Development of Powder Bed Fusion Additive Manufacturing Test Bed for Enhanced Real-Time Process Control

Laser powder bed fusion (PBF) is emerging as the most popular additive manufacturing (AM) method for producing metallic components based on the flexibility in accommodating a wide range of materials with resulting mechanical properties similar to bulk machined counterparts, as well as based on in-class fabrication speed. Although this approach is advantageous, the current limitations in achieving predictable and repeatable material and structural properties, geometric and surface roughness characteristics, and the occurrence of deformations due to residual stresses results in significant variations in part quality and reliability. Therefore, a better understanding and control of PBF AM processes is needed. The National Institute of Standards and Technology (NIST) is developing a testbed to assess in-process and process-intermittent metrology methods and real-time process control algorithms, and to establish foundations for traceable radiance-based temperature measurements that support high-fidelity process modeling efforts. This paper will discuss functional requirements and design solutions to meet these distinct objectives.