iAM-3DPO: Intelligent advanced additive manufacturing enabling dynamic process efficiency
Laser powder bed fusion (LPBF) is a type of additive manufacturing (AM) that uses a laser to melt metal powder into a solid object. However, while it is a promising technology for manufacturing complex metal parts, it can also be susceptible to defects such as porosity, cracking and residual stresses. These are caused by factors such as laser power, scan speed and powder bed temperature. Therefore it is important to address these challenges, and having control over the LPBF process parameters, and monitoring the process in real-time, is intrinsic to this. Consequently, a solution is needed to alleviate the risks associated with parts build failure, and ensure the quality and consistency of additively manufactured components.
The aim of the 2-year long, iAM-3DPO: Intelligent advanced additive manufacturing enabling dynamic process efficiency project was to create a novel, integrated, advanced, laser-based system capable of achieving both zero distortion and defects during the 2D build process, when using LPBF to produce metal additively manufactured components.
Work on the project entailed:
- Development of an optical and thermal monitoring system for LPBF
- Integration of diagnostic data acquisition systems for the metal AM process
- Creation of data interpretation algorithms and artificial intelligence (AI) analytical models
- Implementation of a data driven approach modularising experimentally acquired AM data
- Deployment of cloud based data sharing and AI analytics in AM processes
On completion, iAM-3DPO resulted in a new, laser-based, integrated system that incorporates monitoring capability and cloud-based, AI-enabled, closed-loop process optimisation technology, using predictive thermal simulations and adaptable process parameters to avoid build defects and enable right-first-time manufacturability. The factors associated with build quality have been optimised by leveraging project partner Materialise’ Materialise Control Platform (MCP) technology to enable total beam path control, linked to partner TRUMPF Laser UK’s unique, beam shape control technology for single mode beams.
In terms of future potential, the IAM-3DPO system facilitates dynamic application of advanced process parameters and scan strategies, and could therefore lead to solutions for cost effectively upgrading ageing PBF equipment. It also reduces design and processing cycle times in the AM chain, helping to improve material utilisation, efficiency, productivity and quality assurance, and contributing to cost reductions for manufacturers, suppliers and customers.
Partners: NquiringMinds, ThinkLaser, Materialise, TRUMPF Laser UK and J4IC.
IAM-3DPO was funded by Innovate UK via a EUREKA R&D: SMART Advanced Manufacturing grant.