The US company Phase3D has developed Fringe Inspection: Cold Spray, an inspection system for additive manufacturing using cold spray based on structured light projection. The solution was realized in collaboration with the Air Force Research Laboratory (AFRL) and funded with 1.25 million US dollars as part of an STTR Phase II project. The aim was to improve quality assurance in aerospace repair and manufacturing processes.
The Cold Spray Additive Manufacturing (CSAM) process makes it possible to apply metallic powders to substrates at high speed – a process that is used particularly in the maintenance and repair of components. One challenge to date has been the non-destructive testing of the applied layers during the process. This is where Phase3D comes in with a sensor-based system that uses structured light projection to identify geometric deviations, cracks and surface defects in real time. The system is able to generate comprehensive measurement data that can be immediately implemented in process adjustments. The hardware was developed at the University of Dayton Research Institute (UDRI) and successfully tested at Ellsworth Air Force Base under operational conditions.
“The successful completion of this project underscores the importance of real-time inspection in additive manufacturing,” said Niall O’Dowd, Founder and CEO of Phase3D. “The deployment at Ellsworth AFB proves that structured light inspection is a game-changer for cold spray applications. This technology not only ensures higher-quality repairs but also delivers significant cost and time savings for the Air Force.”
In a final blind test, various test components were evaluated and correctly classified using these criteria. Phase3D is now planning to use the system in industrial applications outside the military environment and is looking for partners to validate it in other manufacturing contexts. In the long term, structured light inspection is set to become the standard method for quality-critical processes in 3D printing.
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