Technology
AMiRIS is an integrated solution that leverages a patented combination of near infrared sensors for real-time data acquisition for immediate analysis and feedback, with modern browser-based software for data visualisation and advanced insights.
The AMiRIS system consists of three core components:
AMiRIS Sensor
An array of 8 high‑resolution hybrid long exposure near‑infrared (NIR) sensors capturing meltpool emissions, morphology, and topology adaptable to any L-PBF system.
AMiRIS Analytics
Advanced computer vision and AI models perform real‑time detection of porosity, thermal deviation, spatter, distortion, and risk signatures.
AMiRIS Platform
Browser‑based visualisation, control, alerting, and traceable build reporting unify sensor outputs and analytics into actionable workflows for qualification and continuous improvement.
AMiRIS is Industry Relevant Sensing
The AMiRIS sensor suite captures high-resolution meltpool data across three complementary modalities, providing a holistic view of the meltpool dynamics essential for accurate defect detection and process monitoring in metal additive manufacturing. The resulting data streams include:
Meltpool Emissions
Quantifiable energy emissions show the thermal behavior of the meltpool.
Meltpool Morphology
The meltpool size, shape, and dynamics can be used to identify lack‑of‑fusion, keyholing, and drift from qualified parameter windows.
3D Topology
Using the high resolution texture map, geometry deviations, recoater interactions, and part anomalies are detected.
High Resolution AMiRIS Sensor Data
At its core, highly detailed meltpool data is essential for accurate defect detection and process monitoring in metal additive manufacturing. The meltpool contains thermal signatures, morphological features, and dynamic behaviors that directly correlate with part quality and integrity. AMiRIS captures this data with high spatial resolution in large contiguous "layer" images, enabling detailed analysis of meltpool characteristics.
An exemplar case showing consistent emission profile and uniform meltpool morphology within validated parameter envelope. Consistent meltpool intensity, scan vector width and spacing with few discontinuities. 2D data shown in false colour (turbo colormap).
Elevated localized intensity, discontinuous meltpool shape, and irregular topology showing high levels of melt pool ejecta (spatter). 2D data shown in false colour (turbo colormap).
Hardware Architecture
The patented AMiRIS approach uses matched pairs of NIR cameras with a long exposure technique, working in tandem to produce very high resolution melt pool imagery in a continuous capture mode without any gaps in coverage. Multiple camera modules are joined together, typically eight, into an array to increase the resolution and coverage of the system.
The NIR modules are capturing in the 720-850nm spectral range, which is ideal for meltpool monitoring as it balances sensitivity to thermal emissions while minimising interference from ambient sources. The added benefit of using NIR is that the sensors can be positioned outside of the build chamber, protecting them from harsh environmental conditions. This allows for fast and effective integration with existing metal AM systems without requiring significant modifications to the build chamber.
The AMiRIS system employs an automated calibration process to align the captured data to the machine coordinate system, allowing each pixel in the captured images to be mapped directly to a physical location on the build plate. This spatial mapping is critical for correlating meltpool data with specific regions of the part being manufacturing, enabling precise defect localisation and part-wise quality assurance.
Hardware Specifications
| Feature | Value |
|---|---|
| Spatial Resolution | 30 - 40 µm |
| Spectral Sensitivity | 720 - 850 nm |
| Capture Frequency | 0.25 - 2 Hz |
| Layer Duration | 2 - ∞ Seconds |
| Coverage | 100% |
| Raw Data Generation | ~30 MB/cm³ |
Values may vary by machine configuration.
Contact us for your machine specifications.
AMiRIS Analytics
At the heart of the AMiRIS platform is an in-house-developed deep learning engine. This system provides a deep understanding of material deposition and defect formation by moving beyond 2D snapshots to create a 3D model of the build's health. Our method begins with 2D semantic segmentation. As each layer is manufactured, our algorithms analyse the high-resolution sensor data, segmenting the image to identify localised thermal variances and anomalous textures. The textures of concern are the initial fingerprints of potential flaws.
Near Real-Time Detection
Layerwise analytic routines run at the completion of each layer, returning defect detections in seconds.
Defect Detections
Meltpool texture and emission density is used to forecast porosity and other defect types as they occur.
Multi-layer Context
A continuous local history of meltpool behavior enables tracking of defect formation and healing over multiple layers.
Each identified anomaly is compared against a proprietary library of known defect signatures. This library, trained on millions of real-world data points, allows AMiRIS to classify and assess the potential severity of a defect in real-time. The power of our analytics lies in 3D context mapping. AMiRIS doesn't just flag a 2D anomaly and move on. It actively tracks the behavior of that anomaly across successive layers, monitoring its progression in the z-direction. This 3D tracking allows our system to distinguish between a one-off phenomenon, that is remelted or repaired in subsequent layers, or a real issue of concern, which persists or grows over time.
By understanding the 2D and 3D context of every potential flaw, AMiRIS provides clear insights. This approach filters out the noise of single-layer events to deliver three-dimensional quality assurance from the ground up.
Defect types detected by the AMiRIS analytics suite include:
Porosity
Lack of fusion defects
Delamination
Support failures & layer separation
Thermal Anomalies
Hot & cold spot detection
Spatter Generation
Melt pool ejection events
Spatter Inclusions
Reconsolidated particles
Distortion
Geometric warping & deviation
Recoater Defects
Streaks, short feeds & damage
Custom Definitions
Customised for your application
AMiRIS Platform: Your Data, Made Actionable
The AMiRIS Platform is a modern, intuitive, and scalable web application that transforms your in-process data into clear, actionable intelligence. It serves as a single dashboard for all your AM machines, regardless of brand. Accessible from anywhere on your desktop or phone, it provides a complete suite of tools to review, analyse, and report on every aspect of your build — from a high-level overview down to a single voxel.
Powerful Visualisation & Statistics
Easily investigate your build from any angle. The platform's interactive viewports give you the flexibility to see a high-level 3D model or dive into
the raw sensor data of a single layer or voxel. Toggle defect overlays directly onto 2D and 3D views to pinpoint exactly where an issue
is forming. Go beyond visualisation by correlating this data with detailed part and build statistics, from layer-by-layer intensity trends to comprehensive defect summaries.
Unified Dashboard
Consolidated multi‑machine view with live layer progress, alert feed, and quick drill‑down to anomaly timesteps.
Actionable Alerts
Configurable thresholds reduce noise; contextual recommendations accelerate operator decisions.
Qualification Reports
Exportable build certificates with layer summaries, and detected risk signatures.
Detailed Visualisations
Identify defects at a glance, or dive into detail to understand the root cause.
Automated Reporting & Advanced Analysis Tools
The platform makes it easy to translate complex build data into shareable reports and extract detailed analytics using a flexible set of tools:
Rapid Go/No-Go Gauge
The similarity module compares any part against your reference design to generate a quantitative similarity score, enabling fast and objective pass/fail decisions.
CT Data Validation
Upload, align, and directly compare your in-process AMiRIS data against post-build CT scans in a unified 3D environment.
Part Grading
Define your own quality standards with Defect Profiles. Automatically grade parts based on your specific thresholds for defect type, size, and persistence across layers.
PDF Reports
Generate comprehensive PDF reports for builds and individual parts, complete with 3D defect imagery, summaries, and your custom grades.
Location Based Heatmaps
Identify systemic machine or process faults by visualizing defect trends across several builds on a machine.
Statistical Reports
Analyze build stability by generating trendlines and statistical reports for layer intensity.
From real-time inspection to final validation, the AMiRIS Platform provides the tools you need to take full control of your additive manufacturing quality.
A Few Examples of the AMiRIS Platform
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