Recent Advances in Sensor Fusion Monitoring and Control Strategies in Laser Powder Bed Fusion: A Review

Abstract

Laser Powder Bed Fusion (LPBF) has emerged as a leading additive manufacturing (AM) process for producing complex metal components. Despite its advantages, the inherent LPBF process complexity leads to challenges in achieving consistent quality and repeatability. To address these concerns, recent research efforts have focused on sensor fusion techniques for process monitoring, and on developing more elaborate control strategies. Sensor fusion combines information from multiple in situ sensors to provide more comprehensive insights into process characteristics such as melt pool behavior, spatter formation, and layer integrity. By leveraging multimodal data sources, sensor fusion enhances the detection and diagnosis of process anomalies in real-time. Closed-loop control systems may utilize this fused information to adjust key process parameters–such as laser power, focal depth, and scanning speed–to mitigate defect formation during the build process. This review focuses on the current state-of-the-art in sensor fusion monitoring and control strategies for LPBF. In terms of sensor fusion, recent advances extend beyond CNN-based approaches to include graph-based, attention, and transformer architectures. Among these, feature-level integration has shown the best balance between accuracy and computational cost. However, the limited volume of available experimental data, class-imbalance issues and lack of standardization still hinder further progress. In terms of control, a trend away from purely physics-based towards Machine Learning (ML)-assisted and hybrid strategies can be observed. These strategies show promise for more adaptive and effective quality enhancement. The biggest challenge is the broader validation on more complex part geometries and under realistic conditions using commercial LPBF systems.

Topics & Concepts