Additive Manufacturing: Main Reasons For Monitoring

In 2025, additive manufacturing (AM), commonly known as 3D printing, is no longer just a prototyping tool; it’s a cornerstone of production for industries like aerospace, medical, and automotive. By building parts layer by layer, AM enables complex geometries and lightweight designs that traditional machining can’t match. However, its true potential is unlocked when paired with advanced monitoring systems, which ensure precision, quality, and efficiency. 

The Rise of Additive Manufacturing in 2025

Additive manufacturing has evolved rapidly, with metal 3D printing and hybrid manufacturing (combining additive and subtractive processes) leading the charge. Technologies like Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS), and Binder Jetting are now used to produce end-use parts, from turbine blades to medical implants. According to a 2025 MarketsandMarkets report, the global AM market is projected to reach $28.5 billion by 2027, driven by demand for high-precision, customized components.

Yet, AM’s complexity—layer-by-layer construction, high temperatures, and sensitive materials—introduces challenges like defects, inconsistencies, and process variability. This is where real-time monitoring steps in, transforming AM into a reliable, production-ready technology.

How Monitoring Enhances Additive Manufacturing

Monitoring systems, powered by IoT sensors, AI analytics, and digital twins, track critical parameters during the AM process to ensure quality and efficiency. By integrating these systems, manufacturers can:

• Detect defects like porosity or cracks in real time.
• Optimize process parameters to reduce waste.
• Ensure repeatability for high-volume production.
• Minimize costly post-processing by catching issues early.

For example, in hybrid manufacturing, where AM builds a part and subtractive machining refines it, monitoring ensures seamless transitions between processes. Platforms like Siemens AM Monitor or GE Additive’s PrintRiser use sensors and AI to provide actionable insights, making AM viable for mission-critical applications.

Crucial Parameters to Monitor in Additive Manufacturing

To address the question, “What parameters are crucial to monitor in additive manufacturing?”, here’s a breakdown of the key factors that monitoring systems track to ensure quality and efficiency:

1. Laser/Power Source Parameters

   • Why it matters: In processes like SLM or DMLS, the laser’s power, speed, and focus determine material melting and fusion quality. Variations can cause incomplete melting or overheating, leading to defects.
   • What to monitor: Laser power (watts), scan speed (mm/s), beam focus, and energy density. For example, monitoring ensures consistent energy input to prevent porosity in metal parts.
   • Example: A 2025 case study from Renishaw showed that real-time laser power monitoring reduced defect rates in titanium parts by 15%.

2. Build Chamber Environment

   • Why it matters: The environment inside the build chamber affects material behavior. Oxygen levels, humidity, or temperature fluctuations can cause oxidation or thermal stress.
   • What to monitor: Oxygen concentration (ppm), chamber temperature (°C), humidity, and gas flow rate. Inert gases like argon or nitrogen must be maintained to prevent contamination.
   • Example: EOS systems use oxygen sensors to keep levels below 0.1%, ensuring defect-free prints for aerospace components.

3. Material Feed and Powder Quality

   • Why it matters: In powder-based AM, inconsistencies in powder flow or quality (e.g., particle size, moisture content) can lead to uneven layers or weak parts.
   • What to monitor: Powder flow rate, layer thickness (microns), particle size distribution, and powder bed density. Monitoring ensures uniform deposition and consistent part strength.
   • Example: Stratasys monitoring systems flagged irregular powder flow in a 2025 trial, preventing a failed print run.

4. Thermal Dynamics

   • Why it matters: Uneven heating or cooling causes thermal stresses, warping, or cracking, especially in metal AM.
   • What to monitor: Melt pool temperature, thermal gradients, and cooling rates. Infrared cameras and thermocouples track these in real time.
   • Example: Additive Industries uses thermal imaging to monitor melt pools, reducing warping in large-scale metal parts by 20%.

5. Part Geometry and Surface Quality

   • Why it matters: Dimensional accuracy and surface finish are critical for end-use parts, especially in precision industries like medical or aerospace.
   • What to monitor: Layer alignment, surface roughness, and geometric deviations using laser scanners or optical sensors.
   • Example: A 2025 GE Additive project used in-process scanning to correct layer misalignment, improving dimensional accuracy by 10%.

6. Machine Health and Vibration

   • Why it matters: Mechanical issues, like vibrations or misaligned components, can disrupt the printing process, affecting part quality.
   • What to monitor: Vibration levels, recoater blade alignment, and build platform stability.
   • Example: DMG MORI’s hybrid systems use vibration sensors to detect recoater issues, ensuring smooth powder spreading.

By monitoring these parameters, manufacturers can catch anomalies early, adjust processes on the fly, and ensure high-quality outputs. AI-driven analytics further enhance this by predicting potential failures based on historical and real-time data.

Real-World Impact in 2025

The integration of monitoring with AM is driving transformative results:

• Aerospace: A jet engine manufacturer uses SLM Solutions’ Melt Pool Monitoring to track laser performance during titanium alloy printing, reducing scrap rates by 25% and ensuring FAA-compliant parts.
• Medical: A dental implant producer employs 3D Systems’ in-process monitoring to verify layer thickness, achieving ±0.01 mm precision for biocompatible parts.
• Automotive: A car manufacturer combines AM with Mitsubishi Electric’s monitoring tools in hybrid systems, streamlining production of lightweight chassis components.

Challenges and Solutions

While monitoring enhances AM, challenges remain:

• Challenge: High costs of advanced monitoring systems.
  Solution: Start with modular sensors for critical parameters and scale up as ROI justifies investment.
• Challenge: Data overload from multiple sensors.
  Solution: AI platforms like Hexagon’s Nexus filter and prioritize data for actionable insights.
• Challenge: Lack of skilled technicians for AM monitoring.
  Solution: User-friendly interfaces and training programs, like those from Markforged, simplify adoption.

The Future of AM and Monitoring in 2025

In 2025, the AM-monitoring synergy is propelled by Industry 5.0 trends:

• Edge Computing: Processing sensor data locally for faster defect detection.
• Digital Twins: Simulating AM processes to optimize parameters before printing.
• Sustainability: Monitoring energy use and material waste to align with green manufacturing goals.

A 2025 Deloitte report predicts that 80% of AM adopters will integrate real-time monitoring by year-end, up from 55% in 2023, highlighting its critical role in scaling AM for production.

Why Manufacturers Should Care

The convergence of additive manufacturing and monitoring is a trend to watch in 2025 because it unlocks AM’s full potential for high-volume, high-precision production. By ensuring quality, reducing waste, and enabling complex designs, monitored AM gives manufacturers a competitive edge. For industries like aerospace and medical, where failure isn’t an option, monitoring is non-negotiable.

About MDCplus

Our key features are real-time machine monitoring for swift issue resolution, power consumption tracking to promote sustainability, computerized maintenance management to reduce downtime, and vibration diagnostics for predictive maintenance. MDCplus's solutions are tailored for diverse industries, including aerospace, automotive, precision machining, and heavy industry. By delivering actionable insights and fostering seamless integration, we empower manufacturers to boost Overall Equipment Effectiveness (OEE), reduce operational costs, and achieve sustainable growth along with future planning.