Evaluation of selective laser sintering processes by optical coherence tomography

• Published in: Materials & design Vol. 88; pp. 837 - 846
• Main Authors: Guan, Guangying, Hirsch, Matthias, Lu, Zeng Hai, Childs, David T.D., Matcher, Stephen J., Goodridge, Ruth, Groom, Kristian M., Clare, Adam T.
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 25.12.2015; Elsevier
• Subjects: Construction; Defects; In-situ monitoring; Irregularities; Monitoring; OCT; Optical Coherence Tomography; Selective laser sintering; Surface defects; Three dimensional; OCT; Selective laser sintering; In-situ monitoring; AM
• ISSN: 0264-1275; 1873-4197
• DOI: 10.1016/j.matdes.2015.09.084

Selective laser sintering (SLS) enables the fast, flexible and cost-efficient production of parts directly from 3D CAD data. Unlike more established machine tools, there is a marked lack of process monitoring and feedback control of key process variables. In-situ analysis techniques permit the emergence of repair techniques, in-process optimization of production parameters, and will also serve to save time and material. In this study, optical coherence tomography (OCT) is used for the first time to evaluate components produced by SLS. Using a Polyamide-PA2200, surface defects are analyzed and the limiting factors associated with the measurement technique are quantified. OCT is shown to be a useful technique for evaluating surface irregularities alongside sub-surface defects that have resulted from poor sintering or non-homogeneous powder spreading. We demonstrate detection and quantification of surface defects such as cracks, pores and voids on a ~30μm scale. Furthermore, we show that this technique can resolve ‘built-in’ fine features within a 200 to 400μm depth below the surface, covering typical layer thicknesses used by this process. This capability paves the way for real-time monitoring of the SLS process for assurance, or even dynamic correction of defects during the build. [Display omitted] •OCT is used for the first time to process AM parts.•Use of this method to differentiate between solid, semi-melted and loose powders is presented.•Surface analysis is undertaken in simple demonstrator parts and the accuracy of this method presented.•Subsurface defects are analysed and the resolution of the instrument for detecting ‘hidden’ defects is presented.•The suitability of this technique for AM is reported and future avenues for research are presented.