During the DMLS build process, EOSTATE MeltPool observes the light emitted by the melt pool. Hardware helps to separate the process light from the reflected laser light. The data that is obtained is further processed in software that also offers automatic error correction of the data that is created, as well as process visualisation and evaluation in real time. The data that is collected can be used to draw conclusions regarding the quality of the final components.

Lukas Fuchs, application development consultant, MeltPool, for Monitoring Solutions at EOS states: “The decisive factor for customers on the road towards series manufacturing based on AM is reproducible top-quality parts at the lowest costs per part possible. The EOSTATE MeltPool Monitoring allows to move part quality assurance from post- to in-process, as such not only supporting a better risk management, but as well reducing time and costs for quality assurance and as a consequence overall costs per part.”

After market introduction, the system went into a testing phase with a handful of pilot customers. This phase has been recently completed. TUSAS Engine Industries Inc. (TEI), a joint venture established in 1985 between Turkish Aerospace Industries, General Electric, Turkish Armed Forces Foundation and Turkish Aeronautical Association, has been one of the customers to support this.

Semih Pilatin, technology programs manager at TEI, states: “We consider the EOSTATE Meltpool monitoring system as an initial step for online control and part quality inspection. As such, it was part of our initial technical specifications for the DMLS process and we felt privileged to be one of the first pilot customers to test it.” And he continues: “We are planning to use this tool for aerospace engine parts manufacturing where tight tolerances and high performance are expected. With this tool, we can capture potential part defects online at an early stage and with minimal effort to assess the part quality.”