Skip to main content
SpringerLink
Log in

Penelope: A Novel Prototype for In Situ Defect Removal in LPBF

  • Solid Freeform Fabrication 2019
  • Published:
JOM Aims and scope Submit manuscript

Abstract

A new laser powder bed fusion prototype for in situ monitoring of defects and in situ and inline flaw removal has been developed at and patented by Politecnico di Milano (Italy). This prototype allows the identification of a defective layer thanks to an innovative in situ monitoring approach that combines image and video-image data in the visible and infrared ranges. When an alarm is issued, the layer containing the defect is removed in situ and inline, thanks to a novel self-repairing system acting as a grinder on the powder bed. After this removal step, subsequent layers are additively produced starting from the healed height. By comparing specimens obtained with and without such intermediate layer removal, the aim of this preliminary study is to investigate the feasibility of the methodology, revealing that no discontinuity is introduced into the part by the novel inline removal operation. This solution is conceived to enable novel zero-defect and first-time-right capabilities in additive manufacturing.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1

Reprinted with permission from Ref. 4

Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8

Similar content being viewed by others

References

  1. M. Grasso and B.M. Colosimo, Meas. Sci. Technol. 28, 044005 (2017).

    Article  Google Scholar 

  2. S.K. Everton, M. Hirsch, P. Stravroulakis, R.K. Leach, and A.T. Clare, Mater. Des. 95, 431 (2016).

    Article  Google Scholar 

  3. B. Zhang, J. Ziegert, F. Farahi, and A. Davies, Addit. Manuf. 12, 100 (2016).

    Google Scholar 

  4. F. Caltanissetta, M.L. Grasso, S. Petro, and B.M. Colosimo, Addit. Manuf. 24, 183 (2018).

    Google Scholar 

  5. T. Craeghs, F. Bechmann, S. Berumen, and J. Kruth, Phys. Procedia 5, 505 (2010).

    Article  Google Scholar 

  6. J. Mireles, S. Ridwan, P.A. Morton, A. Hinojos, and R.B. Wicker, Surf. Topogr. Metrol. Prop. 3, 034002 (2015).

    Article  Google Scholar 

  7. E. Yasa, J.P. Kruth, and J. Deckers, CIRP Ann. 60, 263 (2011).

    Article  Google Scholar 

  8. J. Grum and J.M. Slabe, Appl. Surf. Sci. 252, 4486 (2006).

    Article  Google Scholar 

  9. T. Heeling and K. Wegener, Addit. Manuf. 22, 334 (2018).

    Article  Google Scholar 

  10. V. Renken, A. Von Freyberg, K. Schünemann, F. Pastors, and A. Fischer, Prog. Addit. Manuf. 4, 1 (2019).

    Article  Google Scholar 

  11. G. Repossini, V. Laguzza, M.L. Grasso, and B.M. Colosimo, Addit. Manuf 16, 35 (2018).

    Article  Google Scholar 

  12. M.L. Grasso, A.G. Demir, B. Previtali, and B.M. Colosimo, Robot. Comput. Integr. Manuf. 49, 229 (2018).

    Article  Google Scholar 

  13. M. Grasso, V. Laguzza, Q. Semeraro, and B.M. Colosimo, J. Eng. Ind. 139, 051001-1 (2017).

    Google Scholar 

  14. B.M. Colosimo, Q. Huang, T. Dasgupta, and F. Tsung, J. Qual. Technol. 50, 233 (2018).

    Article  Google Scholar 

Download references

Acknowledgements

This study was partially supported by the AMATHO project (Additive MAnufacturing Tiltrotor HOusing), funded by the European Community in the framework of the H2020 IADP Fast Rotorcraft - CleanSky 2 - Programme, and by the agreement n. 2018-5-HH.0, between the Italian Space Agency (ASI) and Politecnico di Milano.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Politecnico di Milano, Via La Masa 1, 20156, Milan, Italy

    B. M. Colosimo, E. Grossi, F. Caltanissetta & M. Grasso

Authors
  1. B. M. Colosimo
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. E. Grossi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. F. Caltanissetta
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. M. Grasso
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to F. Caltanissetta.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Colosimo, B.M., Grossi, E., Caltanissetta, F. et al. Penelope: A Novel Prototype for In Situ Defect Removal in LPBF. JOM 72, 1332–1339 (2020). https://doi.org/10.1007/s11837-019-03964-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11837-019-03964-0

Search

Navigation