Partners Developing In Situ Optical Monitoring System to Enhance 3D Printing Process for Brass

Researchers at the Fraunhofer Research Institution for Additive Manufacturing Technologies (IAPT) are partnering with Italian metal 3D printer manufacturer 3D4MEC to develop an in situ optical monitoring system for the 3D4Brass printer. The collaboration also involves Thetascan GmbH, which will provide an optical system, with the aim to improve the stability and reliability of the AM process for complex materials like brass.

The in situ monitoring system is designed to detect real-time defects during the selective laser melting process to enhance the quality and repeatability of produced components. The department of LPBF – In-situ Monitoring and Process Control at Fraunhofer IAPT is contributing scientific expertise for the development of this new technology for metal 3D printing. The project will also explore the capabilities of an advanced version of 3D Optical Tomography (3D-OT) to further expand the monitoring capabilities of the system.

3D4MEC specializes in processing specific alloys such as steels and brass, offering customized solutions to optimize the performance of AM for its customers. The 3D4Brass 3D printer is capable of processing lead-free brass.

“The collaboration with Fraunhofer IAPT and Thetascan is a tremendous opportunity for 3D4MEC to strengthen our commitment to research and development, an area in which we have heavily invested over the past years,” says Fabrizio Marino Corsini, managing director of 3D4MEC. “With this synergy, we aim to develop customized additive manufacturing solutions for special materials, meeting the specific needs of our clients and the market.”

The Fraunhofer IAPT focuses its research and development on the industrialization of AM. It has previous experience working with Thetascan on research in optical tomography, which is a tool that can be used to take measurements where conventional tools cannot.

“In 3D4MEC, we have found an excellent partner to move on and advance the further development of optical tomography technology beyond the state of the art by means of extended sensor integration and fusion of multiple sensing technologies for a data-based quality control in laser powder bed fusion,” says Dennis Jutkuhn, scientific assistant for in situ monitoring and process control in LPBF at Fraunhofer IAPT. “The project will also profit from our previous investigations into optical tomography with ThetaScan.”

The partners say that integrating the technology will enable 3D4MEC to offer an optimized solution capable of real-time monitoring and correcting process defects during 3D printing of brass, thereby reducing material waste and improving energy efficiency. They say the project will not only enhance component quality but will also have a positive impact on the sustainability of the production process.