THE CHALLENGE
The challenge facing Laser Powder Bed Fusion additive manufacturing lies in consistently producing high-quality metal parts while managing the complexity of the process. Current machines typically operate with fixed parameters, such as constant laser power, which cannot adapt to the changing thermal conditions and varying feature sizes of a part. This rigidity often leads to defects like over-melting in small intricate features, insufficient melting in larger areas, and dimensional inaccuracies, which in turn increase waste, production time, and costs. While advanced feedforward strategies exist, they rely on pre-set models and cannot respond to real-time variability caused by powder inconsistencies or thermal fluctuations. Implementing effective feedback control could transform quality assurance by dynamically adjusting process parameters, but commercial machines often lack the high-speed sensing, rapid data processing, and flexible controls required to make this possible. Addressing this challenge represents a significant opportunity for manufacturers to improve reliability, reduce scrap, and accelerate production of complex, high-value components.
OUR SOLUTION
Our solution is a real-time closed-loop control system for Laser Powder Bed Fusion additive manufacturing that dynamically regulates laser power to consistently produce high-quality metal parts. By using an affordable sensor to monitor the thermal emission of the melt pool and feeding this data into a fast-acting controller, the system adjusts laser power on the fly to maintain optimal thermal conditions. This approach prevents common defects such as over-melting, insufficient fusion, and dimensional inaccuracies, which are costly and time-consuming to fix. Unlike traditional machines that rely on fixed settings, our solution adapts in real time to varying feature sizes and heat conditions, improving yield, reducing scrap, and ensuring reliable production of complex, high-value components. Its low-cost, rapid-response design makes it accessible for both research and industrial applications, offering a practical way for manufacturers to enhance efficiency and part quality.
Figure: Ti-64 Impeller Printed by Adaptive Laser Power.
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