In-Situ Process Surveillance and Monitoring for AM (PRISM-AM-STUDY)

The study's objective is to evaluate the feasibility and state of the art (SOA) of in-situ surveillance monitoring and control for additive manufacturing (AM). The technology is important for terrestrial AM and enabling for in-space AM. A foundational framework for addressing gaps of real-time in-process defect detection within AM machine builds will be established. Initially focusing on the laser powder bed fusion and directed energy processes, this effort aligns with NASA's strategic goals of advancing in-situ process monitoring for reliable qualification of AM parts, especially in space environments. The study encompasses a feasibility assessment to determine the sensitivity of AM defects on mechanical properties, focusing on the laser powder bed fusion process but broadly applicable across AM methods. Deliverables will include: (1) A report identifying technical gaps for in-situ process monitoring that support AM qualification. (2) Recommendations for future research and development (R&D) efforts, emphasizing systematic methodologies, experimental systems, and standard approaches. (3) A framework for in-situ process monitoring as a qualification tool for aerospace parts, enabling enhanced reliability in AM processes. This effort will leverage a public-private partnership with the Air Force Research Laboratory (AFRL), the Federal Aviation Administration (FAA), and Auburn University, utilizing contractual resources to conduct research and analysis. The partnership will ensure access to expertise, experimental capabilities, and data necessary to achieve the study's objectives. The approach includes: (1) Collaboration with NASA and industry stakeholders to identify and assess technical gaps. (2) Potential sensitivity studies linking AM defects to mechanical properties. (3) Developing a framework to address in-situ process monitoring challenges and defining next steps for qualification methodologies.

​By enhancing the understanding of AM physics, optimizing the manufacturing processes, and addressing technical gaps identified in the Additive Manufacturing Standardization Collaborative (AMSC)-v3 roadmap, the study supports NASA's objectives of ensuring quality and performance in critical aerospace components through innovative manufacturing technologies. The AM community recognizes that more integrated efforts are required to accelerate the pace of implementation and industrialization of ISM in advancing AM. This proposal provides a high-level framework for conducting such an integrated effort, which has been developed in close coordination with experts from NASA, AFRL, and FAA, and a support group consisting of Raytheon Technologies, Boeing, and Lockheed Martin, representing the AM end-user community. This study's activity will provide an understanding of the current SOA related to in-situ monitoring of AM processes, non-destructive evaluation (NDE) techniques and will identify gaps and needs to address in a future investment strategies and project activity. The study will be executed through the GCD program office for the Enable Domain and will support the Advanced Materials, Structures, and Manufacturing portfolio. ​​

This is early/mid-stage (TRL 4) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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