Imagine you could 3D-print metal parts for engines or medical implants — but every time you print, the piece comes out slightly warped, rough, or with tiny hidden holes inside. That's the reality manufacturers face today with metal additive manufacturing. PAM² brought together 13 partners across Europe to fix the precision problem: they built optical inspection tools that watch the printing process in real time, catching defects as they form. They also trained a new generation of engineers who understand the entire production chain from design to final quality check.
Metal 3D printing promises unlimited design freedom and local, material-efficient production — but manufacturers constantly battle shrinkage, built-in stresses, surface roughness, and hidden porosity that make parts unreliable. Current quality checks happen after printing is finished, meaning a defective part wastes the full build time and expensive metal powder. Companies also struggle to find engineers who understand the entire additive manufacturing chain from design through quality assurance.
The project delivered a characterized prototype hybrid optical instrument that combines a vision system with a focus variation system to detect defects and measure their surface topography during the AM process itself. Across 12 deliverables, the consortium also produced improved design layout rules, modelling tools for first-time-right processing, and optimized post-processing methods.
If you are an aerospace parts manufacturer dealing with rejected 3D-printed components due to hidden porosity or dimensional inaccuracy — this project developed a hybrid optical inspection system that combines vision and focus variation to detect defects during printing, not after. With 7 industry partners validating the approach, the tools target first-time-right processing to cut your scrap rate.
If you are a medical device company struggling with post-processing costs and quality assurance for patient-specific metal implants — PAM² developed in-process measurement instruments that catch surface roughness and defect issues while the part is still being built. This means fewer rejected implants and faster time to market for custom prosthetics.
If you are a tooling company where shrinkage and built-in stresses ruin the precision of your 3D-printed mold inserts — this project produced improved design rules and modelling tools aimed at first-time-right processing. The prototype optical instrument developed with UNOTT and ALICON can measure defect topography in-process, reducing your need for costly rework.
The project does not publish pricing for the prototype hybrid optical instrument. Since it was developed as a research prototype by UNOTT and ALICON, commercialization terms would need to be negotiated directly with these partners. Based on available project data, expect research-grade pricing rather than off-the-shelf product costs.
The prototype was characterized for in-process use, combining vision and focus variation measurement in a single hybrid system. Based on available project data, it was validated in lab/research settings. Scaling to a multi-machine production floor would likely require further engineering and integration work.
PAM² was funded under MSCA-ITN-ETN, a training network. IP from the hybrid optical instrument would be shared between the developing partners (UNOTT and ALICON) under the consortium agreement. Licensing discussions would go through KU Leuven as coordinator or directly with the technology developers.
The project addressed additive manufacturing broadly, with expertise spanning laser physics and optical sensors. Based on the objective, the focus was on powder-bed and similar metal AM processes where shrinkage, built-in stresses, roughness, and porosity are key challenges. Compatibility with specific machine brands would need to be verified with the consortium.
Most current inspection happens after printing is complete, meaning defective parts waste full build time and material. PAM²'s hybrid system measures defects and their topography during the process itself, enabling real-time quality control. This in-situ approach targets process stability rather than post-mortem rejection.
The hybrid optical instrument reached prototype stage and was characterized in a research environment. With the project closed in 2020, some results may have advanced further through the 7 industry partners. Based on available project data, additional development would be needed for plug-and-play industrial deployment.
PAM² assembled a strong industry-academia mix with 13 partners across 7 countries (AT, BE, DE, DK, IT, NL, UK), where 7 out of 13 partners — a 54% industry ratio — came from the private sector. This is unusually high for a training network and signals that the research was shaped by real manufacturing needs rather than pure academic curiosity. KU Leuven in Belgium coordinated, a university with deep expertise in precision engineering. The 6 university partners provided research capability while the 7 industry partners ensured practical relevance. No SMEs were listed among the partners, suggesting the industry side consisted of established companies with existing AM operations. For a business looking to adopt these results, the strong industry participation means the tools and methods were tested against real production challenges.
The coordinator is KU Leuven (Belgium). For the hybrid optical instrument specifically, contact the developers at University of Nottingham (UNOTT) and ALICON.
Want to connect with PAM² researchers about in-process quality control for your metal AM line? SciTransfer can arrange a targeted introduction to the right consortium partner for your specific use case.
