by Melissa Donovan
Real-time monitoring and issue detection software gather data during the additive manufacturing (AM) process. In doing so, a part’s progress is tracked and measured and printing stops when/if an error occurs. These types of solutions are integral for three-dimensional (3D) printing providers, saving them time and money.
The April issue of Industrial Print magazine includes an article on real-time monitoring and issue detection software. The vendors mentioned in the piece also shared information on their specific products, which is included below.
Addiguru
Addiguru’s real-time monitoring software for AM is based on utilizing low-cost, off-the-shelf sensors that can be deployed quickly and inexpensively. Addiguru’s current base solution, using high-resolution optical cameras, is shown to be machine agnostic and rapidly deployable. Addiguru’s solution is agnostic to not only machine brand, but also material, lighting, angle of camera, and type of camera. In addition, Addiguru’s software tracks machine sensor data and provides notifications to a user if machine sensor data is anomalous.
Moreover, an instrumental augmentation to the core Addiguru software is the introduction of patent pending Inter-Layer Temperature (ILT) detection. Through a collaborative research endeavor undertaken by Addiguru in partnership with The Ohio State University, the significance of ILT data garnered from infrared cameras was conclusively demonstrated. This data revealed that ILT holds a pivotal role, with anomalies or spikes serving as indicators of potential issues during the manufacturing process. It was empirically substantiated that these issues could be effectively mitigated by adjusting the dwell time between layers. The ILT data, in essence, serves as a guiding compass not only for dwell time optimization but also for ensuring the overall quality of the manufactured components. This ILT detection technology serves as an “add-on” enhancement to the core Addiguru software suite.
EOS
Ensuring reliable production quality is important to all AM projects and especially so to industrial metal 3D printing. The EOS Smart Monitoring Plan is ideal. EOS Smart Monitoring includes all of the end-to-end monitoring capabilities critical for series production, and the cutting-edge automation of Smart Fusion makes a viable business case for more applications.
Smart Fusion brings a degree of control to metal 3D printing. The automated feature adjusts laser power levels to match the standards established in pre-processing, making corrections during the build as needed. Exposure OT’s heat distribution monitoring is critical to the process, as its data informs Smart Fusion’s power corrections during the build. Smart Fusion reduces the likelihood of overheating and helps ensure fewer part iterations. Smart Fusion’s benefits improve the entire EOS software landscape. AM designers who know Smart Fusion, can craft part designs optimized for supportless building.
Materialise
The Materialise Quality & Process Control (QPC) system is a software solution for companies that want to take AM quality and process control in certified manufacturing to the next level. QPC enables companies to track, monitor, analyze, and correlate all data critical to part quality. It interconnects AM data sources such as 3D models, raw materials, process parameters, in-situ process monitoring, post-processing, and quality inspection. QPC users can collect and monitor this data during the different stages of product development, including research, validation, and production.
Compared to other systems, it adds another level to quality and process control by integrating multiple data sources, including non-AM machine data, through collaborations with technology partners. QPC is designed to handle all relevant data sources, including part test lab results and 3D printer maintenance events.
The Materialise QPC system consists of different modules allowing AM users to choose the functionalities they require. The QPC Layer Analysis module is developed to include in-situ process monitoring data sources and to correlate its results with 3D models and non-destructive testing output. The QPC Process Lab module further fosters collaboration across different teams to centralize research and production data in a structured way. Each module allows them to accelerate product development, support process validation, and seamlessly monitor process stability and material properties from research to actual production.
The QPC system is part of the Materialise CO-AM Software Platform. CO-AM gives manufacturers access to a full range of software tools to plan, manage, and optimize every step of the 3D printing process. It provides access to complementary solutions from Materialise and third parties, including CO-AM partner solutions for design automation, mass customization, automated labeling, and various post-processing technologies. CO-AM enables AM users to connect and manage technologies from different machine builders over one platform.
Phase3D
Fringe uses structured light to create objective measurements. By measuring every layer of the AM process, anomalies are detected in real-time that correlate to part defects. Build anomalies include short feeds, recoater streaks and hops, spatter particles, part protrusions, and many more. Identifying the anomalies in the build allow for fast decision making using said objective measurements and the ability to one day certify a part using build data. Other companies in the market are working on in-situ monitoring yet nobody is using objective data to quantify the process, making Phase3D standout from the rest of the industry.
printpal.io
PrintWatch is a real-time defect detection solution that is over 99 percent accurate and will detect print failures on any printer, with filament of any color, any material, and in low or high lighting. printpal.io also offers automation with a clear bed checking feature and machine health checks with preventative maintenance capabilities. The solution is built with flexibility in mind for easy integration with 3D printer OEMs or cloud management providers. A partnership with SimplyPrint is a testament to PrintWatch’s ability to support our partners with high-quality solutions. PrintWatch competes with cloud management providers, Obico and OctoEverywhere, who offer defect detection as an add-on feature. Its focus is to provide quality assurance, savings, and peace of mind.
Implement Worry-Free Printing
Avoid worrying about unnecessary waste and print failures by implementing any of this real-time monitoring or issue detection software solutions into an AM workflow.
Apr2024, Industrial Print Magazine