Abstract

This project investigated the feasibility of using a non-contact 3D scanning sensor integrated into an additive manufacturing machine for the in-situ characterization of parts produced by material extrusion of thermoplastic feedstock (MEX-TRB/P). Unlike conventional ex-situ inspection methods, an integrated scanning system makes it possible to analyse layer topography during the manufacturing process itself and detect phenomena that may remain hidden once the part is complete. The project was based on a test bench developed at the University of Oviedo, equipped with a laser line triangulation sensor mounted on inspection axes independent of the manufacturing axes. After its metrological reliability had been validated through comparisons with reference artefacts and a reference system based on conoscopic holography, the system was shown to be capable of identifying different features of layer topography, as well as their relationship with manufacturing parameters and deviations from the process setpoints. The results showed that the system could detect irregularities associated with material deposition, variations in roughness and waviness, as well as other material changes occurring during cooling and phenomena such as warping. The project thus established an in-situ inspection methodology capable of providing a more comprehensive and traceable characterization of the MEX-TRB/P process, with the potential for future application to other materials and additive manufacturing technologies.