In-situ monitoring options
In-situ monitoring options
(OP)
Hello. I was curious what most people are using for their in-situ monitoring of their AM processes. If anything. There are a couple of products on the market, and was curious of the pros and cons of each. Seems this is an area that is still being developed. Any help would be appreciated. Thanks.





RE: In-situ monitoring options
Dan - Owner
http://www.Hi-TecDesigns.com
RE: In-situ monitoring options
Monitoring CNC machine codes is done with a plethora of different software options, some incorporated in the machine controller, some remotely monitoring certain sensor states or controller states. For AM, I would think the webcam is all you need, but being able to remotely monitor some conditions has benefits.
RE: In-situ monitoring options
"Even,if you are a minority of one, truth is the truth."
Mahatma Gandhi.
RE: In-situ monitoring options
RE: In-situ monitoring options
The answer is "yes" to all of your questions, followed with "depending on the details"
Yes, a 'shut down' can be issued if certain parameters are exceeded on any particular sensor or error code. That's pretty commonplace and standard. You can watch the monitor for FDM machines, for example, to ensure something doesn't go haywire - part shifts, nozzle blockage, or your support structure was inadequate and the part is drooping, etc. There isn't -much- you can do (within practical means) for those situations, as the machine is going to blindly keep-on-truckin' since it senses no problems.
With experience, vetted processes, and proper machine care and maintenance, you don't need to monitor things AS MUCH.
The requirements and solutions will vary based on machine type and typical part run time, I expect.
RE: In-situ monitoring options
There is also a 3D printer controller you can use on many different machines that connects via the internet and shows you what's happening and allows you control of the printer. It's about 200 bucks IRC.
Keith Cress
kcress - http://www.flaminsystems.com
RE: In-situ monitoring options
STF
RE: In-situ monitoring options
They don't use feedback to keep welt pool, heat rate, cooling rate, scan speed, and a few other variables in a control window.
Right now it is considered 'exotic' to just watch and record where in the build there was an 'event'. Then afterward they try to figure out if it mattered.
Considering that no one in production is currently designing the microstructure there is a long ways to go.
= = = = = = = = = = = = = = = = = = = =
P.E. Metallurgy, Plymouth Tube
RE: In-situ monitoring options
"Design the microstructure"... Heck, can you imagine how anyone would inspect the microstructure?
It is issues like these that make me struggle to see how 3D printed parts could be approved for structural use in aircraft.
STF
RE: In-situ monitoring options
I have been skeptical of this aspect, but since the Gurus suggest successful replacement of legacy parts by 3D printed parts, I tend to agree.
The present race is towards my 3D print looks better than yours or the least more accurate.
I have been able to accept 3D printed sand moulds and cores or wax patterns for investment casting.
But, metal printing I am still learning to come to terms. Hope, someday, some of my concerns will get answered.
"Even,if you are a minority of one, truth is the truth."
Mahatma Gandhi.
RE: In-situ monitoring options
RE: In-situ monitoring options
RE: In-situ monitoring options
When a part is cast for forged we know from practice what the structure will be, and we deliberately modify the process (or post treatment) in order to control the structure, and achieve desired strength and fatigue properties.
Right now with AM you don't know any of those properties until you make a part and destructively test it.
This is one reason why AM wax or sand work has been so valuable, we know how to get the desired properties from that point.
There are people working on controlling heating rates, deposition, and cooling rates in order to control microstructures. This will part of the key. The other part is detecting deviations of that those areas can be tested.
Today high res CT on a metal part costs more than building it did.
= = = = = = = = = = = = = = = = = = = =
P.E. Metallurgy, Plymouth Tube