Part defects identification in selective laser melting via digital image processing of powder bed anomalies

Despite the potential of additive manufacturing and specifically of selective laser melting, several considerable barriers exist to widespread utilization, especially in specific industries that produce high-value components. Quality control and mechanical characterization remain the most expensive challenge. The quality and mechanical properties of the manufactured parts are influenced by potential defects; the characteristics of these defects, such as size, shape, location, and distribution, have shown to play key roles in mechanical properties. This work proposes a methodology for providing the identification of powder bed anomalies and consequent part defects through a synchronized analysis of the powder layers via digital image processing. This method can be used to study the critical defects formation during the layerwise process, providing important information about their location without the use of expensive or destructive measurements.