A systematic study and framework of fringe projection profilometry with improved measurement performance for in-situ LPBF process monitoring

Haolin Zhang, Chaitanya Krishna Prasad Vallabh, Yubo Xiong, Xiayun Zhao

Research output: Contribution to journalArticlepeer-review

23 Scopus citations

Abstract

Fringe Projection Profilometry (FPP) is a cost-effective and non-invasive technology that has been shown to measure finer features. In this work, we developed an in-situ FPP method to measure the dynamic topography of powder bed and printed layer during Laser Powder Bed Fusion (LPBF) additive manufacturing (AM) process. A systematic study towards developing a comprehensive framework of LPBF-specific FPP is demonstrated to enhance and evaluate the performance of applying FPP for in-situ LPBF monitoring, including 1) a modified sensor model with localized correction; 2) improved phase unwrapping with FFT filtering 3) quantitative uncertainty analysis; and 4) experimental validation with ex-situ characterization. The developed LPBF-specific FPP system and methods are implemented on a commercial LPBF-AM machine, achieving better accuracy, more robustness, and increased field of view while maintaining sufficient measurement range and decent resolution, in contrast to literature methods. The established FPP framework will facilitate the development of closed-loop control strategies for advancing LPBF based AM.

Original languageEnglish
Article number110796
JournalMeasurement: Journal of the International Measurement Confederation
Volume191
DOIs
StatePublished - 15 Mar 2022

Keywords

  • Additive Manufacturing
  • Fringe Projection
  • In-situ Monitoring
  • Powder Bed Fusion
  • Sensor Model
  • Uncertainty Analysis

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