is sent directly to the printer. The system then executes the corresponding adjustments to restore optimal conditions. This continuous cycle of measurement, comparison, correction, and validation transforms the printing process into an intelligent, self-regulating system.

From data to process optimisation: “SituGuard”

In addition, the system automatically generates process reports and digital twins, transforming the previously “black box” of 3D printing into a transparent and traceable process. Every layer of the print is scanned by a profile line laser and multiple of other sensors, generating a dense 3D point cloud that precisely represents the actual geometry of the printed part. This data, the Digital Twin, is continuously compared with the G-code reference model, enabling detection of even the smallest deviations in extrusion rate, layer height, or positional accuracy. Through our closed-loop feedback system, the process outcome is precisely controlled, ensuring consistent part quality and a stable extrusion process. With SituGuard, every print gains complete digital traceability, providing full visibility into what happens during production. The system operates under transparent, closed-loop control, continuously recording and analysing critical parameters such as extrusion flow, temperature, and layer formation in real time. This intelligent monitoring and feedback not only stabilise the build, but also automatically generate a comprehensive digital process log, detailed process reports, and traceable quality documentation for each printed part.

These traceable datasets empower manufacturers to:

• Verify process consistency for every build,
• Document and prove quality for auditing and certification.
• Detect, correct, and prevent deviations before they impact part integrity.

TRACK3D transforms the formerly “black box” nature of 3D printing into a transparent, traceable and data-driven process, establishes true industrial-level quality assurance and process validation which are key prerequisites for certified, repeatable additive manufacturing in demanding industries.

Impact

In industries such as aerospace, automotive, medical technology and railway industries, the lack of precision in additive manufacturing doesn’t just cost time, it costs money, safety and trust in the technology. TRACK3D’s TrueFormer 600, powered by SituGuard, delivers real-time accuracy and process control, ensuring that every part meets the strict standards these sectors demand. With closed-loop monitoring, adaptive correction and a documented process for every printed part, we transform 3D printing into a certifiable, high-precision manufacturing process ready for industrial deployment.