Abstract
In additive manufacturing (AM), especially for advanced powder fusion machines, it is of high importance to develop an in situ inspection system to monitor the printed surface and pre-print powder bed as the build cycle proceeds. Consequently, high resolution, high precision and fast detection measurement systems need to be investigated, as such optically based measurement systems can provide feedback for manufacturing process optimisation. Fringe projection technology has a great advantage in the measurement of topography in such environments. The implementation of a fringe projection system requires that the system is pre-calibrated in order to obtain high measurement resolution and repeatability. This paper presents a simple calibration method for an AM-based in situ fringe projection system using a phase-depth calibration model. If a calibration plate with certificated marks is used, however, the texture of the plate will affect the measured phase accuracy. A simple calibration method to reduce the calibration plate texture effect in the process of calibration is outlined. Experimental results show that the proposed method can eliminated these effects and improve measurement resolution and repeatability. The proposed in situ/in process inspection technique has been implemented within a commercial electron beam powder bed fusion additive manufacturing machine (EBAM), to demonstrate the capability for effective feedback during the manufacturing process.
Highlights
Additive manufacturing (AM) techniques have been developing in recent decades with new machine providers continually joining the market
In the AM process environment, measurement can allow the inspection of the powder bed, the printed surface and the consequent 3D reconstruction of the part shape
Machine consists of four parts with different functions: these these are are an an electron electron beam beam melting melting source, source, aa powder powder delivery delivery system, system, aa powder powder bed bed transfer transfer stage, stage, and and the the fringe fringe projection projection inspection inspection system
Summary
Additive manufacturing (AM) techniques have been developing in recent decades with new machine providers continually joining the market. Fringe projection technology can provide a full-field, fast, high-resolution and high-precision layer-by-layer areal surface measurement [4]. In the AM process environment, measurement can allow the inspection of the powder bed, the printed surface and the consequent 3D reconstruction of the part shape. Such a measurement can help classify and predict defects [5]. The assessment of manufacturing quality by such methods would be advantageous in the process and provide feedback for process control
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