Advanced Defect Detection Software for Additive Manufacturing

This invention is a novel software solution that processes in-situ infrared (IR) camera data during laser powder bed fusion (LPBF) to identify and locate manufacturing defects. The software's innovative mapping approach accurately superimposes thermal data onto a 3D reconstructed part geometry, drastically reducing data storage needs by over 99% and paving the way for real-time quality control.

Description

This software addresses key challenges in LPBF by automatically correcting image distortion from the IR camera and precisely mapping the acquired data to a voxel mesh of the part's CAD geometry. This eliminates the need for manual, post-processing steps and enables the reconstruction of a full 3D model that accurately pinpoints areas of potential defects. The system also generates 10 distinct IR features, including laser intensities, melt pool area, and cooling rates, to provide valuable insights for defect detection and process control. By retaining only data within the part's geometry, the software transforms terabytes of raw data into a more manageable size, making it feasible to analyze complex builds and large-scale productions.

Applications

- Quality control in laser powder bed fusion (LPBF) manufacturing.
- Aerospace industry for the production of critical components.
- Industries requiring high-density parts with minimal defects.
- Advanced materials and metal fabrication.
- Process qualification and certification for additive manufacturing builds.

Advantages

- Significantly Reduced Data Storage
- Enables Real-Time Defect Detection
- Increased Accuracy
- Enhanced Process Monitoring
- Improved Part Qualification: The 3D reconstruction of the part allows for a complete analysis of complex geometries, making it a valuable tool for identifying potential failure areas after the build is complete and for preemptive measures during printing.

Invention Readiness

The technology is currently in a functional software prototype stage, successfully validated through experiments with a complex test artifact. This software, which processes infrared camera data, has proven its ability to perform thermal and spatial calibrations, create a 3D reconstruction of a part, and identify areas of high heat accumulation and defect anomalies. The data generated by this tool lays the groundwork for future developments aimed at achieving real-time defect detection during the additive manufacturing process.

IP Status

Software

Related Publication(s)

Hinnebusch, S., Anderson, D., Bostan, B., & To, A. C. (2024). In-Situ Infrared Camera Monitoring for Defect and Anomaly Detection in Laser Powder Bed Fusion: Calibration, Data Mapping, and Feature Extraction (Version 1). arXiv. https://doi.org/10.48550/ARXIV.2407.12682