In-Process Monitoring and Closed-Loop Control

IN-PROCESS FEATURES

And Data Collection with DEDSmart

TM

FormAlloy systems are built for additive manufacturing and metal part repair using a wide range of materials. To ensure high-quality and repeatable parts, FormAlloy provides advanced in-process monitoring and closed-loop control. The DED software suite allows users to record, analyze, and improve builds using real-time data-driven manufacturing. This combination of DED technology and build quality analysis helps deliver consistent and precise results in metal additive manufacturing.

Optical Monitoring

The FormAlloy optical monitoring solution delivers a dynamic range image of the melt pool in real-time, offering the operator a live view during the process. With speeds of up to 55 FPS monitoring, customers can access off-axis video recording for live process monitoring and save recordings for post-print playback. This advanced system improves laser additive manufacturing control, ensuring precise and consistent results in metal printing.

Dynamic Layer Selection

Dynamic Layer Selection enables a layer-by-layer inspection with closed-loop operation to achieve geometric accuracy during the build process. A laser profilometer scans the build after each layer for a fast, accurate, and non-contact form of inspection. Enable the closed-loop operation to auto-adjust your build during the process and utilize the point cloud output for post-process analysis.

Melt Pool Monitoring and Control System

FormAlloy integrates two melt pool variables to monitor and control: Melt Pool Size and Melt Pool Temperature. Both variables are tracked along the laser’s optical path. With a closed-loop control system, the laser power adjusts in real-time to regulate heat input into the part. This advanced melt pool monitoring system ensures consistent part quality and enhanced process control, leading to more reliable and precise metal additive manufacturing outcomes.