Process Monitoring Software Aims to Improve Additive Consistency

(Image courtesy of Renishaw.)

In an effort to improve additive manufacturing (AM) users’ understanding of their processes, Renishaw has developed new process monitoring software, InfiniAM Spectral, for use on Renishaw systems. After its launch at formnext 2017, Renishaw released the software package to help manufacturers overcome the barriers to AM in critical applications, process stability and part quality.

Laser powder-bed fusion (LPBF) builds components from millions of laser exposures. This process must be highly accurate to produce a functional part. However, sources of variation that can occur during the build process potentially produce anomalies that will impact the longevity of the part. Real-time spectral monitoring technology enables manufacturers to gather melt-pool data to enable traceable production and process optimisation.

InfiniAM Spectral is part of a developing family of Renishaw products that aim to help users capture, evaluate and store process data from the company’s LPBF technologies. To that end, the software enables data capture, presentation and analysis.

The new software offers two measurement functions in the sensor modules. The first module, LaserVIEW, uses a photosensitive diode to measure the intensity of the laser energy. The second module, MeltVIEW, captures emissions from the melt pool in the near-infrared and infrared spectral ranges. These two sensor signals can be compared to help identify discrepancies.

(Image courtesy of Renishaw.)

MeltVIEW and LaserVIEW stream data across a conventional computer network on a layer-by-layer basis, so manufacturers can analyse process monitoring data in real-time. As the build progresses, the data is rendered live in 3D for viewing in InfiniAM Spectral. Engineers can compare data from each sensor to identify any deviations, which may indicate the presence of anomalies that could lead to defects.

“For additive manufacturing to become a truly ubiquitous manufacturing technology, users and practitioners require a deep understanding of the process,” explained Robin Weston, Marketing Manager at Renishaw's Additive Manufacturing Products Division. “The amount of process data generated during an AM build is immense, which means it can be difficult to make practical use of it without the correct interpretation tools. Access to real-time data opens the door to future developments in process control – detecting and correcting problems in real-time.”

According to Renishaw, InfiniAM Spectral will be a valuable asset for those producing a series of identical parts in high-value applications. When producing the first part in a series, data from LaserVIEW and MeltVIEW can be compared with existing X-Ray or Computed Tomography (CT) data from a known good part. The manufacturer can use this gold standard signal data and can compare it against data from subsequent parts to judge quality and consistency.

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