Develop monitoring solutions for real-time assessment of the thermo-mechanical profile within the manufacturing piece & early estimation of the final quality.
Add3DSense
Partner Call open until: Q4 2025
Project Start: Q2 2026
Goal of the project „Smart In-Situ Sensing and Real-Time Monitoring for Quality Prediction in Additive Manufacturing” is the development of advanced algorithms for reconstructing the full temperature / strain profile within the workpiece during the printing / manufacturing process. The reconstruction will be based only on available scarce sensor data and knowledge on the individual printing geometry.
Advantages: Detailed monitoring as basis for
- fast process parameter estimation to increase the printing efficiency
- error correction measures to improve print quality of each individual part
- early estimation of final part quality
- early detection of thermal anomalies to avoid defects like warping, delamination, uneven cooling, etc.
Approach: The in-place sensor infrastructure is enhanced with a combination of our thermal simulation workflow & physics-aware ML-models.
- No additional sensing infrastructure needed
- The use of an automatized simulation workflow removes the need for collecting extensive high-quality measurement datasets for data-hungry AI models
- The combination with ML techniques removes the need for extensive calibration of the simulation models and allows the usage of simpler low-fidelity models
- We setup & generate the training dataset based on domain knowledge from the partner
- We develop, train & evaluate suitable physics-aware ML models
Challenges:
- Development of simulation workflow for specific use case / printing / manufacturing technique
- Selection of suitable randomization parameters (e.g. geometry representation, print path, environment conditions) for generation of ML dataset
- Generalization of monitoring solution for arbitrary printing geometries
Expected results
SAL as one partner for the whole workflow:
- We help you develop a first-time-right additive manufacturing solution with our advanced thermal monitoring
- Reduce cost, material waste and energy requirements
- We optimize the model for deployment on an embedded device (e.g. microcontrollers)
- We validate the developed solutions in cooperation with the partner based on experiments on partner site
