AI-vision based real-time in-situ monitoring of the metallic deposition in μ-plasma transferred arc directed energy deposition process

• AI vision based real-time monitoring of the μ-PTADED process using HDR imaging and advanced image segmentation. • Arc-robust segmentation under challenging glare and spatter, reliably isolating melt pool and deposition regions. • Real-time deposition height tracking via calibrated pixel-to-millimetre mapping and its experimentally validation. • Rapid and accurate deposition-quality classification making the framework suitable for closed-loop monitoring.