Test setup in university laboratory with 2 IDS industrial cameras

IDS case study: Layer by Layer

15/1/2026

High-precision process monitoring and error detection in additive manufacturing

In additive manufacturing, every detail counts when it comes to the quality of the final product – and in powder bed fusion using a laser (PBF-LB/M), even the smallest deviations can have significant effects. Researchers at the Laser Application Centre (LAZ) of Aalen University are tackling this challenge with an innovative approach: using high-resolution IDS industrial cameras to dynamically monitor the manufacturing process and analyse individual powder layers in detail.

Two powerful IDS cameras play a key role: they capture the laser process in real time, detect deviations at an early stage, and provide high-resolution image data for subsequent analysis. This allows process parameters to be optimised precisely, significantly improving the quality of 3D-printed components – from more efficient electric motors to complex parts for industrial applications.

In our case study of the month, discover how intelligent image processing contributes to the optimisation of 3D printing processes and what this means for the future of manufacturing, including the development of more efficient electric motors.