In-situ process monitoring in Laser Powder Bed Fusion using eddy current non-destructive testing for lattice structures

Additive Manufacturing, particularly Laser Powder Bed Fusion, enables the production of complex metallic components and lightweight lattice structures with high functional potential. However, the reliable industrial application of such structures requires robust quality assurance methods, since defects such as porosity, cracks, dimensional deviations, and local overheating can strongly influence component performance.

This doctoral project investigates the use of Eddy Current Testing as an in-situ process monitoring method for Laser Powder Bed Fusion. In contrast to many existing monitoring approaches that focus mainly on the melt pool or the most recently deposited layer, Eddy Current Testing offers the possibility of detecting surface and subsurface defects. The research focuses especially on lattice structures, where complex geometries and edge effects create additional challenges for reliable defect detection.

The objective is to develop a deeper understanding of how eddy current signals are influenced by process deviations, material defects, and lattice geometry. Based on experimental investigations, the project aims to identify the limitations of current eddy current monitoring systems and to derive recommendations for improved sensor design, measurement strategies, and data evaluation methods. In the long term, the work contributes to more reliable quality assurance and real-time process control in metal Additive Manufacturing.