Aim: To evaluate and develop ultrasonic and laser-based non-destructive testing (NDT) methods for in-situ monitoring of additively manufactured (AM) parts, with a focus on thickness measurement and flaw detection.

Brief description: In collaboration with VLM Robotics and CEA, this project investigated advanced NDT techniques for robotized AM processes such as Wire Arc Additive Manufacturing (WAAM) and Direct Energy Deposition (DED). Key approaches included the use of laser ultrasound for contactless inspection and piezoelectric ultrasonic probes for reference measurements. Tests on aluminum and stainless steel samples assessed the feasibility of detecting flaws and measuring material thickness, with promising results for in-process applications.

Benefits: The project demonstrated the potential of integrating NDT technologies into AM workflows to ensure quality and reliability. Benefits include:

• Enhanced Quality Control: Accurate detection of defects and dimensional inconsistencies during the manufacturing process.
• Scalability: Contactless methods like laser ultrasound are adaptable to various materials and AM techniques.
• Reduced Waste: Early detection of flaws minimizes material waste and rework costs.
• Improved Safety: Non-invasive inspections ensure the integrity of critical components without damaging them.

Company/Venture Website:

• VLM Robotics