OPTIMA (OPTimization and In-process Monitoring for Additive-manufacturing)

Interactive Aptitude LLC, in collaboration with Savannah River National Laboratory (SRNL), proposes to develop the OPTIMA (OPTimization and In-process Monitoring for Additive-manufacturing) system to address the critical need for improved quality assurance and process control in additive manufacturing (AM). OPTIMA is a modular, scalable solution that leverages advanced sensors and machine learning algorithms to identify potential issues during 3D printing and dynamically adjust parameters to maintain optimal quality. The proposed system integrates a comprehensive suite of sensors, including power monitors, motor current sensors, accelerometers, thermocouples, and lidar, to capture key process parameters. Sensor data is processed in real-time using advanced algorithms to correlate with part quality and material properties. Machine learning models are trained to predict print quality and recommend optimal parameters. OPTIMA is designed as an easy-to-install kit compatible with a wide range of commercial FDM 3D printers. In Phase I, a prototype tailored to a specific Army-relevant polymer will be developed. The effectiveness will be demonstrated by comparing material properties of parts printed using OPTIMA's optimized parameters against stock machine settings. A plan will be outlined for further modularization in preparation for Phase II, enhancing the commercial viability of this innovative technology.