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Artificial Intelligence for Control in Laser-Based Additive Manufacturing: A Systematic Review
Faculty of Engineering, University of Porto (FEUP), 4200-465 Porto, Portugal; Artificial Intelligence and Computer Science Laboratory (LIACC), Faculty of Engineering, University of Porto (FEUP), 4200-465 Porto, Portugal; Additive Manufacturing and Surface Technology Center, Fraunhofer IWS, 01277 Dresden, Germany; Unity of Advanced Manufacturing, Institute of Science and Innovation in Mechanical and Industrial Engineering (INEGI), 4200-465 Porto, Portugal; Associate Laboratory for Energy, Transports and Aerospace (LAETA), Faculty of Engineering, University of Porto (FEUP), 4200-465 Porto, Portugal.
Luleå University of Technology, Department of Engineering Sciences and Mathematics, Product and Production Development. Research and Development Laser Processing Center, JENOPTIK Automatisierungstechnik GmbH, 07745 Jena, Germany.ORCID iD: 0000-0001-8601-2923
Faculty of Engineering, University of Porto (FEUP), 4200-465 Porto, Portugal; Associate Laboratory for Energy, Transports and Aerospace (LAETA), Faculty of Engineering, University of Porto (FEUP), 4200-465 Porto, Portugal.
Faculty of Engineering, University of Porto (FEUP), 4200-465 Porto, Portugal; Center for Robotics in Industry and Intelligent Systems (CRIIS), INESC Technology and Science (INESC TEC), 4200-465 Porto, Portugal.
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2025 (English)In: IEEE Access, E-ISSN 2169-3536, Vol. 13, p. 30845-30860Article, review/survey (Refereed) Published
Abstract [en]

Laser-based additive manufacturing (LAM) offers the ability to produce near-net-shape metal parts with unparalleled energy efficiency and flexibility in both geometry and material selection. Despite advantages, these processes are inherently, as they are characterized by multiphysics interactions, multiscale phenomena, and highly dynamic behaviors, making their modeling and optimization particularly challenging. Artificial intelligence (AI) has emerged as a promising tool for enhancing the monitoring and control of additive manufacturing. This paper presents a systematic review of AI applications for real-time control of laser-based manufacturing processes, analyzing 16 relevant articles sourced from Scopus, IEEE Xplore, and Web of Science databases. The primary objective of this work is to contribute to the advancement of autonomous manufacturing systems capable of self-monitoring and self-correction, ensuring optimal part quality, enhanced efficiency, and reduced human intervention. Our findings indicate that 62.5 % of the 16 analyzed studies have deployed AI-driven controllers in real-world scenarios, with over 56 % using AI for control strategies, such as Reinforcement Learning. Furthermore, 62.5 % of the studies employed AI for process modeling or monitoring, which was integral to the development or data pipelines of the controllers. By defining a groundwork for future developments, this review not only highlights current advancements but also hints future innovations that will likely include AI-based controllers.

Place, publisher, year, edition, pages
Institute of Electrical and Electronics Engineers Inc. , 2025. Vol. 13, p. 30845-30860
Keywords [en]
Additive manufacturing, artificial intelligence, close-loop control, machine learning, reinforcement learning
National Category
Manufacturing, Surface and Joining Technology
Research subject
Manufacturing Systems Engineering
Identifiers
URN: urn:nbn:se:ltu:diva-111720DOI: 10.1109/ACCESS.2025.3537859ISI: 001425531400034Scopus ID: 2-s2.0-85217544216OAI: oai:DiVA.org:ltu-111720DiVA, id: diva2:1939655
Note

Validerad;2025;Nivå 2;2025-02-24 (u2);

Full text: CC BY license;

Funder: Project Hi-rEV—Recuperação do Setor de Componentes Automóveis co-financed by the Plano de Recuperação e Resiliência (PRR), Portuguese, through NextGeneration European Union (EU) under Grant C644864375-00000002;

Available from: 2025-02-24 Created: 2025-02-24 Last updated: 2025-10-21Bibliographically approved

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Brandau, BenediktBrueckner, Frank

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