Title: Feature Quantification for Complex Geometries Manufactured Using Powder Bed Fusion for Polymeric and Metallic Materials

Authors: Savannah Rose, David Jack, Nathan Emerson, Adam Swinney

DOI:

Abstract: Powder bed fusion (PBF) is an industrial additive manufacturing (AM) method. This method builds components layer-by-layer through the spreading of a thin layer of powder followed by selective spatial sintering using a laser. This method allows for more geometric complexity due to the layer-by-layer nature, and has greater geometric complexity capabilities than other AM methods due to not requiring added support material. It is also amenable to polymeric and metallic materials. To enable the acceptance of AM fabricated components, nondestructive testing methods are required to quantify internal fabricated features. Inspections of curved components are often performed manually and regulated to surface inspections, thus automation is desired both for throughput and consistency. This paper presents an inspection method that uses immersion based focused ultrasound with full waveform capture, polymer and metal PBF cylindrical components with designed in features. For precise feature quantification, it is observed that inspection parameters differ by material system. A novel rotational ultrasound inspection system is used, allowing for inspections of axisymmetric cross-sections (i.e., cones and cylindrical sections). The designed in features are quantified by analyzing the ultrasound waveforms and validated using x-ray computed tomography measurements. Several feature geometries within each sample are investigated, including rectangular, circular, and hexagonal extruded features. The internal feature size ranges from 3 mm to 7 mm across the longest span, with measurement differences ranging from 0.3 mm to 1.5 mm between the ultrasonic inspection and x-ray computed tomography.

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Conference: SAMPE 2026

Publication Date: 2026/04/27

SKU: 60

Pages: 9

Price: $18.00