{"title":"Spatiotemporal monitoring and control for foam additive manufacturing processes of thermoplastics","authors":"Zhaowei Zhou, Kaicheng Ruan, Donghua Zhao, Xuguang Xu, Ziwen Chen, Yi Xiong","doi":"10.1016/j.addma.2025.104949","DOIUrl":null,"url":null,"abstract":"<div><div>Foam Additive Manufacturing (Foam-AM) offers a novel approach to fabricating architected structures with tunable density by leveraging in-situ foaming. However, precise control of the foaming process remains challenging due to the complex interplay of multiple process parameters. This complexity has limited the broader adoption of Foam-AM in applications such as packaging, protective gear, automotive components, and beyond. To address these challenges, this study proposes a novel spatial-temporal monitoring and control method using a multi-sensor platform to optimize the performance and geometry of Foam-AM. The platform integrates a thermal camera and positioning encoders to monitor the temperature field and speed distribution, identifying bead interference and speed variations as the primary causes of foaming defects. Additionally, a line laser profiler is used to measure sample’s spatial information, complemented by extruder encoder data for in-situ density estimation. This in-situ approach facilitates high-throughput data acquisition, forming the basis for a process-performance model developed using Invertible Neural Networks (INN). Leveraging the INN model, two major advancements are achieved: (1) off-line control strategies effectively minimize bead interference, ensuring consistent density and geometric precision; and (2) localized foaming defects, especially in regions with rapid speed changes, are accurately identified and addressed through real-time parameter adjustments, significantly improving overall print quality.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"110 ","pages":"Article 104949"},"PeriodicalIF":11.1000,"publicationDate":"2025-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Additive manufacturing","FirstCategoryId":"5","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S2214860425003136","RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"ENGINEERING, MANUFACTURING","Score":null,"Total":0}
引用次数: 0
Abstract
Foam Additive Manufacturing (Foam-AM) offers a novel approach to fabricating architected structures with tunable density by leveraging in-situ foaming. However, precise control of the foaming process remains challenging due to the complex interplay of multiple process parameters. This complexity has limited the broader adoption of Foam-AM in applications such as packaging, protective gear, automotive components, and beyond. To address these challenges, this study proposes a novel spatial-temporal monitoring and control method using a multi-sensor platform to optimize the performance and geometry of Foam-AM. The platform integrates a thermal camera and positioning encoders to monitor the temperature field and speed distribution, identifying bead interference and speed variations as the primary causes of foaming defects. Additionally, a line laser profiler is used to measure sample’s spatial information, complemented by extruder encoder data for in-situ density estimation. This in-situ approach facilitates high-throughput data acquisition, forming the basis for a process-performance model developed using Invertible Neural Networks (INN). Leveraging the INN model, two major advancements are achieved: (1) off-line control strategies effectively minimize bead interference, ensuring consistent density and geometric precision; and (2) localized foaming defects, especially in regions with rapid speed changes, are accurately identified and addressed through real-time parameter adjustments, significantly improving overall print quality.
期刊介绍:
Additive Manufacturing stands as a peer-reviewed journal dedicated to delivering high-quality research papers and reviews in the field of additive manufacturing, serving both academia and industry leaders. The journal's objective is to recognize the innovative essence of additive manufacturing and its diverse applications, providing a comprehensive overview of current developments and future prospects.
The transformative potential of additive manufacturing technologies in product design and manufacturing is poised to disrupt traditional approaches. In response to this paradigm shift, a distinctive and comprehensive publication outlet was essential. Additive Manufacturing fulfills this need, offering a platform for engineers, materials scientists, and practitioners across academia and various industries to document and share innovations in these evolving technologies.