Shape Measurements of Lattice Materials from Few X-Ray Radiographs Using the 3D Virtual Image Correlation (3D-VIC) Method

the development of additive manufacturing technologies (3D printing) has made it possible to manufacture complex structures such as architected materials. However, traditional inspection methods are not suited to these materials, which require volume inspection to examine their internal structure.

the aim is to provide a 3D shape measurement method based on the initial computer-aided design (CAD) model used for 3D printing and X-ray radiographs.

the CAD model is deformed until its virtual radiographs obtained by simulating the absorption of X-rays through the solid register with experimental radiographs. This registration is achieved by minimising a cost function with respect to the position of control points using radial basis function interpolation.

the method’s performance is first evaluated using synthetic data. Its robustness is assessed with respect to image resolution, number of radiographs and noise level. Subsequently, the geometry of a solid with a tetrahedral architecture was quantified by means of a mere five radiographs. Global variation in shape and local defects in lattice structure can be detected.

the method enables the in-volume shape of architected materials to be checked without reconstructing the 3D computed tomography volume, but from just a few radiographs. It is robust and can detect local defects.