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At the Ecole Polytechnique Fédérale de Lausanne, a team of scientists has been studying the problem of defects in metal 3D printing, particularly when using laser processes. They aim to develop a method based on 3D printer sound analysis to predict printing errors and thus achieve better results. So, they studied the sounds the machine makes during a perfect process, and the sounds a 3D printer makes when something goes wrong during the printing process. In collaboration with the Paul Scherrer Institute (PSI) and the Swiss Federal Laboratory for Materials Science and Technology (Empa), Lausanne University of Technology placed a microphone in the printing chamber to detect changes in the sound signal when the metal powder changes state.
Detecting printing errors is not new, and many projects have been developed in recent years to guarantee reliable and reproducible results. This process often relies on algorithms that can conclude known situations. As such, they are often imperfect and require extensive testing. By relying on sound-based technology, scientists at EPFL aim to overcome this limitation.
In laser powder bed fusion, a thin layer of metal powder is heated to form the desired object layer by layer. The material passes through different phases—solid, liquid, and gas—to form a molten bath. EPFL explains: “Sometimes, the process can falter due to variables such as the laser angle or specific geometric properties of the powder or part. These conditions, known as ‘inter-regime instabilities,’ can sometimes prompt both melts. The transition between methods is called “conduction” and “keyhole” systems.
The team used X-ray images to measure this molten pool (width and depth) and developed a method to see how the metal changed in the liquid state. Thanks to microphones installed in the printing room, they could record the sounds produced during the transition between regimes and detect any changes. If present, a defect is detected. Lead researcher Milad Hamidi Nasab added: “The synergy of synchrotron X-ray imaging and acoustic recording provides real-time insights into the LPBF process, helping to detect defects that may compromise product integrity, so powder bed fusion 3D printing has broad applications. Application areas.
Application fields of powder bed fusion 3d printing
Automobile manufacturing: In the automotive industry, powder bed fusion 3D printing technology is widely used to manufacture complex metal parts, such as engine parts, brake system components, etc. The technology can significantly decrease production time and costs while improving product quality and performance.
Medical device manufacturing: Because of powder bed fusion, 3D printing technology can produce high-precision, customized medical devices. For example, it can create customized prosthetics, implants, and surgical tools.
Aerospace: Due to the extremely high accuracy and performance requirements for parts, powder bed fusion 3D printing technology has been extensively used in the aerospace field. It can manufacture complex, lightweight structures such as aircraft engine parts and satellite components.
Jewelry: Powder bed fusion 3D printing is extensively used in jewelry and art manufacturing. This technology allows the creation of metal artwork and jewelry with complex shapes and detailed textures.
Food manufacturing: Although food manufacturing is not a 3D printing application field in the traditional sense, there have been some cases of using powder bed fusion 3D printing technology to manufacture food in recent years. For example, the technology can create customized chocolates, candies, and more.
Architecture and architectural design: In architecture and architectural design, powder bed fusion 3D printing technology can fabricate architectural models, layout prototypes, etc. This technology can greatly enhance the accuracy and beauty of designs while reducing production costs and time.
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