Power control for additive manufacturing of thin-walled structures

Important results from the project

The aim of the project was to develop a control system for Additiv Manufacturing (AM) based on visual feedback from the process with the goal of enabling AM in the aerospace industry for thin-walled applications where the geometric accuracy is a particular challenge. Successful results have been achieved and the project has also produced a new sensor for temperature feedback that can measure at high speed and at low cost compared to e.g. IR cameras, while being robust and easy to integrate with existing vision systems and optical elements.

Expected long term effects

Thin-walled structures form a significant part of the total capability that must exist for AM to be used on a large scale in the aerospace industry. The successful project results enable new applications for AM in metal which is an important step towards increased electrification of metal production, less waste and greater design freedom. Through increased design freedom, components can be made lighter and stronger, which can result in more energy-efficient machines. More local processing also becomes possible, which strengthens national production and reduces transportation.

Approach and implementation

The project has been carried out at Production Technology Centre in Trollhättan in an industrially relevant environment using production-like AM equipment, which has been a key factor for the project´s success. The project was divided into five different work packages: 1. Mapping and procurement of hardware. 2. Integration of hardware and development of vision algorithms. 3. Development of closed-loop controller. 4. Validation of the control system´s performance, robustness and repeatability. 5. Dissemination of project results through workshops with potential customers.