A comparison of anomaly detection algorithms with applications on recoater streaking in an additive manufacturing process

Abstract

Purpose Powder bed additive manufacturing has recently seen substantial growth, yet consistently producing high-quality parts remains challenging. Recoating streaking is a common anomaly that impairs print quality. Several data-driven models for automatically detecting this anomaly have been proposed, each with varying effectiveness. However, comprehensive comparisons among them are lacking. Additionally, these models are often tailored to specific data sets. This research addresses this gap by implementing and comparing these anomaly detection models for recoating streaking in a reproducible way. This study aims to offer a clearer, more objective evaluation of their performance, strengths and weaknesses. Furthermore, this study proposes an improvement to the Line Profiles detection model to broaden its applicability, and a novel preprocessing step was introduced to enhance the models’ performances. Design/methodology/approach All found anomaly detection models have been implemented along with several preprocessing steps. Additionally, a new universal benchmarking data set has been constructed. Finally, all implemented models have been evaluated on this benchmarking data set and the effect of the different preprocessing steps was studied. Findings This comparison shows that the improved Line Profiles model established it as the most efficient detection approach in this study’s benchmark data set. Furthermore, while most state-of-the-art neural networks perform very well off the shelf, this comparison shows that specialised detection models outperform all others with the correct preprocessing. Originality/value This comparison gives new insights into different recoater streaking (RCS) detection models, showcasing each one with its strengths and weaknesses. Furthermore, the improved Line Profiles model delivers compelling performance in detecting RCS.