Checking 3D-printer filament: micrometers, layers and feed speed
1.1 Physical quantities and measurement1.3 Mass, weight and density1.2 Speed, velocity and motion graphsCore
A student who runs a 3D printer checks a new spool of plastic filament. The label on the spool states that the diameter of the filament is 1.75 mm ± 0.03 mm.
The student first closes the jaws of a micrometer screw gauge with nothing between them. The gauge reads +0.03 mm. The filament is then placed between the jaws. Figure 1 shows the scales of the micrometer.
Determine the diameter of the filament.
Show solution
| reading = 1.5 mm + 26 × 0.01 mm = 1.76 mm | ✓ 1 | Sleeve 1.5 mm and thimble 0.26 mm both needed. |
| diameter = 1.76 − 0.03 = 1.73 mm | ✓ 1 | Allow ECF from an incorrect reading. Unit required. 1.79 mm (zero error added) scores this mark 0. |
Answer: 1.73 mm
State, with a reason, whether the filament is within the range given on the label.
Show solution
| yes: 1.73 mm lies within the range 1.72 mm to 1.78 mm | ✓ 1 | Allow ECF from (a). The range or the lower limit 1.72 mm must be seen. |
Answer: Yes, 1.73 mm is between 1.72 mm and 1.78 mm
The student prints a test block 40 layers tall and measures its height with a 30 cm ruler. The height is 8.0 mm.
Calculate the thickness of one layer.
Show solution
| 8.0 ÷ 40 = 0.20 mm | ✓ 1 | Accept 0.020 cm or 2.0 × 10−4 m. |
Answer: 0.20 mm
Explain why the student measures the height of 40 layers instead of measuring one layer.
Show solution
| one layer is much thinner than the smallest division of the ruler (1 mm), so it cannot be measured directly / accurately | ✓ 1 | Accept: the ruler's resolution is too large for one layer. |
| the reading error of the ruler is shared out over 40 layers, so the error in the thickness of one layer is (40 times) smaller | ✓ 1 | Accept: the percentage uncertainty is smaller. "More accurate" alone is not enough. |
The student changes a setting so that each layer is now 0.10 mm thick.
Suggest how many layers should be measured with the same ruler to give the thickness of one layer with the same percentage uncertainty as before. Give a reason.
Show solution
| 80 layers | ✓ 1 | Allow ECF from (c)(i): 8.0 mm ÷ new thickness. |
| the stack is then the same height (8.0 mm), so the same ruler reading error is the same fraction of the height measured and the percentage uncertainty in one layer is unchanged | ✓ 1 | Accept: the total height measured must stay the same. |
Answer: 80 layers
The student prints a small solid test piece and finds its mass on a balance. The mass is 15.6 g. The test piece is lowered on a thread into a measuring cylinder containing water. The water level rises from 50.0 cm3 to 63.0 cm3 and the test piece is completely under the water.
Show that the density of the plastic is about 1.2 g/cm3.
Show solution
| volume = 63.0 − 50.0 = 13.0 cm3 | ✓ 1 | Using 63.0 cm3 as the volume scores 0 for this mark. |
| density = mass ÷ volume | ✓ 1 | Equation in words or symbols (ρ = m/V), or a correct substitution. |
| 15.6 ÷ 13.0 = 1.20 g/cm3 | ✓ 1 | The full substitution must be seen; 1.2 alone scores 0 for this mark. |
Answer: 1.20 g/cm3
State the density of the plastic in kg/m3 and state whether the test piece floats or sinks in water. Give a reason. The density of water is 1000 kg/m3.
Show solution
| 1200 kg/m3 | ✓ 1 | Allow ECF from (d)(i). |
| sinks, because its density is greater than the density of water | ✓ 1 | Must compare densities. "Because it is heavy" scores 0. Allow ECF consistent with the student's density. |
Answer: 1200 kg/m3; it sinks
During a print, the printer feeds filament at a steady rate. The table shows the length L of filament fed into the printer after time t.
| t / s | 0 | 20 | 40 | 60 | 80 | 100 |
|---|---|---|---|---|---|---|
| L / mm | 0 | 35 | 67 | 103 | 136 | 170 |
On Figure 2, plot the points and draw the line of best fit.
Show solution
| all six points plotted correctly to within half a small square | ✓ 1 | Five correct points: allow this mark. |
| single straight line of best fit through (or very close to) the origin, with points evenly scattered either side | ✓ 1 | Do not accept a dot-to-dot line or a curve. |
Use your graph to determine the speed at which the filament is fed into the printer. Give your answer in mm/s.
Show solution
| gradient found from a large triangle on the line, e.g. 170 ÷ 100 | ✓ 1 | Values read from the line, not just from the table, using a triangle covering at least half the line. |
| 1.7 mm/s | ✓ 1 | Accept 1.6 mm/s to 1.8 mm/s. Unit required. |
Answer: 1.7 mm/s
Show full solution
| Marking point | Mark | Notes |
|---|---|---|
| Part (a) | ||
| reading = 1.5 mm + 26 × 0.01 mm = 1.76 mm | ✓ 1 | Sleeve 1.5 mm and thimble 0.26 mm both needed. |
| diameter = 1.76 − 0.03 = 1.73 mm | ✓ 1 | Allow ECF from an incorrect reading. Unit required. 1.79 mm (zero error added) scores this mark 0. |
| Part (b) | ||
| yes: 1.73 mm lies within the range 1.72 mm to 1.78 mm | ✓ 1 | Allow ECF from (a). The range or the lower limit 1.72 mm must be seen. |
| Part (c)(i) | ||
| 8.0 ÷ 40 = 0.20 mm | ✓ 1 | Accept 0.020 cm or 2.0 × 10−4 m. |
| Part (c)(ii) | ||
| one layer is much thinner than the smallest division of the ruler (1 mm), so it cannot be measured directly / accurately | ✓ 1 | Accept: the ruler's resolution is too large for one layer. |
| the reading error of the ruler is shared out over 40 layers, so the error in the thickness of one layer is (40 times) smaller | ✓ 1 | Accept: the percentage uncertainty is smaller. "More accurate" alone is not enough. |
| Part (c)(iii) | ||
| 80 layers | ✓ 1 | Allow ECF from (c)(i): 8.0 mm ÷ new thickness. |
| the stack is then the same height (8.0 mm), so the same ruler reading error is the same fraction of the height measured and the percentage uncertainty in one layer is unchanged | ✓ 1 | Accept: the total height measured must stay the same. |
| Part (d)(i) | ||
| volume = 63.0 − 50.0 = 13.0 cm3 | ✓ 1 | Using 63.0 cm3 as the volume scores 0 for this mark. |
| density = mass ÷ volume | ✓ 1 | Equation in words or symbols (ρ = m/V), or a correct substitution. |
| 15.6 ÷ 13.0 = 1.20 g/cm3 | ✓ 1 | The full substitution must be seen; 1.2 alone scores 0 for this mark. |
| Part (d)(ii) | ||
| 1200 kg/m3 | ✓ 1 | Allow ECF from (d)(i). |
| sinks, because its density is greater than the density of water | ✓ 1 | Must compare densities. "Because it is heavy" scores 0. Allow ECF consistent with the student's density. |
| Part (e)(i) | ||
| all six points plotted correctly to within half a small square | ✓ 1 | Five correct points: allow this mark. |
| single straight line of best fit through (or very close to) the origin, with points evenly scattered either side | ✓ 1 | Do not accept a dot-to-dot line or a curve. |
| Part (e)(ii) | ||
| gradient found from a large triangle on the line, e.g. 170 ÷ 100 | ✓ 1 | Values read from the line, not just from the table, using a triangle covering at least half the line. |
| 1.7 mm/s | ✓ 1 | Accept 1.6 mm/s to 1.8 mm/s. Unit required. |
Answers: (a) 1.73 mm · (b) Yes, 1.73 mm is between 1.72 mm and 1.78 mm · (c)(i) 0.20 mm · (c)(iii) 80 layers · (d)(i) 1.20 g/cm3 · (d)(ii) 1200 kg/m3; it sinks · (e)(ii) 1.7 mm/s
Common error (a) Adding a positive zero error. If the gauge reads +0.03 mm with nothing in the jaws, every reading is 0.03 mm too large, so 0.03 mm is subtracted.
Exam tip (d)(i) In a "show that" question, give your answer to one more significant figure than the value quoted (here 1.20 g/cm3), so it is clear you have calculated it yourself.