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Real-time digital twin of vat-based 3D printing using in-situ ultrasonic monitoring.

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Title: Real-time digital twin of vat-based 3D printing using in-situ ultrasonic monitoring.
Authors: Jamshididana, Saman1 (AUTHOR), Bischoff, Adam1 (AUTHOR), Olarra, Andre1 (AUTHOR), Holmgren, Ben1 (AUTHOR), Roach, Devin J.1 (AUTHOR) devin.roach@oregonstate.edu
Source: Virtual & Physical Prototyping. Dec2025, Vol. 20 Issue 1, p1-13. 13p.
Subjects: Digital twin, Ultrasonic measurement, Real-time computing, Three-dimensional printing, Fault diagnosis, Mechanical behavior of materials
Abstract: Vat-based photopolymerization (VP) 3D printing processes, such as Digital Light Process (DLP), enable rapid fabrication of geometrically complex parts with tunable mechanical properties. However, measuring polymerisation and part quality in real-time is challenging due to complex platform configurations and opaque resin systems. This study introduces an in-situ ultrasonic testing (UT) system that tracks ultrasonic wave propagation through each printed layer to create a digital twin of the part with 0.2 mm geometric accuracy. Simultaneously, ultrasonic waves can be used to estimate material properties in real-time such as Young's modulus, detecting changes from 65 MPa to 1.4 GPa, depending on the resin system used. To validate these measurements, ex-situ tensile tests were performed, and the resulting Young's modulus values confirmed the UT estimates with a maximum mean absolute percentage error of 8.97%. Finally, the UT system could detect internal defects as small as 0.249mm2 during printing. This work uses a UT-based system to monitor VP 3D printing in real-time, providing geometric and material property insights to improve reliability for high-precision applications such as biomedical devices or microfluidic components. [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
Description
Abstract:Vat-based photopolymerization (VP) 3D printing processes, such as Digital Light Process (DLP), enable rapid fabrication of geometrically complex parts with tunable mechanical properties. However, measuring polymerisation and part quality in real-time is challenging due to complex platform configurations and opaque resin systems. This study introduces an in-situ ultrasonic testing (UT) system that tracks ultrasonic wave propagation through each printed layer to create a digital twin of the part with 0.2 mm geometric accuracy. Simultaneously, ultrasonic waves can be used to estimate material properties in real-time such as Young's modulus, detecting changes from 65 MPa to 1.4 GPa, depending on the resin system used. To validate these measurements, ex-situ tensile tests were performed, and the resulting Young's modulus values confirmed the UT estimates with a maximum mean absolute percentage error of 8.97%. Finally, the UT system could detect internal defects as small as 0.249mm2 during printing. This work uses a UT-based system to monitor VP 3D printing in real-time, providing geometric and material property insights to improve reliability for high-precision applications such as biomedical devices or microfluidic components. [ABSTRACT FROM AUTHOR]
ISSN:17452759
DOI:10.1080/17452759.2025.2592734