Towards an integrated sensor system for additive manufacturing

Product defects are a major challenge for the understanding and application to new products of mass additive manufacturing. This work starts from an overview of typical defect categories, especially focusing on direct metal laser sintering (DMLS), their causes and the capability/reliability of in process sensors. Individual sensor applications are available in the literature. The proposed sensor system preliminary explores the qualitative and quantitative correlation and integration of an accelerometer mounted on the powder spreading recoater, with photodiodes, a visible and an IR camera. An online control strategy is also proposed for early detection and prevention of product defects.