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Sensors 2018, 18(4), 1180; https://doi.org/10.3390/s18041180

In Situ 3D Monitoring of Geometric Signatures in the Powder-Bed-Fusion Additive Manufacturing Process via Vision Sensing Methods

1
State Key Laboratory of Material Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan 430074, China
2
The Institute of Technological Sciences, Wuhan University, Wuhan 430072, China
3
School of Power and Mechanical Engineering, Wuhan University, Wuhan 430072, China
*
Authors to whom correspondence should be addressed.
Received: 1 March 2018 / Revised: 29 March 2018 / Accepted: 10 April 2018 / Published: 12 April 2018
(This article belongs to the Special Issue Depth Sensors and 3D Vision)
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Abstract

Lack of monitoring of the in situ process signatures is one of the challenges that has been restricting the improvement of Powder-Bed-Fusion Additive Manufacturing (PBF AM). Among various process signatures, the monitoring of the geometric signatures is of high importance. This paper presents the use of vision sensing methods as a non-destructive in situ 3D measurement technique to monitor two main categories of geometric signatures: 3D surface topography and 3D contour data of the fusion area. To increase the efficiency and accuracy, an enhanced phase measuring profilometry (EPMP) is proposed to monitor the 3D surface topography of the powder bed and the fusion area reliably and rapidly. A slice model assisted contour detection method is developed to extract the contours of fusion area. The performance of the techniques is demonstrated with some selected measurements. Experimental results indicate that the proposed method can reveal irregularities caused by various defects and inspect the contour accuracy and surface quality. It holds the potential to be a powerful in situ 3D monitoring tool for manufacturing process optimization, close-loop control, and data visualization. View Full-Text
Keywords: in situ monitoring; additive manufacturing; surface topography; contour detection; quality inspection in situ monitoring; additive manufacturing; surface topography; contour detection; quality inspection
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Li, Z.; Liu, X.; Wen, S.; He, P.; Zhong, K.; Wei, Q.; Shi, Y.; Liu, S. In Situ 3D Monitoring of Geometric Signatures in the Powder-Bed-Fusion Additive Manufacturing Process via Vision Sensing Methods. Sensors 2018, 18, 1180.

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