A high-resolution and large field-of-view scanner for in-line characterization of powder bed defects during additive manufacturing
Powder bed defects are irregularities in the powder layer, which alter the energy input during the powder bed fusion process. As a result, they are directly responsible for the formation of flaws in the consolidated material, which cause quality and property variability in additive manufactured part...
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doaj-91408fa322324778a3cc8a48b6487e682020-11-25T00:19:35ZengElsevierMaterials & Design0264-12752019-02-01164A high-resolution and large field-of-view scanner for in-line characterization of powder bed defects during additive manufacturingLe Tan Phuc0Matteo Seita1Singapore Centre for 3D Printing, School of Mechanical and Aerospace Engineering, Nanyang Technological University, Singapore 639798, SingaporeSingapore Centre for 3D Printing, School of Mechanical and Aerospace Engineering, Nanyang Technological University, Singapore 639798, Singapore; School of Materials Science and Engineering, Nanyang Technological University, Singapore 639798, Singapore; Corresponding author at: Singapore Centre for 3D Printing, School of Mechanical and Aerospace Engineering, Nanyang Technological University, Singapore 639798, Singapore.Powder bed defects are irregularities in the powder layer, which alter the energy input during the powder bed fusion process. As a result, they are directly responsible for the formation of flaws in the consolidated material, which cause quality and property variability in additive manufactured parts. Because of their small size and ubiquity across the powder bed, powder bed defects are difficult to detect and correct. In this work, we propose a new method to assess powder bed defects across the entire powder bed at the remarkable spatial resolution of ~5 μm. Our method relies on the integration of a contact image sensor taken from a flatbed document scanner to the powder re-coater module. Owing to the narrow depth-of-field of the sensor, we detect powder bed defects by identifying out-of-focus regions in the acquired scans using numerical image analysis techniques. Moreover, we show that we can assess the defects height (or depth) by quantifying the degree of “blurriness” in such regions. Our “powder bed scanner” is a rapid and cost-effective tool for in-line characterization of the powder bed quality. This technology may be instrumental to develop novel close loop strategies aimed at improving the consistency of additive manufactured parts. Keywords: Powder bed fusion, In-situ monitoring, Surface topography, In-line powder bed defect characterization, Contact image sensor, Numerical image analysishttp://www.sciencedirect.com/science/article/pii/S0264127518309262 |
collection |
DOAJ |
language |
English |
format |
Article |
sources |
DOAJ |
author |
Le Tan Phuc Matteo Seita |
spellingShingle |
Le Tan Phuc Matteo Seita A high-resolution and large field-of-view scanner for in-line characterization of powder bed defects during additive manufacturing Materials & Design |
author_facet |
Le Tan Phuc Matteo Seita |
author_sort |
Le Tan Phuc |
title |
A high-resolution and large field-of-view scanner for in-line characterization of powder bed defects during additive manufacturing |
title_short |
A high-resolution and large field-of-view scanner for in-line characterization of powder bed defects during additive manufacturing |
title_full |
A high-resolution and large field-of-view scanner for in-line characterization of powder bed defects during additive manufacturing |
title_fullStr |
A high-resolution and large field-of-view scanner for in-line characterization of powder bed defects during additive manufacturing |
title_full_unstemmed |
A high-resolution and large field-of-view scanner for in-line characterization of powder bed defects during additive manufacturing |
title_sort |
high-resolution and large field-of-view scanner for in-line characterization of powder bed defects during additive manufacturing |
publisher |
Elsevier |
series |
Materials & Design |
issn |
0264-1275 |
publishDate |
2019-02-01 |
description |
Powder bed defects are irregularities in the powder layer, which alter the energy input during the powder bed fusion process. As a result, they are directly responsible for the formation of flaws in the consolidated material, which cause quality and property variability in additive manufactured parts. Because of their small size and ubiquity across the powder bed, powder bed defects are difficult to detect and correct. In this work, we propose a new method to assess powder bed defects across the entire powder bed at the remarkable spatial resolution of ~5 μm. Our method relies on the integration of a contact image sensor taken from a flatbed document scanner to the powder re-coater module. Owing to the narrow depth-of-field of the sensor, we detect powder bed defects by identifying out-of-focus regions in the acquired scans using numerical image analysis techniques. Moreover, we show that we can assess the defects height (or depth) by quantifying the degree of “blurriness” in such regions. Our “powder bed scanner” is a rapid and cost-effective tool for in-line characterization of the powder bed quality. This technology may be instrumental to develop novel close loop strategies aimed at improving the consistency of additive manufactured parts. Keywords: Powder bed fusion, In-situ monitoring, Surface topography, In-line powder bed defect characterization, Contact image sensor, Numerical image analysis |
url |
http://www.sciencedirect.com/science/article/pii/S0264127518309262 |
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