Defect Identification and Mitigation Via Visual Inspection in Large-Scale Additive Manufacturing

Michael Borish, Brian K. Post, Alex Roschli, Phillip C. Chesser, Lonnie J. Love, Katherine T. Gaul

Research output: Contribution to journalArticlepeer-review

36 Scopus citations

Abstract

Defect identification and mitigation is an important avenue of research to improve the overall quality of objects created using additive manufacturing (AM) technologies. Identifying and mitigating defects takes on additional importance in large-scale, industrial AM. In large-scale AM, defects that result in failed prints are extremely costly in terms of time spent and material used. To address these issues, researchers at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility investigated the use of a laser profilometer and thermal camera to collect data concerning an object as it was constructed. These data provided feedback for an in situ control system to adjust object construction. Adjustments were made in the form of automated height control. This paper presents results for both a polymer- and metal-based system. Object construction for both systems was improved significantly, and the resulting objects were more geometrically identical to the ideal 3D representation.

Original languageEnglish
Pages (from-to)893-899
Number of pages7
JournalJOM
Volume71
Issue number3
DOIs
StatePublished - Mar 15 2019

Funding

This material is based upon work supported by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Office of Advanced Manufacturing, under Contract Number DE-AC05-00OR22725. The authors would also like to acknowledge the contributions of Christy White in the preparation of this work. This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan).

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