With the advent of Powder Bed Fusion – Laser Beam (PBF-LB) technologies in industrial production, implementing in-process monitoring has become essential to ensure stable printing conditions and satisfactory final outcomes. Despite significant technological advancements, the rejection rate of parts remains unacceptably high compared to conventional production techniques. Various defects influencing the printing process are well-known, particularly when intricate geometries and lattice structures, which are highly critical, are fabricated. To address these challenges and enhance the quality of such critical structures, a high-resolution monitoring system based on Optical Tomography (OT), known as High Resolution-Optical Tomography (HR-OT), has been proposed. This system utilizes an ultra-high-resolution sensor operating within the visible light spectrum, covering a wide area of the surface layers across the entire printing platform.


The primary objective of this study is to assess the performance of the HR-OT monitoring system through the creation and analysis of a metallic benchmark produced using PBF-LB technology. To design an appropriate benchmark, the most relevant characteristics for monitoring methodology application during the printing process were identified. This analysis underscored the need to select feature types, dimensions, and positioning based on the results of statistical analyses conducted at the end of the fabrication process.


Furthermore, it is highlighted that the HR-OT monitoring technique is particularly suited for laser processes, as it meticulously monitors the interaction between the laser and material during the laser scanning phase. This aspect underscores its potential to significantly improve the quality control and optimization of additive manufacturing processes.