Use of polymer additive manufacturing within the aerospace industry has been limited by the lack of a cost effective method for non-destructive part inspection. Despite extensive material and process characterization efforts, these manufacturing technologies are unable to provide parts having guaranteed mechanical properties due to the potential for formation of undetected random defects.<br/>To address this challenge, Boeing has developed a method for in situ inspection of the Fused Filament Fabrication (FFF) process. This method uses a laser line scanner to measure the upper surface of each part layer immediately after it is fabricated. A prototype inspection system was developed and integrated into an industrial FFF machine as a proof of concept. This system has been used to demonstrate the collection of inspection data for complete builds. Preliminary effects of defects testing has been conducted which indicates a strong correlation between inspection data and part mechanical strength.

<i>In situ</i> inspection of the fused filament fabrication process using laser profilometry

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In situ inspection of the fused filament fabrication process using laser profilometry