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On-Demand Webinar

In-Situ Monitoring and Control in PBF Process

July 29, 2021

About the Webinar:

Metals additive manufacturing (AM) has been embraced by aerospace, defense, and medical industries for production and repair of high-value components and constitutes a market size of several billion dollars. In particular, laser powder bed fusion (PBF) additive manufacturing, owing to its ability to produce complex, metal components, is the subject of significant research, development, and commercialization efforts. Many such efforts are focused on ensuring reliability, repeatability, and accelerating qualifications of PBFAM processes, often with an emphasis on process mapping, in-situ process monitoring, or post-build materials characterization.

In this webinar, accepted and emerging methods for in-situ monitoring and control in PBF process will be detailed. Sensing and control efforts will be framed within the context of holistic quality assurance, including pre-process, in-process, and post-process monitoring. Both high-fidelity (e.g., high-speed visible and infrared imaging) and low-fidelity (e.g., photodiode, acoustic) methods, applied to laboratory- and production-scale systems will be critically examined. Requirements for data acquisition systems, with a focus on data synchronization and registration will be emphasized as will the role of robust data analysis (e.g., statistical methods and machine learning).

Learning Outcomes:

After completing this webinar, attendees will achieve the following:

  • Identify primary modalities for in-situ monitoring and control in powder bed fusion additive manufacturing.
  • Appreciate the roles of pre-process, in-process, and post-process monitoring in ensuring part and build quality.
  • Become aware of the advantages and limitations of available high-fidelity and low-fidelity sensing approaches.
  • Recognize the need for robust statistical methods and machine learning in conjunction with sensing.
  • Discern between the hype and reality of available in-situ monitoring and control systems.

Who Should Attend:

Research Engineers, AM Process Engineers, AM Design Engineers, Application Engineers


Dr. Abdalla R Nassar is an Associate Research Professor and a department head within the Materials Science Division of the Applied Research Laboratory (ARL) at Penn State. Dr. Nassar also holds Graduate Faculty appointments with the Engineering Science and Mechanics Department, the Additive Manufacturing & Design Graduate Program, and the Department of Mechanical Engineering at Penn State. He has worked in the field laser processing of metals for over a decade and specifically focused on laser-based AM of metals over the past nine years. In 2020, Dr. Nassar was awarded the International Outstanding Young Researcher in Freeform and Additive Manufacturing Award for his contributions towards in-situ monitoring and control of additive manufacturing processes, development of novel processing methods, and elucidating interactions in directed energy deposition and powder bed fusion additive manufacturing. His work has also led to over seven patent filings along with several dozen peer-reviewed publications.

AM CoE by the Numbers

With decades of experience in additive manufacturing, our team of experts is integral to our work. With team members located throughout the Americas, Europe, and Asia, the AM CoE is able to provide agile support for global initiatives.


combined in-kind, government agency, and ASTM investment
projects initiated that will address AM standardization gaps

How can I participate?

  • Support through Research and Development

    Through the AM CoE, research priorities are identified by the top minds in the field and are matched from the start to the standards that need to be generated to ensure the resulting AM technology’s success.

  • Consortium for Materials Data and Standardization

    Consortia for Materials Data & Standardization (CMDS) enables companies of all sizes from across the entire additive manufacturing ecosystem to collaborate on standardizing the best practices for materials data generation.

  • Explore On-Demand Webinars

    The webinar series provides guidance sessions on multiple and diverse topics in AM Design, Fabrication, Post-processing, Mechanical testing, Non-destructive evaluation, Applications, and Qualification and Certification.

  • Education & Workforce Development

    Comprehensive program that educates and trains the additive manufacturing workforce at all levels, while continually incorporating new advances to respond to industry needs and leverage standardization, certification, and AM CoE partner expertise.