In-process inspection of lattice geometry with laser line scanning and optical tomography in fused filament fabrication
Michele Moretti, Arianna Rossi, Nicola Senin
download PDFAbstract. One of the challenges of lattice manufacturing by fused filament fabrication is to achieve geometric accuracy of the internal reticular structures. In this work a solution for in-process inspection is presented, based on combining a custom laser scanner system, mounted into the fabrication machine, and a method for optical tomography. The scanner allows for 2.5D layer measurement, with superior detection of layer edges with respect to 2D optical imaging. Optical tomography is then achieved by vertical stacking of reconstructed layer boundaries, leading to a full volumetric reconstruction of the lattice as a voxel model. Inspection can be performed layer-wise, by comparing the current slice measured by the laser scanner with a reference virtual layer obtained by simulation of the deposition process, or on entire portions of reconstructed 3D geometry, by performing voxel-wise comparisons in 3D, to identify local missing or excess deposited material. The proposed solution proves capable of monitoring an evolving 3D part geometry, allowing also the observation of internal regions, invisible when using conventional optical, post-process imaging methods.
Keywords
Additive Manufacturing, Material Extrusion, Lattice Manufacturing, In-Process Measurement
Published online 9/5/2023, 7 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Michele Moretti, Arianna Rossi, Nicola Senin, In-process inspection of lattice geometry with laser line scanning and optical tomography in fused filament fabrication, Materials Research Proceedings, Vol. 35, pp 216-224, 2023
DOI: https://doi.org/10.21741/9781644902714-26
The article was published as article 26 of the book Italian Manufacturing Association Conference
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
References
[1] S. Singh, G. Singh, C. Prakash and S. Ramakrishna, “Current status and future directions of fused filament fabrication,” J. Manuf. Process., (2020), 288-306 https://doi.org/10.1016/j.jmapro.2020.04.049
[2] International Organization for Standardization, “ISO/ASTM 52900:2021-Additive manufacturing – General principles – Fundamentals and vocabulary” BSI Standards Ltd
[3] X. Wang, L. Zhao, J. Y. H. Fuh and H. P. Lee, “Effect of porosity on mechanical properties of 3D printed polymers: Experiments and micromechanical modeling based on X-ray computed tomography analysis,” Polymers (Basel)., (2019), 11(7). https://doi.org/10.3390/polym11071154
[4] A. Thompson, I. Maskery and R. K. Leach, “X-ray computed tomography for additive manufacturing: A review,” Meas. Sci. Technol., vol. 27, no. 7, (2016), 072001. https://doi.org/10.1088/0957-0233/27/7/072001
[5] B. M. Colosimo, M. Grasso, F. Garghetti and B. Rossi, “Complex geometries in additive manufacturing: A new solution for lattice structure modeling and monitoring,” J. Qual. Technol., 2022, VolL. 54, No. 4, 392-414 https://doi.org/10.1080/00224065.2021.1926377
[6] M. Moretti, A. Rossi and N. Senin, “In-process monitoring of part geometry in fused filament fabrication using computer vision and digital twins,” Addit. Manuf., (2020), 101609. https://doi.org/10.1016/j.addma.2020.101609
[7] Y. Wu, K. He, X. Zhou and W. Ding, Machine vision based statistical process control in fused deposition modeling, in Proceedings of the 2017 12th IEEE Conference on Industrial Electronics and Applications, ICIEA. (2017), 936-941.
[8] F. Imani, A. Gaikwad, M. Montazeri, P. Rao, H. Yang and E. Reutzel, Layerwise in-process quality monitoring in laser powder bed fusion, ASME 2018 13th International Manufacturing Science and Engineering Conference, MSEC. 1 (2018). https://doi.org/10.1115/MSEC2018-6477
[9] B. M. Colosimo, F. Garghetti, L. Pagani and M. Grasso, “A novel method for in-process inspection of lattice structures via in-situ layerwise imaging,” Manuf. Lett., (2022),Vol 32, 67-72. https://doi.org/10.1016/j.mfglet.2022.03.004
[10] M. Grazia Guerra, M. Lafirenza, V. Errico and A. Angelastro, “In-process dimensional and geometrical characterization of laser-powder bed fusion lattice structures through high-resolution optical tomography,” Opt. Laser Technol., (2023), Vol 162, 109252. https://doi.org/10.1016/j.optlastec.2023.109252
[11] S. Nuchitprasitchai, M. Roggemann and J. M. Pearce, Factors effecting real-time optical monitoring of fused filament 3D printing, Prog. Addit. Manuf. 2 (2017) 133-149. https://doi.org/10.1007/s40964-017-0027-x
[12] M. Faes, W. Abbeloos, F. Vogeler, H. Valkenaers, K. Coppens, T. Goedemé and E. Ferraris, Process Monitoring of Extrusion Based 3D Printing via Laser Scanning. International Conference on Polymers and Moulds Innovations (PMI). (2014).
[13] W. Lin, H. Shen, J. Fu and S. Wu, “Online quality monitoring in material extrusion additive manufacturing processes based on laser scanning technology,” Precis. Eng., (2019), Vol 60, 76-84. https://doi.org/10.1016/j.precisioneng.2019.06.004
[14] K. Xu, J. Lyu and S. Manoochehri, “In situ process monitoring using acoustic emission and laser scanning techniques based on machine learning models,” J. Manuf. Process., (2022), Vol 84, 357-374. https://doi.org/10.1016/j.jmapro.2022.10.002
[15] Information on https://www.berlinlasers.com/it/oem-lab-lasers/laser-line-generator
[16] Information on https://www.dino-lite.eu/it/component/eshop/am7915mzt-edge?Itemid=0
[17] Information on https://docs.arduino.cc/hardware/leonardo
[18] M. Moretti, F. Bianchi and N. Senin, “Towards the development of a smart fused filament fabrication system using multi-sensor data fusion for in-process monitoring,” Rapid Prototyp. J., (2020), Vol 36, 7. https://doi.org/10.1108/RPJ-06-2019-0167
