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<p>With the widespread of additive manufacturing technologies, real-time monitoring of deficiencies during the printing process has become essential for improving product quality and manufacturing efficiency. An ultrasonic method based on Lamb wave leakage from the printing bed to the deposition layers is proposed for the in-situ monitoring of the time-varying geometry during fused deposition modeling (FDM). An array sensor network is arranged on the printing bed to collect energy attenuation coefficients in a pitch-catch configuration. The leakage characteristics of various Lamb wave modes under different deposition conditions have been explored in detail through both simulation and experimental. The energy attenuation coefficient of each mode exhibits a stable linear relationship with deposition length in a given layer. Oscillation can be observed initially with deposition thickness due to resonance. A high sensitivity can be found for the first layer, which is lowered for the subsequent layers. Nonlinear effects exist for the deposition location and distribution across modes. The fastest mode can be selected to prevent secondary source interference. An imaging scheme based on the simultaneous iterative reconstruction technique (SIRT) is established to reconstruct the PLA deposition contour on an aluminum printing bed. The imaging error in the central region is less than 10%, with each image completed within 380&#xa0;ms. The proposed methodology is powerful for the first layer quality inspection throughout the whole FDM process.</p>

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In-situ Monitoring Of Time-varying Geometry During FDM via Ultrasonic Leaky Lamb Waves

  • 期刊论文

  • 发表日期：

    2026年7月27日

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  • Qi Zhu,
  • Yiming Liu,
  • Feng He,
  • Haiyan Zhang,
  • Qingqing Zhang,
  • Shiwei Ma

摘要

With the widespread of additive manufacturing technologies, real-time monitoring of deficiencies during the printing process has become essential for improving product quality and manufacturing efficiency. An ultrasonic method based on Lamb wave leakage from the printing bed to the deposition layers is proposed for the in-situ monitoring of the time-varying geometry during fused deposition modeling (FDM). An array sensor network is arranged on the printing bed to collect energy attenuation coefficients in a pitch-catch configuration. The leakage characteristics of various Lamb wave modes under different deposition conditions have been explored in detail through both simulation and experimental. The energy attenuation coefficient of each mode exhibits a stable linear relationship with deposition length in a given layer. Oscillation can be observed initially with deposition thickness due to resonance. A high sensitivity can be found for the first layer, which is lowered for the subsequent layers. Nonlinear effects exist for the deposition location and distribution across modes. The fastest mode can be selected to prevent secondary source interference. An imaging scheme based on the simultaneous iterative reconstruction technique (SIRT) is established to reconstruct the PLA deposition contour on an aluminum printing bed. The imaging error in the central region is less than 10%, with each image completed within 380 ms. The proposed methodology is powerful for the first layer quality inspection throughout the whole FDM process.