Phase3D - Media Center

Phase3D has successfully deployed Fringe Inspection™: Cold Spray, a $1.25M Air Force-funded quality inspection system that provides real-time defect detection for cold spray additive manufacturing at Ellsworth Air Force Base. The technology uses structured light to identify surface defects, measure flatness, and enable process optimization during cold spray applications, addressing key quality challenges in aerospace and defense manufacturing. The system was validated through extensive testing that established quality thresholds and go/no-go gages for evaluating surface characteristics of cold spray deposits.

This case study details how an aerospace company resolved powder dropping issues in their laser powder bed fusion (L-PBF) additive manufacturing process using Fringe Inspection technology. The company was experiencing a 5% failure rate due to powder inconsistently falling onto parts during printing, which standard machine imaging couldn't effectively detect. After implementing Fringe Inspection, they were able to identify that powder accumulating on the recoater assembly was dropping onto the build surface when parts protruded slightly, causing vibrations. By adding a fixed blade to remove excess powder and setting a 200-micron threshold for acceptable powder deposition, they eliminated failures and reduced wasted costs by over 90%.

Additive manufacturing has transformed design and production, offering unmatched complexity but introducing challenges in part validation due to its digital-first nature. Unlike traditional manufacturing, which benefits from decades of qualification data, AM requires real-time oversight to ensure reliability, making in-situ inspection essential for quality assurance.

Phase3D has partnered with Taiyo Nippon Sanso Corporation (TNSC) to expand its Fringe Inspection product suite and AM quality control solutions into the Japanese market. This collaboration provides Japanese manufacturers with comprehensive support and access to Phase3D’s cutting-edge inspection technologies through TNSC’s robust distribution network and technical expertise.

Traditional post-build inspections in Additive Manufacturing (AM) are costly and limit scalability. In-process solutions like Fringe Inspection™ enable real-time validation, reducing waste and ensuring certifiable quality for efficient, large-scale production.

Phase3D is collaborating with UK manufacturer Alloyed to assess part quality and identify how build anomalies cause defects using the Fringe in-situ inspection system.

Additive Manufacturing (AM) is a crucial technology for the future of aviation, but current processes require extensive post-inspection, such as CT scans, to validate safety. In-situ inspection offers a more efficient solution by ensuring real-time quality control during production, moving the industry closer to FAA approval for high-safety-critical parts. At Phase3D, we are developing in-situ inspection technology to streamline this process and help revolutionize the use of AM in aviation.

Phase3D is providing Oak Ridge National Laboratory with in-situ process monitoring technologies, including the Fringe imaging system, to support the qualification of additively manufactured materials for nuclear energy. This collaboration advances AM processes for high-performance materials in the nuclear industry.

Phase3D research with Illinois Institute of Technology to advance Binder Jetting.

Phase3D is First to Correlate Additive Manufacturing Build Anomalies to Part Defects for the U.S. Air Force and NASA.

The multiyear Cooperation between Phase3D and the US Air Force is Contributing to the Continued Development of Metal Additive Manufacturing for the Defense Sector.

Understanding Fringe Projection: Phase3D's Approach to Objective Measurements.

U.S. Air Force Employs Phase3D to Develop Multiple Sensor Real-Time Inspection for Additive Manufacturing.

Phase3D Releases True Layer Thickness Measurement for a Prominent Aerospace Company.

US Air Force Awards Phase3D $1.25M Contract for Cold Spray Additive.

Phase3D and DMG MORI Announce Research Collaboration Initiative.

Phase3D, in Partnership with 1000Kelvin, Awarded Phase I STTR Contract from the US Air Force — Real-Time Anomaly Detection to Optimizing Laser Pathing.

Phase3D Announces Collaboration with Materialise.

Synchrotron X-rays Show Causal Link Between Height Defects and Gas Entrapped Porosity.

Phase3D Introduces Early Adopter Program for 3D Printing Real-Time Inspection.

Phase3D Completes Technical Collaboration with Oak Ridge National Laboratory.

Phase3D Wins Air Force Research Lab Open Call for Innovative Dual-Purpose Technologies.

Additive Monitoring Systems Re-brands as Phase3D.

NASA Marshall Space Flight Center Selects Additive Monitoring Systems To Integrate In-situ Monitoring for Additive Manufacturing Production.

US Air Force Contracts Chicago Startup Additive Monitoring Systems to Integrate In-situ Monitoring for Additive Manufacturing.

Phase3D has launched Fringe Qualification, a cutting-edge tool for real-time, production-scale quality control in additive manufacturing.