Title: Real-Time Optical Defect Detection, Identification and Correction Technology for Wire-Feed Additive Manufacturing

Authors: Halina S. Tran, Nikolas Aizpuru, Peter Relich, Kevin Pichay, Sivanesan Ponniah

DOI: 10.33599/nasampe/s.21.0443

Abstract: A novel real-time optical defect detection, identification, and correction technology that incorporates hardware and software modules for wire-feed additive manufacturing was developed. The hardware module consists of optical sensors for high-resolution spatial mapping, thermal mapping, and wire-feed speed rate monitoring. The software module generates point cloud data of each printed layer, compares it to the CAD model of the part, determines the locations, volumes, and types of defects, and creates new printing instructions to correct the detected printing defects. This real-time corrective printing is enabled by the simultaneous monitoring of the printed surface, the dispensed printing material, and the temperature irregularities through the use of high-speed miniature sensors and by the implementation of data fusion and elevation deformation inference. Integrated monitoring methods target a broad range of defect types that can be identified, located, and quantified in real time. In addition, when a discrepancy is detected at a certain location, additional 3D printing steps necessary to correct the defect are computed and executed. This novel development will significantly reduce the need for post-build full part inspection and re-printing in case of inferior part quality.

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Conference: SAMPE NEXUS 2021

Publication Date: 2021/06/29

SKU: TP21-0000000443

Pages: 10

Price: FREE