Meeting the In-Process Inspection Needs of Large-Scale Additive Manufacturing Processes
Large-scale additive manufacturing of polymer and composite components presents a unique set of challenges for in-process inspection efforts — challenges that LASERVISION-AI is uniquely qualified to address.
In this emerging field, reduced cycle time is a critical objective to achieve the efficiencies needed for commercial production. An easy way to attain sizable reductions is to accelerate the nonvalue-added activities of inspection and corrective measures. LASERVISION-AI delivers these capabilities.
Inspect While Production Continues
Mounted above the work-in-progress, LASERVISION-AI provides a giant field of view (FOV) for inspections that do not interfere with production operations. On any visible surface within the FOV, LASERVISION-AI captures images of superior quality compared to smart cameras. Rather than the data-intensive analysis required by metrology point clouds, these images come with photogrammetric transforms that directly relate captured features and attributes to the digital model.
Real-Time Capture and Analysis
LASERVISION-AI’s rapid inspections of your AM work-in-progress are able to identify nearly any visible attribute, including cracks, discontinuities and other anomalies that metrology fails to identify. And when a nonconformance is detected, LASERVISION-AI’s laser projector highlights its location with a laser pattern so that your operators quickly find where to perform corrective measures.
LASERVISION-AI is a mature automatic inspection solution, and it is supported by today’s emerging technologies: artificial intelligence for rapid application development of your AM inspection needs, and Internet 4.0 connectivity for full integration into your digital manufacturing and enterprise systems.
| LASERVISION-AI FEATURE | BENEFITS TO ADDITIVE MANUFACTURING |
|---|---|
| Operates 3m or more away from production equipment | Does not interfere with or disrupt production equipment Value-added operations continue while inspections are performed |
| Captures detailed, calibrated high-resolution images in 3m x 3m envelope | Enables inspection of large 3D surfaces with complex contours High-magnification camera provides required detail in each image (typically 20cm x 20cm) |
| Verifies attributes and flags nonconformances for immediate corrective action | Enables inspection of all attributes (not just a sampling) Keeps nonconformances from advancing through production |
| Pinpoints anomalies with laser projector | Directs operators efficiently to the anomaly’s location |
| Feeds the as-built digital twin | Enhances traceability with images and data for the life of the component Provides data needed for deep learning and continuous process improvement |
| Provides operators with electronic work instructions | Facilitates the paperless factory Helps ensure that processes are carried out as planned |
| Enables tablet- or phone-size remote control | Eliminates step-away time to consult the work cell controller |
| Performs laser templating | Accelerates manual tasks |
ADDITIVE MANUFACTURING APPLICATIONS
LASERVISION-AI verifies (or flags nonconformances)
- Discontinuities
- Droop and drool
- Cracks
- Porosity
- Absence of foreign object debris (FOD)