In-process 3D Deviation Mapping and Defect Monitoring (3D-DM2) in High Production-rate Robotic Additive Manufacturing

Additive manufacturing (AM) is an emerging digital manufacturing technology to produce complex and freeform objects through a layer-wise deposition. High deposition rate robotic AM (HDRRAM) processes, such as cold spray additive manufacturing (CSAM), offer significantly increased build speeds by delivering large volumes of material per unit time. However, maintaining shape accuracy remains a critical challenge, particularly due to process instabilities in current open-loop systems. Detecting these deviations as they occur is essential to prevent error propagation, ensure part quality, and minimize post-processing requirements. This study presents a real-time monitoring system to acquire and reconstruct the growing part and directly compares it with a near-net reference model to detect the shape deviation during the manufacturing process. The early identification of shape inconsistencies, followed by segmenting and tracking each deviation region, paves the way for timely intervention and compensation to achieve consistent part quality.

Nano-scale reservoir computing

This work describes preliminary steps towards nano-scale reservoir computing using quantum dots. Our research has focused on the development of an accumulator-based sensing system that reacts to changes in the environment, as well as the development of a software simulation. The investigated systems generate nonlinear responses to inputs that make them suitable for a physical implementation of a neural network. This development will enable miniaturisation of the neurons to the molecular level, leading to a range of applications including monitoring of changes in materials or structures. The system is based around the optical properties of quantum dots. The paper will report on experimental work on systems using Cadmium Selenide (CdSe) quantum dots and on the various methods to render the systems sensitive to pH, redox potential or specific ion concentration. Once the quantum dot-based systems are rendered sensitive to these triggers they can provide a distributed array that can monitor and transmit information on changes within the material.