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<p>Additive Manufacturing/3D Printing (AM/3DP) offers the ability to fabricate an intricate part from its digital design model directly, reducing the need for extensive post-processing and reliability assessments. However, process variability, material inconsistencies, and defect formation affect print quality and reproducibility. In Fused Filament Fabrication (FFF), deviations in track curvature affect extrusion uniformity, induce thermal stresses, and reduce dimensional accuracy. In the quest for developing a real-time quality monitoring system, this proof-of-concept sensitivity study focuses on ultrasonic detection of the reproduction accuracy of track curvatures in a build as a building block for developing such a system. Specially designed Phononic Test Coupons (PTC) with varying track curvatures were analyzed to evaluate their spectral responses and internal resonance frequencies. The PTC geometry designed for this work, RC20_<i>A,</i> consists of twenty connected single-layer tracks separated by a constant pitch distance. A track’s radius of curvature quantified by its lateral amplitude (<i>A</i>), defined as its maximum deviation from its central (chord) line, was systematically varied to transition straight to curved shapes. By fabricating and analyzing seven distinct types of RC20_<i>A</i>’s with lateral amplitude <i>A</i> ranging from 0 to 6&#xa0;mm, the relationship between the track’s radius of curvature of RC20_<i>A</i> coupons and their spectral responses and resonance frequencies during the AM/3DP process was investigated. Results indicate that frequency peaks in spectral responses decrease as lateral amplitude <i>A</i> increases, confirming the observability of track curvature through ultrasonic analysis. A lateral amplitude of Δ<i>A</i> = 1&#xa0;mm corresponds to an approximate Δ<i>f</i> = 15&#xa0;kHz shift in peak frequency. Variations in resonance frequencies and attenuation coefficients further demonstrate the sensitivity of ultrasonic response to curvature changes. This study introduces a real-time, non-destructive quality monitoring mechanism for AM/3DP, enhancing defect detection, process reliability, and overall print quality.</p>

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In-process ultrasonic monitoring of additive manufacturing: impact of track curvature on spectral responses of periodic builds

  • 期刊论文

  • 发表日期：

    2025年7月21日

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  • Avijit Chakrobarty,
  • Tipu Sultan,
  • Andrew Davidson,
  • Cetin Cetinkaya

摘要

Additive Manufacturing/3D Printing (AM/3DP) offers the ability to fabricate an intricate part from its digital design model directly, reducing the need for extensive post-processing and reliability assessments. However, process variability, material inconsistencies, and defect formation affect print quality and reproducibility. In Fused Filament Fabrication (FFF), deviations in track curvature affect extrusion uniformity, induce thermal stresses, and reduce dimensional accuracy. In the quest for developing a real-time quality monitoring system, this proof-of-concept sensitivity study focuses on ultrasonic detection of the reproduction accuracy of track curvatures in a build as a building block for developing such a system. Specially designed Phononic Test Coupons (PTC) with varying track curvatures were analyzed to evaluate their spectral responses and internal resonance frequencies. The PTC geometry designed for this work, RC20_A, consists of twenty connected single-layer tracks separated by a constant pitch distance. A track’s radius of curvature quantified by its lateral amplitude (A), defined as its maximum deviation from its central (chord) line, was systematically varied to transition straight to curved shapes. By fabricating and analyzing seven distinct types of RC20_A’s with lateral amplitude A ranging from 0 to 6 mm, the relationship between the track’s radius of curvature of RC20_A coupons and their spectral responses and resonance frequencies during the AM/3DP process was investigated. Results indicate that frequency peaks in spectral responses decrease as lateral amplitude A increases, confirming the observability of track curvature through ultrasonic analysis. A lateral amplitude of ΔA = 1 mm corresponds to an approximate Δf = 15 kHz shift in peak frequency. Variations in resonance frequencies and attenuation coefficients further demonstrate the sensitivity of ultrasonic response to curvature changes. This study introduces a real-time, non-destructive quality monitoring mechanism for AM/3DP, enhancing defect detection, process reliability, and overall print quality.