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About this Abstract
Meeting 2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
Symposium 2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
Presentation Title A Compact In-Situ Artifact for Real-Time Monitoring in Laser Powder Bed Fusion
Author(s) Sina Nejati Eghteda, Albert C. To
On-Site Speaker (Planned) Sina Nejati Eghteda
Abstract Scope Laser Powder Bed Fusion still lacks an inexpensive, real-time gauge linking process drift to mechanical reliability. We present a compact in-situ artifact: two arms joined by a 0.8 mm ligament that fractures mid-build when longitudinal residual stress equals the alloy’s ultimate tensile strength. The break ejects a visible powder plume captured by any webcam; counting the fracture layer instantly reveals peak residual stress using a finite-element calibration curve. Thirty Inconel 718 coupons printed across an EOS M290 plate broke reproducibly within layers 104–107, mirroring subtle location-dependent strength shifts in co-fabricated tensile bars. Systematic hatch-angle and laser-power sweeps produced cosine-like and monotonic break-layer trends. Controlled experiments confirm accuracy across plate position, orientation, and power loss. The coupon occupies 6 mm × 61.5 mm, adds minimal print time, and needs no auxiliary sensors, enabling routine parameter qualification and laser-health monitoring in production LPBF in standard production builds.
Proceedings Inclusion? Planned: Post-meeting proceedings

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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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