Machine learning for real-time monitoring and control of additive manufacturing
A machine learning (ML) approach enables real-time direct ink write (DIW) print-parameter optimization through in-situ monitoring of printed line geometry. The method can use an invertible neural network (INN) to solve both forward and inverse, or optimization, problems using a single network. By combining in-situ computer vision and INNs, DIW printing parameters can be autonomously optimized to print a target line width in a matter of seconds. Furthermore, defects that occur during printing can be rapidly identified and corrected autonomously. The method eliminates user-intensive, time-consuming, iterative parameter discovery approaches that currently limit accelerated implementation of DIW and other extrusion-based additive manufacturing processes.
1 . A method for in-situ process monitoring and optimization of direct ink write (DIW) printing, comprising:
providing a DIW printer configured to print an ink subject to one or more printing parameters,
measuring an output of the printed ink in real-time using computer vision,
comparing the measured output to a target output,
when the output differs from the target output, adjusting the one or more printing parameters of the DIW printer in real time using a pre-trained invertible neural network model to produce the target output, wherein the invertible neural network models both a forward and an inverse relationship between the one or more printing parameters and the target output, and
printing the ink on a substrate subject to the optimized one or more printing parameters in a single printing step.
2 . The method of claim 1 , wherein the one or more printing parameters comprises a nozzle diameter, print speed, linear extrusion rate, or height from the substrate.
3 . The method of claim 1 , wherein the output comprises a line width, line type, or line shape.
4 . The method of claim 1 , wherein the invertible neural network model and optimizing step finds the one or more printing parameters associated with the target line width that are closest in value to current printing parameters.