Enhancing FDM Rapid Prototyping for Industry 4.0 Applications through Simulation and Optimisation Techniques

Modern production systems increasingly rely on Industry 4.0 technologies, also known as Smart Manufacturing. Among its foundational pillars, additive manufacturing plays a critical role in enabling rapid prototyping and the creation of customised final products with minimal cost and lead time. Key technologies such as Fused Deposition Modelling (FDM), Stereolithography (SLA), and Selective Laser Sintering (SLS) have expanded material capabilities to include plastics, metals, and composites. This study focuses on the implementation of Klipper, an open-source firmware developed to improve 3D printing performance by delegating computational processes to an external microcontroller. A comparative experimental setup was designed using an ordinary printer to evaluate improvements in print speed, dimensional accuracy, and surface quality. The research identifies performance bottlenecks in standard, affordable 3D printers and demonstrates how computer app integration enhances both efficiency and quality. The findings position this kind of computer app as a viable solution for improving the prototyping workflow in cost-sensitive environments, contributing to the broader adoption of advanced manufacturing practices aligned with Industry 4.0 principles.