In-operando fault monitoring during laser melting of metallic powders for advanced manufacturing

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In the last five years, tremendous advances were made in the field of 3D printing to facilitate rapid prototyping**and/or manufacturing of complex parts. Our industry partner is an established leader in the 3D printing of**metallic parts, mostly serving customers in the aerospace sector as they require high-performance components**but only very low manufacturing volumes.**FusiA Impression 3D Métal Inc. is a Canadian leader in additive manufacturing of complex high-performance**metallic parts, especially designed for the aerospace sector. In close collaboration with our partners, we**propose to design, construct and test a customized monitoring system to be mounted on a commercial-grade 3D**printer. This system will seek to detect and alert machine operators when faulty behaviors occur during**laser-induced melting of metallic powders. In turn, these alerts could be indicators used to either (1) intervene**and correct process anomalies in a timely manner and/or (2) to stop the printing process altogether and save**precious machine time.**As such, a vision system will be mounted directly on the commercial printer to monitor the live camera feed**from the already built-in vision system. Using this approach, there will be no need to alter the printer's**hardware or software in any way. In addition to its simplicity, this approach would also make our solution**compatible with a wider array of commercial 3D printing machines. In turn, this add-on could help**significantly increase the efficiency and competitiveness of metal 3D printing solutions.