Metal process

AddUp’s in-process monitoring software shows real-time status at a glance

The company claims that real-time dashboard data refreshes at a rate as fast as 5 seconds. Photo credit: AddUp
Photo credit: AddUp Inc.

AddUp Inc.’s process monitoring software suite aims to enhance the capabilities of its FormUp 350 Powder Bed Fusion (PBF) machine and accelerate the adoption of its metal 3D printing technology by increasing confidence in the quality of parts for industrial prototyping and end-use applications. The suite includes AddUp, Recoat Monitoring and Meltpool Monitoring dashboards.

AddUp Dashboards is multi-scale monitoring software available with all AddUp FormUp PBF and Directed Energy Deposition (DED) machines. According to the company, the software provides a clear picture of a machine’s real-time and historical process data, and presents it in an easy-to-read dashboard.

The software collects production data in real time and presents it in dashboards tailored to the individual needs of different users. Fully configurable and capable of issuing different alarms, the software is designed to help improve manufacturing efficiency, analyze part defects and monitor a workshop with multiple machines.

The company says the most advanced solution in the suite is Meltpool Monitoring, which aims to provide visibility into print execution on a microscopic scale. Several parameters are measured at very high frequency, such as the position of the laser spot, the power delivered and the emissivity of the weld pool. This data is also available in real time.

The system is said to provide the ability to characterize defects without destroying the part, which is beneficial for distinct unique builds. In the case of mass production, it can be used to create a footprint that serves as a point of comparison for all future production builds.

One of the beneficial elements of Monitoring Suite is layer quality analysis. Called Recoat Monitoring, the company says this program can proactively fix defects during production. Operating on the principle of a closed loop, this analysis in production verifies the homogeneity of the powder bed, revealing the possible presence of deposits or absence of powder. The algorithms developed by AddUp allow users to assign a score and trigger a correction sequence, if necessary.