New multi-function building plate for improving metal laser powder bed fusion by enhancing the alignment accuracy of in-process monitoring data, computed tomography measurements, and building volume geometry

Abstract Laser-based powder bed fusion of metals (PBF-LB/M) is an additive manufacturing process enabling the fabrication of parts with highly complex and customizable geometries, enhanced strength-to-weight properties, and minimized material waste. Despite its unique capabilities, PBF-LB/M needs research and innovation efforts to enhance process dynamics and product quality, as well as to broaden its adoption in high-value industrial sectors, such as aerospace and biomedical. In this context, in-process monitoring solutions and post-process part quality evaluations are fundamental to improving the process towards sustainable, first-time-right, and zero-defect production. This paper describes a novel building plate concept for metal laser powder fusion, whose characteristics were specifically designed to enable and improve the performances of in-process monitoring and high-resolution X-ray computed tomography (CT) measurements. In particular, the plate features markers for perspective correction in off-axis optical monitoring and dismountable inserts with machined geometrical elements to be used for the precise alignment between high-resolution CT reconstructions, in-process gathered data, and building volume geometry. The plate capabilities were demonstrated through examples related to in-process monitoring and post-process X-ray CT measurements.