Nanyang Technological University (NTU Singapore) scientists have developed a new imaging process to assess the quality of 3D printed metal parts.
Said to be both fast and economical, this new technology could benefit the aerospace sector – among others – where low-cost, rapid assessment of mission critical parts such as turbine, fan blades and other components could prove to be a game changer as far as maintenance and repair is concerned.
According to the scientists, most 3D printed metal alloys consist of a myriad of microscopic crystals, which differ in shape, size, and atomic lattice orientation.
Until now, analysing this ‘microstructure’ in 3D printed metal alloys has been achieved through laborious and time-consuming measurements using scanning electron microscopes that cost anywhere between $74,000 to $1.5 million.
According to NTU assistant professor Matteo Seita and his team, their new method provides the same quality of information in a matter of minutes by using a system consisting of an optical camera, a flashlight, and a notebook computer that runs a proprietary machine-learning software developed by the team.
The icing on the cake? All this costs no more than $18,500!
According to the scientists, their new method first requires treating the metal surface with chemicals to reveal the microstructure.
The sample is then placed facing the camera, and multiple optical images are taken as the flashlight illuminates the metal from different directions.
The software then analyzes the patterns produced by light that is reflected off the surface of different metal crystals and deduces their orientation.
According to Seita, this entire process takes about 15 minutes to complete.
“Using our inexpensive and fast-imaging method, we can easily tell good 3D-printed metal parts from the faulty ones,” notes Seita.
“Currently, it is impossible to tell the difference unless we assess the material’s microstructure in detail.”
Image and content: NTU Singapore
