Virginia Tech's AI Revolutionizes Wire-Arc Additive Manufacturing
Researchers at Virginia Tech are harnessing AI to revolutionize wire-arc additive manufacturing. The team aims to monitor and correct flaws in real-time, a significant leap from traditional methods that often discovered defects post-production.
The Grado Department of Industrial and Systems Engineering is at the forefront of this innovation. They're applying systems thinking to make manufacturing faster, smarter, and more efficient. The Learning Factory, equipped with industry-standard additive manufacturing equipment, provides hands-on training for students, fostering the next generation of experts in this field.
The Virginia Tech Made: Center for Advanced Manufacturing is cultivating cross-campus collaborations and partnerships to advance manufacturing technologies. One such breakthrough involves using AI algorithms to predict defects with about 90% certainty. These algorithms are trained to recognize defects in real-time by studying the 'melt pool' of hot metal during printing. This method can detect and fix defects as parts are being built, ensuring they're ready to use once the print is completed. Previously, flaws in parts were often discovered only after they were finished, wasting labor and forcing manufacturers to scrap parts.
This timely breakthrough addresses the Navy's urgent need for faster and more reliable production to maintain its fleet. Additive manufacturing, including wire-arc printing, offers a faster way to produce complex components compared to traditional methods. With real-time defect detection and correction, manufacturers can now ensure the quality and efficiency of their products, opening up new possibilities in various industries.
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