The goal of this work to mitigate flaws in metal parts produced from laser powder bed fusion (LPBF) additive manufacturing (AM) process. As a step towards this goal, the objective of this work is to predict the build quality of a part as it is being printed via deep learning of in-situ layer-wise images obtained from an optical camera instrumented in the LPBF machine. To realize this objective, we designed a set of thin-wall features (fins) from Titanium alloy (Ti-6Al-4V) material with varying length-to-thickness ratio. These thin-wall test parts were printed under three different build orientations and in-situ images of their top surface were acquired during the process. The parts were examined offline using X-ray computed tomography (XCT), and their build quality was quantified in terms of statistical features, such as the thickness and consistency of its edges. Subsequently, a deep learning convolutional neural network (CNN) was trained to predict the XCT-derived statistical quality features using the layer-wise optical images of the thin-wall part as inputs. The statistical correlation between CNN-based predictions and XCT-observed quality measurements exceeds 85%. This work has two outcomes consequential to the sustainability of additive manufacturing: (1) It provides practitioners with a guideline for building thin-wall features with minimal defects, and (2) the high correlation between the offline XCT measurements and in-situ sensor-based quality metrics substantiates the potential for applying deep learning approaches for the real-time prediction of build flaws in LPBF.
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Monitoring and control of biological additive manufacturing using machine learning
The goal of this work is the flaw-free, industrial-scale production of biological additive manufacturing of tissue constructs (Bio-AM). In pursuit of this goal, the objectives of this work in the context of extrusion-based Bio-AM of bone tissue constructs are twofold: (1) detect flaw formation using data from in-situ infrared thermocouple sensors; and (2) prevent flaw formation through preemptive process control. In realizing the first objective, data signatures acquired from in-situ sensors were analyzed using several machine learning approaches to ascertain critical quality metrics, such as print regime, strand width, strand height, and strand fusion severity. These quality metrics are intended to capture the process state at the basic 1D strand-level to the 2D layer-level. For this purpose, machine learning models were trained to classify and predict flaw formation. These models predicted print quality features with accuracy nearing 90%. In connection with the second objective, the previously trained machine learning models were used to preempt flaw formation by changing the process parameters (print velocity) during deposition—a form of feedforward control. With the feedforward process control, strand width heterogeneity was statistically significantly reduced, reducing the strand width difference between strand halves to less than 50 µm. Using this integrated process monitoring, detection, and control approach, we demonstrate consistent, repeatable production of Bio-AM constructs.
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- Award ID(s):
- 1739696
- NSF-PAR ID:
- 10401515
- Date Published:
- Journal Name:
- Journal of Intelligent Manufacturing
- ISSN:
- 0956-5515
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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We developed and applied a model-based feedforward control approach to reduce temperature-induced flaw formation in the laser powder bed fusion (LPBF) additive manufacturing process. The feedforward control is built upon three basic steps. First, the thermal history of the part is rapidly predicted using a mesh-free graph theory model. Second, thermal history metrics are extracted from the model to identify regions of heat buildup, symptomatic of flaw formation. Third, process parameters are changed layer-by-layer based on insights from the thermal model. This technique was validated with two identical build plates (Inconel 718). Parts on the first build plate were made under manufacturer recommended nominal process parameters. Parts on the second build plate were made with model optimized process parameters. Results were validated with in-situ infrared thermography, and materials characterization techniques. Parts produced under controlled processing exhibited superior geometric accuracy and resolution, finer grain size, and increased microhardness.more » « less
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Abstract Aerosol jet printing (AJP) is a direct-write additive manufacturing (AM) method, emerging as the process of choice for the fabrication of a broad spectrum of electronics, such as sensors, transistors, and optoelectronic devices. However, AJP is a highly complex process, prone to intrinsic gradual drifts. Consequently, real-time process monitoring and control in AJP is a bourgeoning need. The goal of this work is to establish an integrated, smart platform for in situ and real-time monitoring of the functional properties of AJ-printed electronics. In pursuit of this goal, the objective is to forward a multiple-input, single-output (MISO) intelligent learning model—based on sparse representation classification (SRC)—to estimate the functional properties (e.g., resistance) in situ as well as in real-time. The aim is to classify the resistance of printed electronic traces (lines) as a function of AJP process parameters and the trace morphology characteristics (e.g., line width, thickness, and cross-sectional area (CSA)). To realize this objective, line morphology is captured using a series of images, acquired: (i) in situ via an integrated high-resolution imaging system and (ii) in real-time via the AJP standard process monitor camera. Utilizing image processing algorithms developed in-house, a wide range of 2D and 3D morphology features are extracted, constituting the primary source of data for the training, validation, and testing of the SRC model. The four-point probe method (also known as Kelvin sensing) is used to measure the resistance of the deposited traces and as a result, to define a priori class labels. The results of this study exhibited that using the presented approach, the resistance (and potentially, other functional properties) of printed electronics can be estimated both in situ and in real-time with an accuracy of ≥ 90%.more » « less
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Abstract In droplet-on-demand liquid metal jetting (DoD-LMJ) additive manufacturing, complex physical interactions govern the droplet characteristics, such as size, velocity, and shape. These droplet characteristics, in turn, determine the functional quality of the printed parts. Hence, to ensure repeatable and reliable part quality it is necessary to monitor and control the droplet characteristics. Existing approaches for in-situ monitoring of droplet behavior in DoD-LMJ rely on high-speed imaging sensors. The resulting high volume of droplet images acquired is computationally demanding to analyze and hinders real-time control of the process. To overcome this challenge, the objective of this work is to use time series data acquired from an in-process millimeter-wave sensor for predicting the size, velocity, and shape characteristics of droplets in DoD-LMJ process. As opposed to high-speed imaging, this sensor produces data-efficient time series signatures that allows rapid, real-time process monitoring. We devise machine learning models that use the millimeter-wave sensor data to predict the droplet characteristics. Specifically, we developed multilayer perceptron-based non-linear autoregressive models to predict the size and velocity of droplets. Likewise, a supervised machine learning model was trained to classify the droplet shape using the frequency spectrum information contained in the millimeter-wave sensor signatures. High-speed imaging data served as ground truth for model training and validation. These models captured the droplet characteristics with a statistical fidelity exceeding 90%, and vastly outperformed conventional statistical modeling approaches. Thus, this work achieves a practically viable sensing approach for real-time quality monitoring of the DoD-LMJ process, in lieu of the existing data-intensive image-based techniques.
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Obeid, I. (Ed.)The Neural Engineering Data Consortium (NEDC) is developing the Temple University Digital Pathology Corpus (TUDP), an open source database of high-resolution images from scanned pathology samples [1], as part of its National Science Foundation-funded Major Research Instrumentation grant titled “MRI: High Performance Digital Pathology Using Big Data and Machine Learning” [2]. The long-term goal of this project is to release one million images. We have currently scanned over 100,000 images and are in the process of annotating breast tissue data for our first official corpus release, v1.0.0. This release contains 3,505 annotated images of breast tissue including 74 patients with cancerous diagnoses (out of a total of 296 patients). In this poster, we will present an analysis of this corpus and discuss the challenges we have faced in efficiently producing high quality annotations of breast tissue. It is well known that state of the art algorithms in machine learning require vast amounts of data. Fields such as speech recognition [3], image recognition [4] and text processing [5] are able to deliver impressive performance with complex deep learning models because they have developed large corpora to support training of extremely high-dimensional models (e.g., billions of parameters). Other fields that do not have access to such data resources must rely on techniques in which existing models can be adapted to new datasets [6]. A preliminary version of this breast corpus release was tested in a pilot study using a baseline machine learning system, ResNet18 [7], that leverages several open-source Python tools. The pilot corpus was divided into three sets: train, development, and evaluation. Portions of these slides were manually annotated [1] using the nine labels in Table 1 [8] to identify five to ten examples of pathological features on each slide. Not every pathological feature is annotated, meaning excluded areas can include focuses particular to these labels that are not used for training. A summary of the number of patches within each label is given in Table 2. To maintain a balanced training set, 1,000 patches of each label were used to train the machine learning model. Throughout all sets, only annotated patches were involved in model development. The performance of this model in identifying all the patches in the evaluation set can be seen in the confusion matrix of classification accuracy in Table 3. The highest performing labels were background, 97% correct identification, and artifact, 76% correct identification. A correlation exists between labels with more than 6,000 development patches and accurate performance on the evaluation set. Additionally, these results indicated a need to further refine the annotation of invasive ductal carcinoma (“indc”), inflammation (“infl”), nonneoplastic features (“nneo”), normal (“norm”) and suspicious (“susp”). This pilot experiment motivated changes to the corpus that will be discussed in detail in this poster presentation. To increase the accuracy of the machine learning model, we modified how we addressed underperforming labels. One common source of error arose with how non-background labels were converted into patches. Large areas of background within other labels were isolated within a patch resulting in connective tissue misrepresenting a non-background label. In response, the annotation overlay margins were revised to exclude benign connective tissue in non-background labels. Corresponding patient reports and supporting immunohistochemical stains further guided annotation reviews. The microscopic diagnoses given by the primary pathologist in these reports detail the pathological findings within each tissue site, but not within each specific slide. The microscopic diagnoses informed revisions specifically targeting annotated regions classified as cancerous, ensuring that the labels “indc” and “dcis” were used only in situations where a micropathologist diagnosed it as such. Further differentiation of cancerous and precancerous labels, as well as the location of their focus on a slide, could be accomplished with supplemental immunohistochemically (IHC) stained slides. When distinguishing whether a focus is a nonneoplastic feature versus a cancerous growth, pathologists employ antigen targeting stains to the tissue in question to confirm the diagnosis. For example, a nonneoplastic feature of usual ductal hyperplasia will display diffuse staining for cytokeratin 5 (CK5) and no diffuse staining for estrogen receptor (ER), while a cancerous growth of ductal carcinoma in situ will have negative or focally positive staining for CK5 and diffuse staining for ER [9]. Many tissue samples contain cancerous and non-cancerous features with morphological overlaps that cause variability between annotators. The informative fields IHC slides provide could play an integral role in machine model pathology diagnostics. Following the revisions made on all the annotations, a second experiment was run using ResNet18. Compared to the pilot study, an increase of model prediction accuracy was seen for the labels indc, infl, nneo, norm, and null. This increase is correlated with an increase in annotated area and annotation accuracy. Model performance in identifying the suspicious label decreased by 25% due to the decrease of 57% in the total annotated area described by this label. A summary of the model performance is given in Table 4, which shows the new prediction accuracy and the absolute change in error rate compared to Table 3. The breast tissue subset we are developing includes 3,505 annotated breast pathology slides from 296 patients. The average size of a scanned SVS file is 363 MB. The annotations are stored in an XML format. A CSV version of the annotation file is also available which provides a flat, or simple, annotation that is easy for machine learning researchers to access and interface to their systems. Each patient is identified by an anonymized medical reference number. Within each patient’s directory, one or more sessions are identified, also anonymized to the first of the month in which the sample was taken. These sessions are broken into groupings of tissue taken on that date (in this case, breast tissue). A deidentified patient report stored as a flat text file is also available. Within these slides there are a total of 16,971 total annotated regions with an average of 4.84 annotations per slide. Among those annotations, 8,035 are non-cancerous (normal, background, null, and artifact,) 6,222 are carcinogenic signs (inflammation, nonneoplastic and suspicious,) and 2,714 are cancerous labels (ductal carcinoma in situ and invasive ductal carcinoma in situ.) The individual patients are split up into three sets: train, development, and evaluation. Of the 74 cancerous patients, 20 were allotted for both the development and evaluation sets, while the remain 34 were allotted for train. The remaining 222 patients were split up to preserve the overall distribution of labels within the corpus. This was done in hope of creating control sets for comparable studies. Overall, the development and evaluation sets each have 80 patients, while the training set has 136 patients. In a related component of this project, slides from the Fox Chase Cancer Center (FCCC) Biosample Repository (https://www.foxchase.org/research/facilities/genetic-research-facilities/biosample-repository -facility) are being digitized in addition to slides provided by Temple University Hospital. This data includes 18 different types of tissue including approximately 38.5% urinary tissue and 16.5% gynecological tissue. These slides and the metadata provided with them are already anonymized and include diagnoses in a spreadsheet with sample and patient ID. We plan to release over 13,000 unannotated slides from the FCCC Corpus simultaneously with v1.0.0 of TUDP. Details of this release will also be discussed in this poster. Few digitally annotated databases of pathology samples like TUDP exist due to the extensive data collection and processing required. The breast corpus subset should be released by November 2021. By December 2021 we should also release the unannotated FCCC data. We are currently annotating urinary tract data as well. We expect to release about 5,600 processed TUH slides in this subset. We have an additional 53,000 unprocessed TUH slides digitized. Corpora of this size will stimulate the development of a new generation of deep learning technology. In clinical settings where resources are limited, an assistive diagnoses model could support pathologists’ workload and even help prioritize suspected cancerous cases. ACKNOWLEDGMENTS This material is supported by the National Science Foundation under grants nos. CNS-1726188 and 1925494. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the National Science Foundation. REFERENCES [1] N. Shawki et al., “The Temple University Digital Pathology Corpus,” in Signal Processing in Medicine and Biology: Emerging Trends in Research and Applications, 1st ed., I. Obeid, I. Selesnick, and J. Picone, Eds. New York City, New York, USA: Springer, 2020, pp. 67 104. https://www.springer.com/gp/book/9783030368432. [2] J. Picone, T. Farkas, I. Obeid, and Y. Persidsky, “MRI: High Performance Digital Pathology Using Big Data and Machine Learning.” Major Research Instrumentation (MRI), Division of Computer and Network Systems, Award No. 1726188, January 1, 2018 – December 31, 2021. https://www. isip.piconepress.com/projects/nsf_dpath/. [3] A. Gulati et al., “Conformer: Convolution-augmented Transformer for Speech Recognition,” in Proceedings of the Annual Conference of the International Speech Communication Association (INTERSPEECH), 2020, pp. 5036-5040. https://doi.org/10.21437/interspeech.2020-3015. [4] C.-J. Wu et al., “Machine Learning at Facebook: Understanding Inference at the Edge,” in Proceedings of the IEEE International Symposium on High Performance Computer Architecture (HPCA), 2019, pp. 331–344. https://ieeexplore.ieee.org/document/8675201. [5] I. Caswell and B. Liang, “Recent Advances in Google Translate,” Google AI Blog: The latest from Google Research, 2020. [Online]. Available: https://ai.googleblog.com/2020/06/recent-advances-in-google-translate.html. [Accessed: 01-Aug-2021]. [6] V. Khalkhali, N. Shawki, V. Shah, M. Golmohammadi, I. Obeid, and J. Picone, “Low Latency Real-Time Seizure Detection Using Transfer Deep Learning,” in Proceedings of the IEEE Signal Processing in Medicine and Biology Symposium (SPMB), 2021, pp. 1 7. https://www.isip. piconepress.com/publications/conference_proceedings/2021/ieee_spmb/eeg_transfer_learning/. [7] J. Picone, T. Farkas, I. Obeid, and Y. Persidsky, “MRI: High Performance Digital Pathology Using Big Data and Machine Learning,” Philadelphia, Pennsylvania, USA, 2020. https://www.isip.piconepress.com/publications/reports/2020/nsf/mri_dpath/. [8] I. Hunt, S. Husain, J. Simons, I. Obeid, and J. Picone, “Recent Advances in the Temple University Digital Pathology Corpus,” in Proceedings of the IEEE Signal Processing in Medicine and Biology Symposium (SPMB), 2019, pp. 1–4. https://ieeexplore.ieee.org/document/9037859. [9] A. P. Martinez, C. Cohen, K. Z. Hanley, and X. (Bill) Li, “Estrogen Receptor and Cytokeratin 5 Are Reliable Markers to Separate Usual Ductal Hyperplasia From Atypical Ductal Hyperplasia and Low-Grade Ductal Carcinoma In Situ,” Arch. Pathol. Lab. Med., vol. 140, no. 7, pp. 686–689, Apr. 2016. https://doi.org/10.5858/arpa.2015-0238-OA.more » « less
- Free Publicly Accessible Full Text
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Accepted Manuscript1.0
- Journal Article:
- https://doi.org/10.1007/s10845-023-02092-6
