Powder Bed Fusion 3D Modeling from NIR Melt and Powder Detection

The patent transitions from 2D threshold-based image processing to 3D volumetric analysis by stacking and processing multiple layer images through the build volume. This dimensional transformation enables accurate measurement of thin-walled structures and complex geometries by analyzing the three-dimensional context of powder agglomeration and weld penetration across multiple layers, rather than treating each layer in isolation.

The patent changes the analysis parameters from simple binary thresholding to multi-parameter 3D analysis including weld pool width variations, powder agglomeration detection, and inter-layer penetration depth. By introducing these additional measurement parameters and using predictive models to account for process variations, the system achieves high measurement precision while maintaining monitoring efficiency.

The patent introduces an intermediary predictive model that acts as a bridge between simple image capture and reliable defect detection. This model incorporates knowledge of the additive manufacturing process, including expected weld pool dimensions, powder agglomeration patterns, and inter-layer penetration characteristics. The intermediary model processes the raw images to distinguish between normal process variations and actual defects, thereby achieving high reliability while maintaining processing simplicity.

The patent performs preliminary analysis by stacking and pre-processing multiple layer images before final defect detection. This preliminary action includes aligning layers, detecting powder agglomeration patterns, and establishing baseline weld pool dimensions. By performing these preparatory steps in advance, the system reduces the complexity of the final detection step while improving overall reliability through cumulative information from multiple layers.

The patent creates a digital copy or digital twin of the physical component by processing images captured during the additive manufacturing process itself. Instead of using separate CT scanning after manufacturing, the system constructs a 3D digital model that mirrors the actual printed geometry, including weld pool dimensions, powder agglomeration, and inter-layer penetration. This digital copy provides comprehensive internal structure information at no additional time cost or expense beyond the normal manufacturing monitoring.

The patent performs 3D modeling as a preliminary action during the manufacturing process itself, rather than as a separate post-processing step. By capturing and processing images layer-by-layer as the component is being printed, the system builds the 3D model concurrently with manufacturing. This preliminary action eliminates the need for separate CT scanning, achieving both high measurement precision and zero additional time delay.