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.

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Rajesh Ramamurthy, Harry Chiu, Kevin Harding, and Robert Tait, "3D on machine metrology for conformal printing of conductors and dielectrics onto complex 3D surfaces," Proc. SPIE 10991, Dimensional Optical Metrology and Inspection for Practical Applications VIII, 109910S (Presented at SPIE Defense + Commercial Sensing: April 17, 2019; Published: 13 May 2019); https://doi.org/10.1117/12.2518629.