3D sensing for direct write error characterization for aerosol jet printing

This report evaluates some of the challenges faced with 2D camera based on-machine metrology and potential options with using 3D sensors for such Direct Write applications. Specifically, in order to fully exploit 3D direct write technology to surfaces in excess of 45 degree to the print direction, non-planar motion employing 4th and 5th rotary axes are often necessary. This report will outline a procedure for doing high accuracy rotary axis calibration. Furthermore, the use of online metrology solution to enable tuning of the rotary axis as well as for online print characterization will be detailed. These efforts will provide a fresh impetus to the use of 3D sensors for on-machine monitoring applications in additive manufacturing.