In-Situ Melt Pool Characterization via Thermal Imaging for Defect Detection in Directed Energy Deposition Using Vision Transformers

Directed Energy Deposition (DED) offers significant potential for manufacturing complex and multi-material parts. However, internal defects such as porosity and cracks can compromise mechanical properties and overall performance. This study focuses on in-situ monitoring and characterization of melt pools associated with porosity, aiming to improve defect detection and quality control in DED-printed parts. Traditional machine learning approaches for defect identification rely on extensive labeled datasets, often scarce and expensive to generate in real-world manufacturing. To address this, our framework employs self-supervised learning on unlabeled melt pool data using a Vision Transformer-based Masked Autoencoder (MAE) to produce highly representative embeddings. These fine-tuned embeddings are leveraged via transfer learning to train classifiers on a limited labeled dataset, enabling the effective identification of melt pool anomalies. We evaluate two classifiers: (1) a Vision Transformer (ViT) classifier utilizing the fine-tuned MAE Encoder's parameters and (2) the fine-tuned MAE Encoder combined with an MLP classifier head. Our framework achieves overall accuracy ranging from 95.44% to 99.17% and an average F1 score exceeding 80%, with the ViT Classifier slightly outperforming the MAE Encoder Classifier. This demonstrates the scalability and cost-effectiveness of our approach for automated quality control in DED, effectively detecting defects with minimal labeled data.

An unsupervised approach towards promptable defect segmentation in laser-based additive manufacturing by Segment Anything

Foundation models are currently driving a paradigm shift in computer vision tasks for various fields including biology, astronomy, and robotics among others, leveraging user-generated prompts to enhance their performance. In the manufacturing domain, accurate image-based defect segmentation is imperative to ensure product quality and facilitate real-time process control. However, such tasks are often characterized by multiple challenges including the absence of labels and the requirement for low latency inference among others. To address these issues, we construct a framework for image segmentation using a state-of-the-art Vision Transformer (ViT) based Foundation model (Segment Anything Model) with a novel multi-point prompt generation scheme using unsupervised clustering. We apply our framework to perform real-time porosity segmentation in a case study of laser base powder bed fusion (L-PBF) and obtain high Dice Similarity Coefficients (DSC) without the necessity for any supervised fine-tuning in the model. Using such lightweight foundation model inference in conjunction with unsupervised prompt generation, we envision the construction of a real-time anomaly detection pipeline that has the potential to revolutionize the current laser-based additive manufacturing processes, thereby facilitating the shift towards Industry 4.0 and promoting defect-free production along with operational efficiency.