Real time fault detection in 3D printers using Convolutional Neural Networks and acoustic signals

Reliable fault detection is crucial for industrial machinery in large-scale facilities, where unexpected failures can cause costly downtime and production interruptions. Although acoustic monitoring provides a scalable solution for machine condition monitoring, its deployment is often constrained by high false-positive rates. We propose a two-step approach to automatic anomalous sound detection: first, when only normal operating audio samples are available, a regularized unsupervised model is deployed; then, after the first machine fault, a few-shot adaptation strategy exploits the anomalous samples acquired during the fault to improve the system. This adaptation increases the area under the precision-recall curve (AUPR) from 23.0 to 64.0 and improves detection in the low false-positive-rate region, with the partial area under the receiver operating characteristic curve (pAUROC) increasing from 39.6 to 72.8. We also show that covariance regularization improves both prediction accuracy and training stability in the unsupervised model. These results provide a practical strategy for acoustic anomaly detection systems, enabling improved accuracy and reduced false alarms.

Active Motor Noise Cancellation (AMNC) ships in commercial fused deposition modeling (FDM) 3D printers as a hardware countermeasure against acoustic side-channel attacks that target intellectual property (IP). We present the first empirical evaluation of a deployed AMNC countermeasure, using a public dataset of synchronized acoustic and vibration recordings from two AMNC-equipped Bambu Lab printers across 12 object classes. AMNC fully neutralizes the acoustic channel: classification accuracy is indistinguishable from the 8.33% random baseline. The vibration channel, which AMNC does not target, still leaks. With summary statistics the leak is coarse and amplitude-driven (vibration accuracy approximately 31% pooled, 36-47% within-printer), while the waveform shape carries essentially nothing (frequency-only features at chance). A full-sequence temporal model that ingests the ordered evolution of the print raises accuracy to approximately 61%, and an order-shuffling control (approximately 33%) shows that a substantial component is genuinely sequential and tied to print progression. The leak is device-specific: a classifier trained on one printer transfers near chance to the other. We conclude that AMNC is an acoustic-only defense: vibration remains a partial, geometry-correlated side channel it does not address, but one that does not, on this dataset, support full geometric reconstruction; reconstruction-grade attacks would require the magnetic or power channels AMNC also leaves untouched. We release all code.

In recent years, Sound AI is being increasingly used to predict machine failures. By attaching a microphone to the machine of interest, one can get real time data on machine behavior from the field. Traditionally, Convolutional Neural Net (CNN) architectures have been used to analyze spectrogram images generated from the sounds captured and predict if the machine is functioning as expected. CNN architectures seem to work well empirically even though they have biases like locality and parameter-sharing which may not be completely relevant for spectrogram analysis. With the successful application of transformer-based models in the field of image processing starting with Vision Transformer (ViT) in 2020, there has been significant interest in leveraging these in the field of Sound AI. Since transformer-based architectures have significantly lower inductive biases, they are expected to perform better than CNNs at spectrogram analysis given enough data. This paper demonstrates the effectiveness of transformer-driven architectures in analyzing Sound data and compares the embeddings they generate with CNNs on the specific task of machine fault detection.