Correlation of Process Parameters and Layer Charactristics in High-Speed Directed Energy Deposition Using Optical Coherence Tomography
Wexel, Helena 1; Krull, Christoph; Gajek, Patrick 1; Maffia, Simone; Stittgen, Tobias; Koß, Stephan; Schleifenbaum, Johannes; Zanger, Frederik
1; Leigh, David [Hrsg.]; Beaman, Joseph [Hrsg.]
1 Institut für Produktionstechnik (WBK), Karlsruher Institut für Technologie (KIT)
1; Leigh, David [Hrsg.]; Beaman, Joseph [Hrsg.]1 Institut für Produktionstechnik (WBK), Karlsruher Institut für Technologie (KIT)
Abstract (englisch):
High-speed directed energy deposition with laser beam (HS DED-LB) represents a key
enabler for circular and resource-efficient production due to deposition velocities up to 200 m/
min and layer heights down to 50 μm. To ensure process stability and product quality, precise in-
situ monitoring techniques are required. This study investigates the application of Optical
Coherence Tomography (OCT) as a high-resolution, non-contact method for real-time
layer height measurement in HS DED-LB. By employing a Design of Experiments (DoE) in
combination with response surface methodology (RSM), correlation models are derived that
link key process parameters - laser power, processing speed, and powder mass flow rate - to
layer height and relative density. The findings highlight the potential of OCT-based monitoring
for early deviation detection in high-speed additive processes and to support the
development of model-driven control approaches. This demonstrates its relevance for the
optimization of resource-efficient additive manufacturing systems in circular production
environments.
enabler for circular and resource-efficient production due to deposition velocities up to 200 m/
min and layer heights down to 50 μm. To ensure process stability and product quality, precise in-
situ monitoring techniques are required. This study investigates the application of Optical
Coherence Tomography (OCT) as a high-resolution, non-contact method for real-time
layer height measurement in HS DED-LB. By employing a Design of Experiments (DoE) in
combination with response surface methodology (RSM), correlation models are derived that
link key process parameters - laser power, processing speed, and powder mass flow rate - to
layer height and relative density. The findings highlight the potential of OCT-based monitoring
for early deviation detection in high-speed additive processes and to support the
development of model-driven control approaches. This demonstrates its relevance for the
optimization of resource-efficient additive manufacturing systems in circular production
environments.
| Zugehörige Institution(en) am KIT | Institut für Produktionstechnik (WBK) |
| Publikationstyp | Proceedingsbeitrag |
| Publikationsmonat/-jahr | 08.2025 |
| Sprache | Englisch |
| Identifikator | KITopen-ID: 1000190195 |
| Erschienen in | Proceedings of the 36th Annual International Solid Freeform Fabrication Symposium, Austin, TX, 10th-13th August 2025 Hrsg.: Leigh, David; Beaman, Joseph |
| Veranstaltung | 36th 36th Annual International Solid Freeform Fabrication Symposium (2025), Austin, Texas, 10.08.2025 – 13.08.2025 |
| Verlag | Minerals, Metals and Materials Society (TMS) |
| Seiten | 1047-1060 |
| Serie | Proceedings SFF ; 1 |
| Projektinformation | SFB 1574 KLF, 471687386 (DFG, DFG KOORD, SFB 1574/1) |
| Externe Relationen | Abstract/Volltext |
| Schlagwörter | High-Speed Directed Energy Deposition, Additive Manufacturing, Process Monitoring,, Optical Coherence Tomography, OCT |