In situ three-dimensional reconstruction of laser powder bed fusion parts by light field camera

Abstract

The assessment of output quality in the laser powder bed fusion process entails the analysis of the three-dimensional morphology of the manufactured parts, which plays a crucial role in quality control to prevent metallurgical defects. This study proposes a novel approach of three-dimensional reconstruction for laser powder bed fusion parts using a light field camera. Initially, a consistency method for high-precision camera calibration was explored to determine the virtual camera pixel size and coefficient of effective focal length of light field camera. Subsequently, the model based light field epipolar-plane image Unet is designed to obtain disparity information without any data augmentation techniques. By leveraging both binocular and light field optical paths, a robust mapping relationship of the disparity, depth, and visually coherent three-dimensional contour was established. Finally, the three-dimensional contours of laser powder bed fusion parts were reconstructed by the established mapping with a single exposure of the light field camera. The proposed method enables three-dimensional contour visualization of laser powder bed fusion parts from multi-view perspectives, which facilitates in situ monitoring of the spattering distance, three-dimensional spatial points and lines of the printed layers and contours of printed parts. With a calibration error of 50 μm and resolution of 180 μm for the light field camera (Lytro illum camera), the maximum relative and absolute errors between reconstructed three-dimensional spatial points were 4.33 % and 260 μm respectively when compared with theoretical dimension, and 0.5 % and 210 μm respectively when compared with manufactured dimension. The maximum root-mean-square error of reconstructed three-dimensional contour surfaces was found to be 1.55 mm. This study represents the first application of a light field camera for in situ three-dimensional reconstruction of laser powder bed fusion parts, which notably can be obtained from only a single round of calibration and exposure, enabling seamless monitoring of their surface morphology and facilitating online quality control. These advancements have vast potential for enhancing high-end additive manufacturing.