A PhD student in Mechanical Engineering at The University of Western Australia is pioneering a safer and more cost-effective future through the utilization of a cutting-edge 3D metal printer. Addam Edwards, while completing his Master of Professional Engineering, embarked on a project at TechWorks under the Woodside FutureLab at UWA. The lab had recently acquired a state-of-the-art laser powder bed fusion printer, but the defect detection monitoring software was a mystery to many.
Edwards took on the challenge of unraveling the intricacies of the defect detection software and presenting his findings to stakeholders at Woodside Energy. This opportunity led him to a decision that would shape his future – pursuing a PhD within the 3D Additive Manufacturing program. This innovative manufacturing process enables the creation of intricate metallic shapes vital for industries like biomedicine and aerospace.
This technology is poised to revolutionize manufacturing processes, especially in industries requiring rapid production of complex components. Aerospace, for instance, stands to benefit from lightweight components for aircraft and spacecraft, enhancing weight efficiency in design. The future implications of this technology extend to potential applications in space colonization, where additive manufacturing could play a pivotal role.
Despite the longstanding presence of 3D printing, the challenge of eliminating defects in manufactured parts persists. Edwards highlighted the critical need for thorough testing to ensure the reliability and safety of engineered components. Current testing methods, such as CT scans and ultrasound, are time-consuming and costly, underscoring the importance of developing more efficient defect detection techniques.
Collaborating with experts in the field, including Professor Tim Sercombe and Associate Professor Du Huynh, Edwards is spearheading a machine learning approach to classify parts for defects. The project’s focus on developing algorithms using raw data aims to enhance defect detection accuracy, ultimately saving time and costs while prioritizing safety.
Woodside Energy’s Chief Technology Materials Engineer, Mike Brameld, and Additive Manufacturing Lead, Dr. Lee Djumas, provide invaluable industry guidance to ensure the project remains relevant and impactful. The evolution towards a machine learning-based defect detection system signifies a significant advancement in additive manufacturing technology.
Edwards’ dedication to his research underscores the potential benefits beyond cost-effectiveness, emphasizing the paramount importance of ensuring safety in manufacturing processes. As he continues to push boundaries and expand human capabilities through his work, the impact of his research extends far beyond the realms of academia.