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Meeting 2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
Symposium 2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
Presentation Title Functionally Inspired Part-Structure-Process Qualification Artifact for Laser Powder Bed Fusion AM With Feature-Specific Metrology, Standardization, and In-Situ Monitoring
Author(s) Utkarsh Thakre, Suman Das, Venkatavardhan Sunderarajan, Lonnie Webb
On-Site Speaker (Planned) Utkarsh Thakre
Abstract Scope A functionally inspired qualification artifact is introduced for laser Powder Bed Fusion (LPBF) that bridges the gap between standardized qualification and industrial application demands. The artifact integrates complex geometries mirroring aerospace and automotive components, while addressing critical limitations in existing standards. A multi-scale metrology framework/standard combines X-CT (≤10 µm voxel resolution), coordinate measuring machines (CMM), and optical profilometry to quantify dimensional accuracy, subsurface defects, and surface roughness. For the first time, in-situ monitoring (infrared thermography, CMOS sensors) is embedded into artifact validation, linking process anomalies to final part quality. The design accounts for multi-orientation builds (0°,45°,90°) to systematically evaluate anisotropic errors, revealing Z-axis shrinkage variations (~2.3%) in Ti6Al4V. Validated across multiple build 3D-Systems DMP320, the artifact enables cross-machine benchmarking via ISO/ASTM 52902-aligned metrics. This work advances LPBF standardization by unifying process-structure-property relationships into a single qualification platform, directly addressing industry needs for reliable AM adoption.
Proceedings Inclusion? Planned: Post-meeting proceedings

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

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3D Printing of Small and Irregular 316L Powder Through a Novel Slurry-Based LPBF Technique
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3D Transient Thermal Simulation for Wire-Arc Additive Manufacturing of Inconel 718
A Compact In-Situ Artifact for Real-Time Monitoring in Laser Powder Bed Fusion
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A Cooling Device for Drastically Reducing Manufacturing Time in Wire-DED
A Data-Driven Approach to Ensuring Manufacturability of Multi-Lattice Structures
A Dual Nozzle Approach to Balancing Fill Speed and Detail Accuracy in Polymer MEXAM Systems
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A Low Computation Method to Account for Attenuation in Tomographic Volumetric Additive Manufacturing: Exponential Radon Transform
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A Method for Improving the Build Time During Wire Arc Based Directed Energy Deposition of Low Carbon Steel
A Novel Additive Manufacturing Approach for the Freeform Deposition of Polymer Matrix Composites With Laser Induced Curing
A Novel Slicing Algorithm for Wall Structures for Additive Construction
A Parametric Workflow for Brazing-Ready, Self-Supporting Metal AM Components With Recoverable Features
A Plug and Play Solution for Improving Optical Cleanliness in Laser Powder Bed Fusion Systems
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A Study of Hybrid Additive Manufacturing Processes for High Melting Point Materials Using Powder Metallurgy
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Adaptive Feedforward Laser Power Control Based on FEM Simulation for Stable Bead Deposition in Laser-Wire DED
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Additive Manufacturing and Characterization of Bimetallic Functionally Graded Materials via DED Blue Laser
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Born Qualified Additive Manufacturing - In-Situ Prediction of Microstructure in Laser Powder Bed Fusion Using Physics and Data-Driven Machine Learning
Calibration of Constitutive Models for High-Strain-Rate Impact Applications
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Characterization of Parameter Effects on Acoustic-Actuated Particle Deposition
Characterization of the Self-Healing Properties of Additively Manufactured PLA Polymer Blends
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Data-Efficient Bayesian Optimization for Layer-wise Dimensional Accuracy Control in Directed Energy Deposition
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Evaluating Critical Variables in Energy-Absorbing Truss Lattices Using Design of Experiments
Evaluating Surface Quality of 3D-Printed ULTEM 1010 and Nylon 12 Surgical Guides
Evaluating the Performance of Novel Tpms-Based Acoustic Liner Designs Created via Vat Photopolymerization
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Exploring the Functional Performance of a Commercial High-Temperature Photopolymer Resin for Vat Photopolymerized Injection Molding Tools
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First-Time-Right Smart Additive Manufacturing – A Physics-Based Feedforward Control Approach for Design and Process Optimization in Laser Powder Bed Fusion
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Force Reduction Through Electrically Assisted Friction Stir Additive Manufacturing
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Fundamental Mechanisms and Practical Applications of Airborne Acoustic Emission in LPBF AM
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Impact of Layer Orientation and Nozzle Diameter on Radio Frequency Transmissivity of Fused Filament Fabricated Ultem 9085
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In-Situ Acoustic Emission-Based Powder Flow Monitoring for Precise Functionally Graded Materials via Powder-Blown Laser Directed Energy Deposition
In-Situ Determination of Powder-Laser Focus Overlap in High-Speed DED Using Multispectral Emission Analysis
In-Situ Femtosecond Micromachining in Laser Powder Bed Fusion Processes
In-Situ Gas-Phase Nanoparticle Synthesis During Directed Energy Deposition of Metallic Alloys
In-Situ Measurements of Selective UV Photocuring Using X-Ray Photon Correlation Spectroscopy for Vat Photopolymerization Additive Manufacturing
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In-Situ Prediction of Flaw Formation and Microstructure in Laser Powder Bed Fusion Using Physics and Data-Driven Machine Learning
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Influence of Melt Pool and Wire Behavior on Process Stability in Hot Wire Directed Energy Deposition
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Influence of Selective Rescanning on Microstructural Evolution and Properties of LPBF Ti6Al-4V Parts
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Integrated Computational-Experimental Framework for Additive Manufacturing and Post Processing of Functionally Graded Materials from Structural to Refractory Alloys
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Inverse Design of Multi-Material Lattice Structures Using Graph Neural Networks
Investigating Microstructure and Gas-Atomization Processability of Novel Mo-Si-B-(Cr, Al) Alloys
Investigating Surface Affinity for the Deposition of Metal-Organic Decomposition Inks in a Vat
Investigation of Drop Mass Deviations in MMJ Systems During Part Printing
Investigation of Molten Metal Jetting wWth Salt Support Structures via an Automated Multi-Material Simulation Framework
Investigation of the Surface Roughness of Micromilled 316L Stainless Steel Fabricated by FDM/FFF Technology
Large Language Model enabled Process Map Discovery Within Additive Manufacturing.
Laser Induced Breakdown Spectroscopy for Material Identification in Laser Powder Bed Fusion Processing
Laser Powder Bed Fusion of NiTi: Compositional Effect
Localization of Nanoplastics in Biocompatible 3D Matrices via Extrusion Printing
Location-Based Structure-Property Relationships of Additively Manufactured Metallic Parts
Low-Cost 3D Scanning for Wire Arc Additive Manufacturing
Low-Cost Melt Pool Monitoring for Wire Arc Additive Manufacturing
Low-Cost Two-Color Pyrometry in Laser Powder Bed Fusion
Machine Learning-Based Optimisation to Design Truss and Plate-Based Multi-Functional Metamaterials
Machine Learning-Based Prediction of Toughness in Fused Filament Fabrication: Leveraging In-Process Annealing With Enhanced Printheads
Mechanical Behavior of an Additively Manufactured Psuedoelastic Nitinol
Mechanical Performance and Porosity of 3D Printed PLA as a Function of Layer Height and Line Width
Mechanical Performance and Weight Reduction of Additively Manufactured Titanium Bolts Aimed for Supply Chain Resiliency of Critical Material
Micro-/Defect-Structure Characterization of Additively Manufactured Metallic Parts Using Laboratory Diffraction Contrast Tomography
Microscopic Analysis of Porosity Distribution and Its Impact on the Mechanical Performance of Binder Jetted Ceramics
Microstructural Insights Into LPBF Manufactured GRX-810 Thin Walls and Complex Inducer Geometries
Microstructure-Driven Fracture Behavior and Thermo-Mechanical Analysis of Large Area Additive Manufactured Short Fiber Composites
Microstructure and Mechanical Properties of Bulk EB-PBF Fabricated γ-TiAl: Post-HIP and Heat Treatment Effects
Microstructure Design in Steels for Power Plant Applications Using Wire Arc Directed Energy Deposition
Mitigation of User-Induced Variation in Tomographic Volumetric Additive Manufacturing
Mixing Tungsten With Inconel 718: Effects on Energy Density and Material Properties in 3D Printing
MODAL: A Scalable Surrogate Modeling Framework for Scanwise Thermal Simulations in Laser Powder Bed Fusion
Modeling and Simulation of Cold Spray Additive Manufacturing: Insights Into Metallic Particle Bonding
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Molten Metal Droplet Watcher Through Optoelectronic Sensing
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Multi-Material Inkjet Print Deposition of Particle-Free Silver and Molecular-Organic-Decomposition Nickel Inks for High Temperature Conductive Circuit Thermal Shielding
Multi-Material, High-Viscosity Vat Photopolymerization
Multi-Nozzle Molten Metal Jetting With Variable Nozzle Pitch
Multi-Sensor Process Monitoring for Blue Laser Directed Energy Deposition of Copper
Multimaterial Aerosol Jet Printing of Memristors on Flexible Substrates
Multimaterial and Isotopically Labeled Specimen Fabrication via Material Extrusion Additive Manufacturing for Interlayer Diffusion Analysis
Multiphysics Modeling to Assess the Powder Bed Characteristics of Inconel 718 for a Circular Substrate in Laser Powder Bed Fusion
Neural Network Prediction of Printing Parameters and Solar Absorptivity via Powder Bed Fusion
Node-Based Closed-Loop Control in Robotic Laser-Wire Directed Energy Deposition
Numerical Analysis of Pre- and Post-Heating Strategies for Reducing Residual Stresses in Laser-Based Directed Energy Deposition
Numerical Modelling of the Interaction of a Laser Beam and Polymeric Powders During Polymer Laser Sintering
Numerical Modelling of Thermal Predictions in Wire-Arc Additive Manufacturing for Online Implementations
Omnidirectional Laser Metal Deposition with Wire (LMD-w) for 6 Feet and Larger Aerostructures
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On the Time Integration for Phase Field Modeling of Grain Growth in Additive Manufacturing
OpenVCAD in Practice: Streamlined Multi-Material Design and Fabrication
Optical Frequency Domain Reflectometry (OFDR) on Fiber Embedded Metal Parts Created with Laser Powder Bed Fusion
Optimizing LPBF for MMCs: Effects of Reduced Powder and Laser Spot Sizes on Reinforcement Distribution, Microstructure, and Mechanical Performance
Packing Fraction Sensing in Metal Binder Jetting Using Airborne Ultrasound Transducer
Photoelastic Visualization of Residual Stresses in PLA After Interlayer Shot Peening During Fused Filament Fabrication
Physics-Aware AI for Born-Qualified Additive Manufacturing: Toward Real-Time, In-Situ Part Qualification
Physics-Guided Thermal History Control to Improve Part Quality in Laser Powder Bed Fusion Additive Manufacturing
Polymer AM Part Thermal History From In-Situ Thermal Data and Heuristic Modeling
Pore Behavior in Melt Pool Properties Based on Ti-6Al-4V and SS316L Powders in Directed Energy Deposition (DED) Processes
Porosity Reduction in Large-Format Additive Manufacturing of Fiber-Reinforced Composites via Elongational Screw Design
Porous Membranes for Controlled Release Profiles using Stereolithography and Phase Separation
Post-Build CT Segmentation and Alignment with L-PBF In-Situ Monitoring Signatures
Powder Bed Interaction with Higher Translation Speed Electron Beams Path for the Area Printing
Powder Dispersion For Removal of Unsintered Powder After Selective Laser Flash Sintering
Powder Flow Dynamics in Laser Metal Deposition
Powder Particle Impact Behavior in Laser, Powder-Blown Directed Energy
Predicting LPBF Ti-6Al-4V Microstructure via Multi-Modal In-Situ Process Monitoring
Predicting Melt Pool Dimensions from Local Thermal Environment Through a Modified Rosenthal Solution
Predicting the Solidified Microstructure in Laser Powder Bed Fusion (LPBF) of Inconel 718 using Physics-Based Modeling and In-situ Sensor Data
Prediction of Failure in Additively Manufactured Metallic Components
Predictive Modeling of Particle Loading for Functional Grading in Reactive Extrusion Additive Manufacturing
Predictive Qualification of Laser Powder Bed Fusion: Leveraging Multi-Modal In-Situ Monitoring and Real-Time Control for Part Qualification
Printing Cryomilled Copper Chips by Blue Laser Directed Energy Deposition (DED)
Process-Aware Topology Optimization for Mitigating Residual Stress and Distortion in Laser Powder Bed Fusion
Process Development and Thermal Monitoring in Electron Beam Additive Manufacturing of Tungsten
Process Mapping for Single-Track Laser Wire Additive Manufacturing of AZ31 Magnesium Alloy
Producing Stochastic Metal Foam on Desktop FFF 3D Printers using Viscous Thread Printing
Pulsed Arc Additive Manufacturing of a Duplex Stainless Steel and HSLA Functionally Graded Material
Pushing the Frontier of Computational Design Leveraging Machine Learning (ML)
Qualification of Laser-Based Powder Bed Fusion of Metals (PBF-LB/M) Using Scanner Data
Quantifying Machine-Induced Error in a Custom Binder Jet Platform for Radio Frequency Additive Manufacturing
Quantifying the Dynamic Properties of 3D Printed Polymers and Polymer Composites Via Ultrasonics
Radiative Property Characterization of Porous Medium Using Liquid-Based Advanced Micro-Additive Manufacturing Technique
Rapid and Non-Contact Density Measurement for Powder-Based AM Via Flash Thermography
Rapid Direct-Write Printing of Metallic Nanostructures Via In-Flight Plasma Reduction
Real-Time Closed-Loop Control for Precision Liquid Metal Jetting
Real-Time Implementability Evaluation of FPGA-Based Trackwise Model Predictive Control for Laser Powder Bed Fusion
Real-Time Prediction of Working Distance in Laser-Wire DED Via Multi-Modal In-Situ Data Fusion Using a CNN Model
Real Time Measurement System for Digital Glass Shaping Processes
Real Time Visualization of Glass Additive Manufacturing Processes
Regolith-Filled Thermoset as a Candidate Material in Lunar Construction
Reinforcement Learning-Based Digital Twin for Predictive Maintenance and Anomaly Detection in UR5 Robots
Repeatability and Reproducibility of Mechanical Properties in HIP-Treated GRX810 Across Multiple LPBF Machines and Build Angles
Review on Atomization of Meals
Rheology-Driven Analysis of Extrusion Forces in Fused Filament Fabrication
Rheology-Informed Mixture Engineering of Aggregates for Extrusion Additive Manufacturing
Rheology Modification and Reinforcement of True Silicone Resins for Vat Photopolymerization
Robotic Subscale Bar-Fed Friction Stir Additive Manufacturing
Robotic Wire Arc DED (Directed Energy Deposition) of 316 l Stainless Steel Preform for Forging Application
Role of Defect Interaction and Multi-Site Damage in Fatigue Life of Additively Manufactured Metals
Sacrificial Preform Design and Parameter Optimization for Thin Walls and Corners in Powder-Blown Hybrid DED
Scalable and Data-Driven Control Strategy for Layer Thickness Consistency in Directed Energy Deposition
Selective Laser Etching of Fused Silica for Complex 3D Geometries
Sequential Element Rejection and Admission (SERA) Method for Topological Design of Cellular Materials
Shape Optimization and Sensitivity Analysis for Triply Periodic Minimal Surface Lattice Structures Under Periodic Boundary Conditions
Silicon Carbide Nanoparticle Filled Nanocomposites Using SLA Resin for Low Thermal Expansion and Enhanced Mechanical Properties
Simultaneous Time Resolved SAXS and WAXS Characterization for Laser Additive Manufacturing via X-Ray Pump Probe at LCLS X-Ray Free Electron Lasers
Single-Crystal Epitaxial Deposition of PWA 1480: Process Development and Microstructural Characterization
Sinusoidal Plate-Based Lattices for Enhanced Crashworthiness
Slit Accuracy of Thin Walls in Laser Powder Bed Fusion
Small-Scale Meta Structures Additively Manufactured from an Alumina Forming Austenitic Stainless Steel
SMOS Hub: Enabling Autonomous Cooperation in Heterogeneous Manufacturing Swarms
Spatiotemporal Laser Beam Shaping for Topographical Control in Laser Powder Bed Fusion
Stress-Corrosion Behavior of Magnesium Alloy AZ91 Manufactured by Laser Powder Bed Fusion
Study of Fatigue Endurance on Artificially Aged Additive Manufactured AlSi10Mg After Stress Relived and Hot Isostatic Pressed
Surface Correction Process Development for 410 SS Deposited with Wire Arc Additive Manufacturing
Synchronized, Multi-Mode Process Monitoring for Wire Arc Additive Manufacturing
Systematic Evaluation of Classical and Adaptive Control Strategies for Gantry‑Positioning Reliability in FDM Additive Manufacturing
Tailoring Binder Jet Green and Sintered Part Strength Through Architected Infills
Tailoring Ceramic Slurry Behavior Through Binder Variation: A Three-System Study
Temperature Control in Volumetrically Heated Digital Glass Forming
Temperature Sensor Comparison Study of Spot Pyrometers and Contact Thermocouples for Improved Thermal Monitoring of Wire-Arc DED
The Alloy Optimization Software (TAOS)
The Effects of Gravity on Track Integrity During Collaborative Robot-Assisted Wire Arc Additive Manufacturing
The Influence of Hot Isostatic Pressing Process on the Fatigue Life of EB-PBF Printed Ti-6Al-4V
Thermal Exposure Optimization for Enhanced Interlayer Strength in FFF-Printed ABS: A DOE and Microstructural Investigation
Thermal History Prediction of More Complex Geometries for DED Based on SciML
Thermal Monitoring in AC Selective Laser Flash Sintering of Ceramics Using a Mid-Wave Infrared Photodiode
Toolpath Planning for Multi-Nozzle Concurrent Molten Metal Jetting Process
Top Layer Quality Assurance of Complex Geometries Based on Region of Interest in Additive Manufacturing
Topology and Orientation Optimized-Inspired Toolpath Planning for Continuous Fiber Material Extrusion
Toward Real-Time Finite Element Analysis-Informed Feedback Control of Wire-Arc Directed Energy Deposition via Robot Operating System 2 In-Situ Monitoring System
Towards Parametric Design for Additive Manufacturing of Coral Structures Using a Digital Twin Approach
Towards Scalable and Energy-Efficient Extrusion Additive Manufacturing of Thermoplastic Polymer Composites
Towards the Production of a 3D Part in Selective Laser Additive Manufacturing Acousto-Optic Light Engine (SLAM – ALE)
Train Small, Predict Big: Scalable Thermal Surrogate Modeling for LPBF Using MODAL
Transfer Learning for Process–Microstructure–Property Mapping in Micro Selective Laser Sintering
Transient Liquid Phase Surface Smoothing
Tribo-Mechanical and Corrosion Characteristics of SS316L-IN625 Alloys of Varying Compositions Fabricated by Twin Wire WAAM-TIG
Two-Component Thermoset Polymer Formwork for Concrete Casting
Uncovering Process-Structure Relationships in Directed Energy Deposition of Nickel-Based Alloys on Low-Alloy Steel with Post-Deposition Heat Treatment
Understanding Hardening Behavior Induced by Interlayer Shot Peening in Laser Powder Bed Fusion of 316L Stainless Steel
Understanding Multi-Line Printing and the Effects of Controlled Prewetting on Binder Jetting Print Cohesion
Understanding Sources of Spatial Density Variation in Green Parts Produced by Binder Jetting
Understanding the Effect of Heat Treatment on Mechanical Properties of Additive Manufactured 1.2709 Grade Maraging Steel
Understanding the Feasibility of Using NiTi55 Interlayer for Ti6Al4V-18Ni Maraging Steel Multi-Metal Deposition in L-PBF
Use of In-Situ Thermography to Study Scan Strategy for Laser Foil Printing of Metallic Glass
Using Acoustic Signals For Torch-to-Bead Distance Estimation and Closed-Loop Control in Wire Arc Additive Manufacturing
Using Coaxial Melt Pool Images to Construct In-Process 3D Volume Model in Powder Bed Fusion Additive Manufacturing
Using Machine Learning-Based Process Map to Guide Evaluation of Inconel 625 Mechanical Properties in Laser Foil Printing
Vat Photopolymerization of Na3V2(PO4)3-Based Electrodes for Sodium-Ion Batteries
Vat Photopolymerization of Ultra-Soft Polymer Foams
Volumetric Medical Models: Direct Imaging to Functional 3D Prints
Wire Arc Additive Manufacturing Benefits and Challenges: A Survey
Wire Arc Additive Manufacturing Development for Aluminum 6061 RAM
Wire Arc Additive Manufacturing of a Large Scale, High Aspect Ratio, Multi-Material Part
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