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<p>Additive manufacturing (AM) and material extrusion processes (MEX) have transformed the fabrication of complex parts from a wide range of materials. However, the widespread use of MEX processes is still hindered by the presence of defects induced during 3D printing. This necessitates the development of an in-process defect detection system for MEX techniques. In this study, an integrated 3D printing and laser scanning apparatus is developed to build and inspect parts automatically, and its effectiveness is assessed using specimens designed with intentional gaps. After printing, the apparatus scans each layer, allowing for detailed internal defect detection. Four sets of tensile samples per ASTM D638-22 with varying gap widths along their centerline are explored. Samples consist of 24 layers and feature a gap on their tenth layer with 0° raster orientation. Three samples are 3D printed and scanned for each specimen set using the apparatus (a total of 12). The data sets from the laser scanning are analyzed, the gap widths are obtained, and compared with the expected values from the design corrected for shrinkage. The coefficient of variation for gap width is between 0.23% and 2.5% for all specimen sets, and the magnitude of percent error for all 12 samples is between 0.3% and 3.3%. This validates the repeatability and accuracy of the apparatus in capturing defects and evaluating variability inherent in the layer-based MEX processes. To demonstrate the apparatus’s capabilities, a complex part is designed, 3D printed, laser scanned, and reconstructed.</p>

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In-process laser scanning for defect detection in material extrusion additive manufacturing

  • 期刊论文

  • 发表日期：

    2025年7月28日

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  • Aryan Rakesh Rana,
  • Kazem Fayazbakhsh

摘要

Additive manufacturing (AM) and material extrusion processes (MEX) have transformed the fabrication of complex parts from a wide range of materials. However, the widespread use of MEX processes is still hindered by the presence of defects induced during 3D printing. This necessitates the development of an in-process defect detection system for MEX techniques. In this study, an integrated 3D printing and laser scanning apparatus is developed to build and inspect parts automatically, and its effectiveness is assessed using specimens designed with intentional gaps. After printing, the apparatus scans each layer, allowing for detailed internal defect detection. Four sets of tensile samples per ASTM D638-22 with varying gap widths along their centerline are explored. Samples consist of 24 layers and feature a gap on their tenth layer with 0° raster orientation. Three samples are 3D printed and scanned for each specimen set using the apparatus (a total of 12). The data sets from the laser scanning are analyzed, the gap widths are obtained, and compared with the expected values from the design corrected for shrinkage. The coefficient of variation for gap width is between 0.23% and 2.5% for all specimen sets, and the magnitude of percent error for all 12 samples is between 0.3% and 3.3%. This validates the repeatability and accuracy of the apparatus in capturing defects and evaluating variability inherent in the layer-based MEX processes. To demonstrate the apparatus’s capabilities, a complex part is designed, 3D printed, laser scanned, and reconstructed.