DigitalClone
for In-Situ Monitoring

DC-IM is a quality assurance system for metal additive manufacturing process. It is customizable for any printer model in partnership with the manufacturer. DC-IM currently leverages Matsuura hybrid metal AM machine and in-situ sensing capability to monitor and correct defects in real time, assuring the highest quality of as-printed metal parts. In the DC-IM system, each printing layer is monitored by using an infrared sensor, followed by Sentient’s proprietary real-time data analysis algorithm to determine the acceptance of layer quality at end of each printing. Bad layers are machined off and re-built based on Sentient’s optimized strategy. This detection and correction process will repeat until the entire component is built.

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Core Functionality

Manage Defects in Real Time
While most AM defect detection capabilities in development are focused on geometric features, DC-IM can identify individual layer abnormalities that - if left uncorrected - can severely limit the fatigue life of the resulting part.
Auto Trigger Repair Process
Each layer that is printed is monitored using an infrared sensor. Once a bad layer is identified, the cutting and reprinting program will be triggered automatically to correct those layers within the Hybrid Additive Manufacturing Machine.
Resume Build Automatically
After the bad layer(s) are cut off as defined by Sentient’s optimal repair strategy, then the layers are reprinted by using good parameters.
Integrated Closed-Loop Feedback
DC-IM is a closed-loop feedback control system that will perform layer-by-layer analysis and anomaly detection.

DC-IM Modeling Results

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How Does It Work?

Closed-Loop Feedback System that monitors the AM build process and analyzes the build quality of each layer.
Detects the presence of abnormal print layers in real-time, and automatically trigger the repair process that removes the defective layers and allows the process to resume without operator interaction.
The software then allows the build process to resume without operator interaction.

 

 

 

 

DC-IM provides an in-process defect monitoring and correction technique for AM to improve repeatability for geometric dimensions, material properties, and quality.

This process can be used in quality assurance plans to obtain the confidence needed for high-quality manufacturing.

DigitalClone can

DigitalClone can

  1. Monitor for defects during the build process using an infrared (IR) camera
  2. Correct defects using optimized AM process parameters through advanced modeling and simulation
  3. Reduce prototype optimization sample builds from dozens to just a handful
  4. Accelerate process optimization timelines from weeks/months to days
  5. Enable faster implementation of AM-based designs
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  • “We knew our product could extend the life of gears and bearings, but we couldn't demonstrate the exact outcome. Through computational testing, DigitalClone allowed us to prove the life extension in exact years and financial numbers for our innovative surface treatment product.”

    Stefan Bill, REWITEC

  • “A front-end to our physical testing process with the newest computational test technology matches with our rigorous test and validation process, always with the final aim of increasing the reliability of the turbine. Using DigitalClone is a first step in our extensive validation program. It will contribute to having a faster certification process and, finally, a more reliable turbine available in serial production in 2018.”

    Maite Basurto, Adwen

  • “Under current paradigm, every system is so unique that going through the qualification process is costly. Computational testing holds promise to reduce the costs, but there are still any uncertainties. Eventually, we’ll get there”

    Bradley Miller, Aviation Development Directorate

  • “We’re trying to help make better helicopters for the general public, and in the helicopter world, gears are very important. When the DigitalClone results came in, and the correlation was so good, the company president got very excited about what his guys had been developing.”

    Tim Krantz, Glenn Research Center

Datasheets - English

DigitalClone for In-Situ Monitoring

DC-IM is a quality assurance system for metal additive manufacturing process…