As metal 3D printing matures, so does the demand for real-time quality assurance. One of the most transformative technologies in this space is optical tomography, a non-invasive method that captures light emissions during laser melting to build a layer-by-layer map of the print process. This high-speed imaging enables engineers to detect porosity, lack of fusion, and other defects as they form, not just after the part is finished.
The concept is simple but powerful: as each layer is fused by the laser, the emitted light provides a fingerprint of what’s happening inside the melt pool. Photodiodes and cameras capture this light intensity and use it to create spatial maps that flag anomalies. These maps reveal where the melt pool is unstable, where gas entrapment is likely, or where the energy density is insufficient, all of which can cause defects if left unaddressed.
What makes optical tomography especially valuable is its ability to drive closed-loop feedback. If an anomaly is detected mid-build, the printer can automatically adjust scan speed, laser power, or pathing parameters in response. This on-the-fly correction reduces part scrap, minimizes downstream inspection costs, and improves first-pass yield.
In highly regulated industries like aerospace or medical devices, this level of control is essential. It reduces the reliance on destructive testing and enables full traceability for every build. As additive manufacturing scales into production, optical tomography isn’t just a quality tool, it’s a production enabler.