Real-time digital twin of vat-based 3D printing using in-situ ultrasonic monitoring.
Saved in:
| 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] |
| Copyright of Virtual & Physical Prototyping is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
| Database: | Engineering Source |
| FullText | Text: Availability: 0 |
|---|---|
| Header | DbId: egs DbLabel: Engineering Source An: 193165861 AccessLevel: 6 PubType: Academic Journal PubTypeId: academicJournal PreciseRelevancyScore: 0 |
| IllustrationInfo | |
| Items | – Name: Title Label: Title Group: Ti Data: Real-time digital twin of vat-based 3D printing using in-situ ultrasonic monitoring. – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Jamshididana%2C+Saman%22">Jamshididana, Saman</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Bischoff%2C+Adam%22">Bischoff, Adam</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Olarra%2C+Andre%22">Olarra, Andre</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Holmgren%2C+Ben%22">Holmgren, Ben</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Roach%2C+Devin+J%2E%22">Roach, Devin J.</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> devin.roach@oregonstate.edu</i> – Name: TitleSource Label: Source Group: Src Data: <searchLink fieldCode="JN" term="%22Virtual+%26+Physical+Prototyping%22">Virtual & Physical Prototyping</searchLink>. Dec2025, Vol. 20 Issue 1, p1-13. 13p. – Name: Subject Label: Subjects Group: Su Data: <searchLink fieldCode="DE" term="%22Digital+twin%22">Digital twin</searchLink><br /><searchLink fieldCode="DE" term="%22Ultrasonic+measurement%22">Ultrasonic measurement</searchLink><br /><searchLink fieldCode="DE" term="%22Real-time+computing%22">Real-time computing</searchLink><br /><searchLink fieldCode="DE" term="%22Three-dimensional+printing%22">Three-dimensional printing</searchLink><br /><searchLink fieldCode="DE" term="%22Fault+diagnosis%22">Fault diagnosis</searchLink><br /><searchLink fieldCode="DE" term="%22Mechanical+behavior+of+materials%22">Mechanical behavior of materials</searchLink> – Name: Abstract Label: Abstract Group: Ab Data: 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] – Name: AbstractSuppliedCopyright Label: Group: Ab Data: <i>Copyright of Virtual & Physical Prototyping is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.) |
| PLink | https://search.ebscohost.com/login.aspx?direct=true&site=eds-live&db=egs&AN=193165861 |
| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.1080/17452759.2025.2592734 Languages: – Code: eng Text: English PhysicalDescription: Pagination: PageCount: 13 StartPage: 1 Subjects: – SubjectFull: Digital twin Type: general – SubjectFull: Ultrasonic measurement Type: general – SubjectFull: Real-time computing Type: general – SubjectFull: Three-dimensional printing Type: general – SubjectFull: Fault diagnosis Type: general – SubjectFull: Mechanical behavior of materials Type: general Titles: – TitleFull: Real-time digital twin of vat-based 3D printing using in-situ ultrasonic monitoring. Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Jamshididana, Saman – PersonEntity: Name: NameFull: Bischoff, Adam – PersonEntity: Name: NameFull: Olarra, Andre – PersonEntity: Name: NameFull: Holmgren, Ben – PersonEntity: Name: NameFull: Roach, Devin J. IsPartOfRelationships: – BibEntity: Dates: – D: 01 M: 12 Text: Dec2025 Type: published Y: 2025 Identifiers: – Type: issn-print Value: 17452759 Numbering: – Type: volume Value: 20 – Type: issue Value: 1 Titles: – TitleFull: Virtual & Physical Prototyping Type: main |
| ResultId | 1 |
