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About this Abstract
Meeting 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Symposium 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Presentation Title Adaptive Feedforward Control of Mass Flow Oscillations in Powder Blown Directed Energy Deposition
Author(s) Neel Shah, Zachary Brunson, Jin Yeon Kim, Aaron Stebner
On-Site Speaker (Planned) Neel Shah
Abstract Scope Consistent powder mass flow is critical to part quality in blown powder Directed Energy Deposition (PB-DED), yet rotary feeders exhibit two persistent instabilities: periodic oscillations driven by hopper mechanics and stochastic parameter drift from powder compaction and settling. We demonstrate a control architecture that tightly couples feedforward and feedback strategies: a feedforward controller derived from a sinusoidal model of rotor-coupled mass flow dynamics provides proactive disturbance cancellation, while a Lyapunov-based Model Reference Adaptive Control (MRAC) layer closes the loop by continuously updating model parameters in response to stochastic powder settling dynamics. Real-time experiments on an Optomec LENS 840 with FPGA-based control demonstrate successful parameter drift tracking and a 31–64% reduction in steady-state mass flow standard deviation across a seven-step setpoint sequence compared to open-loop operation.
Proceedings Inclusion? Undecided

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