current research and development

Intelligent Additive Manufacturing

R3 Digital Sciences is currently developing an Intelligent Additive Manufacturing (IAM) system for metal Laser Powder Bed Fusion (LPBF) that incorporates AI to provide real-time adaptive monitoring and control of the LPBF process and produces defect-free parts while maintaining or reducing part build time.  Our concept consists of a controllable open architecture LPBF AM system, melt-pool temperature sensors, auxiliary process sensors, and machine learning to control the LPBF process. 

The goal of this effort is to develop and transition for Navy use, an Intelligent Additive Manufacturing system for metal Laser Powder Bed Fusion that can incorporate AI/ML to provide real-time adaptive monitoring and control of the LPBF process and produce defect-free parts while maintaining or reducing part build times.

To meet this goal, R3 Digital Sciences is working with the University of Dayton Research Institute (UDRI) and other team members to develop the Open Intelligent Additive Manufacturing (Open-IAM) system. The Open-IAM consists of four components: 1) An open architecture LPBF system that was developed by UDRI.  It is open in that it facilitates the integration of third party sensors and controls; 2) Stratonics’ true temperature pyrometers for measuring the thermal response of the powder bed; 3) Open Additive’s auxiliary sensors for measuring other important process variables and 4) R3-DS' machine learning application called Artisan-AM© that can be taught to recognize the relationship between process variables and part performance and then use this understanding to control the process to produce more consistent parts that meet user requirements.