Quality certification and control of polymer laser sintering: layerwise temperature monitoring using thermal imaging

Abstract

In additive manufacturing (3D printing) of products for aerospace, medical, or other critical applications, the quality of the manufactured part must be “certified” before it can be used. New methods are needed to certify the quality during the fabrication process. The digital 3D quality certificate (3DQC) assures that process monitor values were within specification during the entire fabrication process. This paper proposes an approach for using high resolution infrared thermal imaging to monitor the temperature of individual layers before, during, and after laser scanning. Temperature data is indexed to the part geometry using a binary template created from the sliced 3D model. This data provides a record of the process conditions during the creation of each volume element of the part. Two temperatures are discussed in this paper: the peak temperature achieved during laser scanning and the residual temperature in the layer just before adding the next powder layer. Both of these monitors show a relationship to the geometry of the part, the layer cross-sectional area, and the presence or absence of an underlying solid layer. While both of these temperatures likely relate to part quality, this relationship is not yet understood. Ultimately, this monitor data can be used to control the process, e.g., modify the laser scan or the wait time before recoating, in order to provide more uniform sintering of each volume element of the part.