Boosting the surface quality and geometric accuracy in laser additive manufacturing via a novel data-driven control system design

Additive manufacturing has attracted the attention of industries such as aerospace and automotive as well as the medical technology sectors in recent years.

Laser additive manufacturing technology (LAM) has become a very promising alternative to high-value large metal components in many manufacturing industries.

Although major progress has been made in process development, path slicing, programming, and material analysis, a comprehensive process monitoring, and control system are yet to be developed.

BALSAM project (Boosting Accuracy of Laser Additive Manufacturing) aims to provide in-depth methods, models and tools of sensing and control design suitable for the LAM system, including technologies developed for a generic welding process using the candidate previous results on data-driven control methodology.

Particular focus is given to the integration of sensor-based feedback control, and how they could be implemented into the LAM process to improve the surface quality and geometric accuracy of the final product.

The project concludes with different simulation and experimental results to verify the system’s performance and robustness.

The multidisciplinary nature of the BALSAM project is strong, involving a combination of well-developed control, robotics, laser-welding and manufacturing.

This proposal includes both the transfer of knowledge to the host institution and the training of the candidate in new advanced techniques.

Results have the potential capacity to increase the use of LAM in the European industries and provide room for further studies at the fundamental and applied levels. This project is in line with the EU industrial strategy that aims to make the EU industry more competitive globally.