Phase3D extends in-situ monitoring for metal 3D printing to large build platforms

Phase3D has introduced two large-format variants of its Fringe Inspection system for metal powder bed machines. The “Large Format Fringe Inspection” and “Large Format Fringe Inspection Hi-Rez” configurations can be integrated into printers of the EOS M 400 series as well as Nikon SLM NXG systems and support additional platforms with build volumes of up to 600 x 600 millimeters. This targets users who manufacture large metal components and require documented in-situ quality assurance.

Fringe Inspection uses structured light projection and calibrated optics to capture height-resolved data of the powder and melt pool during the build process. According to Phase3D, the system achieves a vertical accuracy of ±10 micrometers, a lateral resolution of 60 micrometers and a repeatability of 5 micrometers in the calibration plane. Based on these height maps, layer thickness, deposition accuracy and melt surface can be evaluated to detect effects such as short feeds, protrusions, overexposure or recoater collisions.

For large systems, Phase3D offers two configurations. The standard version operates with a pixel size of around 100 micrometers and is aimed at production environments where throughput and integration are key. The Hi-Rez version reduces the pixel size to 60 micrometers and is designed for development and qualification tasks in which detail fidelity and correlation with other measurement variables are paramount.

According to Phase3D, there is a correlation between the in-situ measured layer roughness and part density, allowing conclusions about porosity and thus part quality to be drawn already during the build. This enables delta qualification between different machine configurations without having to fully recharacterize each combination. An aerospace prime contractor uses the system to supplement or partially replace CT inspections of large metal parts and then evaluate the data for qualification in accordance with standards such as SAE AMS7032.

“Scaling Fringe Inspection to large-format systems demonstrates our commitment to enabling qualification through direct measurement, not inference,” said Dr. Niall O’Dowd, Founder and CEO of Phase3D. “Aerospace manufacturers are realizing that in-situ data with units, accurate to microns, can replace the uncertainty of post-build inspection. This is how qualification moves from months to minutes.”