In-process 3D Deviation Mapping and Defect Monitoring (3D-DM2) in High Production-rate Robotic Additive Manufacturing

• URL: http://arxiv.org/abs/2511.05604v1
• Date: Thu, 06 Nov 2025 06:35:06 GMT
• Title: In-process 3D Deviation Mapping and Defect Monitoring (3D-DM2) in High Production-rate Robotic Additive Manufacturing
• Authors: Subash Gautam, Alejandro Vargas-Uscategui, Peter King, Hans Lohr, Alireza Bab-Hadiashar, Ivan Cole, Ehsan Asadi,
• Abstract summary: High deposition rate robotic AM processes offer significantly increased build speeds.<n>Maintaining shape accuracy remains a critical challenge.<n>This study presents a real-time monitoring system to acquire and reconstruct the growing part.
• Score: 38.106912827988154
• License: http://creativecommons.org/licenses/by-nc-sa/4.0/
• Abstract: Additive manufacturing (AM) is an emerging digital manufacturing technology to produce complex and freeform objects through a layer-wise deposition. High deposition rate robotic AM (HDRRAM) processes, such as cold spray additive manufacturing (CSAM), offer significantly increased build speeds by delivering large volumes of material per unit time. However, maintaining shape accuracy remains a critical challenge, particularly due to process instabilities in current open-loop systems. Detecting these deviations as they occur is essential to prevent error propagation, ensure part quality, and minimize post-processing requirements. This study presents a real-time monitoring system to acquire and reconstruct the growing part and directly compares it with a near-net reference model to detect the shape deviation during the manufacturing process. The early identification of shape inconsistencies, followed by segmenting and tracking each deviation region, paves the way for timely intervention and compensation to achieve consistent part quality.

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