Development of An Imaging Setup for Laser-Based Additive Manufacturing of PEEK

This project established a dual-camera imaging setup to analyze melt pool dynamics in laser-based additive manufacturing of polyether ether ketone (PEEK) composites. Initially intended for an 8W, 445 nm blue laser, the effort pivoted to refining the imaging system using a green laser due to equipment delays. An infrared camera captured thermal gradients, while an optical camera documented surface morphology and melt pool dynamics. Filters and external lighting were implemented to reduce interference and improve image clarity. Though pixelation and sensor artifacts posed challenges at high laser intensities, adjustments to filters and camera placement enhanced data quality. After validating the imaging system, the introduction of the blue laser will enable precise control over melting and filler dispersion, advancing the fabrication of multifunctional, compositionally graded PEEK composites. This approach can be adapted for other materials and processes, supporting broader innovation in aerospace and high-performance engineering applications.