In various sectors, such as aerospace and healthcare, creating intricate components can be quite challenging. However, 3D printing has emerged as a robust solution. This technique, known scientifically as additive manufacturing, allows for the layer-by-layer assembly of materials, making the process of producing solid parts not only efficient but also versatile compared to traditional manufacturing methods.
The applications of 3D printing span numerous industries including aerospace, healthcare, automotive, consumer goods, construction, and education. In 2023, around 37 million consumer product parts were produced using 3D printing, equating to a 23% increase from the previous year, according to VoxelMatters. Notably, 16.8 million of these parts were made through polymer 3D printing, while 364,000 were metal parts. For instance, 15% of the components in the VK-650V and VK-1600V helicopter engines from Klimov, a Russian company, utilized 3D printing technology.
Despite its advantages, experts also highlight some limitations associated with 3D printing. Professor Chen Xuefeng from the iHarbour Academy of Frontier Equipment at Xi’an Jiaotong University warns that issues like quality inconsistency and challenges in real-time defect detection hinder the widespread use of additive manufacturing for large-scale production. Collins, an expert in mechanical engineering at the same institution, emphasizes that many current processes lack real-time insights, necessitating offline assessments to determine quality post-manufacture.
The problem is further illustrated by the case of a complex engine part worth millions, which could become obsolete if defects are detected after printing, leading to significant waste of resources. To tackle these issues, a universal quality system for additive manufacturing needs to be established both nationally and globally.
Professor Chen’s research team has developed an innovative laser monitoring system designed for additive manufacturing. This advancement allows for real-time monitoring during the printing process, enabling immediate corrective actions when errors arise. The incorporation of this AI-enhanced technology boosts the precision and reliability of defect identification by up to 95%.
This monitoring system is especially important in sectors like aerospace, where adherence to quality standards is crucial. Chen notes it has begun to be implemented in various countries, including Austria, and is often sold alongside new additive manufacturing equipment. As highlighted by Zhang, this type of monitoring is vital for ensuring consistent quality, a sentiment echoed by institutions like the U.S. National Institute of Standards and Technology in their technical documentation.