Feedback control of Layerwise Laser Melting using optical sensors

Layerwise Laser Melting (LLM) is a layerwise production technique enabling the production of complex metallic parts. Thin powder layers are molten according to a predefined scan pattern by means of a laser source. Nowadays constant process parameters are used throughout the build, leading for some geometries to an overly thick feature size or overheating at downfacing surfaces. In this paper a monitoring and control system is presented which enables monitoring the melt pool continously at high speed throughout the building process. The signals from the sensors can be incorporated in a real-time control loop, in this way enabling feedback control of the process parameters. In this paper the experimental set-up will be first shown. Next the dynamic relation between the melt pool and the process parameters is identified. Finally the proof of concept for feedback control is demonstrated with experimental results.