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Sensors (Basel). 2020 Jan 8;20(2). pii: E360. doi: 10.3390/s20020360.

Smart Build-Plate for Metal Additive Manufacturing Processes.

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Fabrisonic LLC, Columbus, OH 43221, USA.
Luna Innovations Inc., Blacksburg, VA 24060, USA.
Edison Welding Institute (EWI), Columbus, OH 43221, USA.


This paper discusses the development, processing steps, and evaluation of a smart build-plate or baseplate tool for metal additive manufacturing technologies. This tool uses an embedded high-definition fiber optic sensing fiber to measure strain states from temperature and residual stress within the build-plate for monitoring purposes. Monitoring entails quality tracking for consistency along with identifying defect formation and growth, i.e., delamination or crack events near the build-plate surface. An aluminum alloy 6061 build-plate was manufactured using ultrasonic additive manufacturing due to the process' low formation temperature and capability of embedding fiber optic sensing fiber without damage. Laser-powder bed fusion (L-PBF) was then used to print problematic geometries onto the build-plate using AlSi10Mg for evaluation purposes. The tool identified heat generation, delamination onset, and delamination growth of the printed L-PBF parts.


HD-FOS; L-PBF; UAM; additive manufacturing; embedded sensing; fiber optic

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