ASTRO Heads to ICAM 2026! ✈️
In our ICAM preview:
- Reliable In-Situ Flaw Detection of Thin-Walled Lattice Structures
- AFSD: The Process-Microstructure-Property Connection
- Bent Out of Shape: Perspectives on State-of-the-Art Distortion Prediction and Compensation Tools
- Smoke, Mirrors, and Melt Pools: Insights from Inaugural ASTRO-InSPIRE-ASTM In-Situ Awareness Challenge
- Comparing In-Situ Monitoring Sensors with Model-Based Approach for Industrial Laser Metal Powder Bed Fusion Additive Manufacturing
ASTRO will be well represented this week at ICAM 2026, ASTM’s International Conference on Advanced Manufacturing, with team members presenting across a range of advanced manufacturing topics central to qualification, production readiness, and the future of additive manufacturing.
This year’s presentations will highlight ASTRO’s work in laser powder bed fusion (LPBF), in-situ monitoring, distortion prediction and compensation, flaw detection, and Additive Friction Stir Deposition (AFSD). Together, the talks reflect ASTRO’s broader mission to help move advanced manufacturing technologies from research and demonstration into reliable, repeatable, production-ready applications.
Reliable In-Situ Flaw Detection of Thin-Walled Lattice Structures
Wednesday, September 30
11:50 a.m. EDT
Regency Ballroom P
Presenter: Alex Riensche, Advanced Research Scientist, ASTRO South
Thin-walled lattice structures offer major potential benefits for weight reduction, stiffness, heat transfer, and structural efficiency. However, their complex geometries can be difficult and expensive to inspect using conventional non-destructive techniques such as computed tomography, ultrasonic inspection, and 2D radiography.
This presentation will highlight work using high-resolution near-infrared and illuminated-visible imaging, combined with machine learning trained against CT data, to support in-situ flaw detection in PBF-LB additive manufacturing. The work targets detection of geometric deviations and voids exceeding 300 microns and explores how more effective in-situ inspection can reduce time and cost while supporting broader use of lattice structures in demanding applications.
AFSD: The Process-Microstructure-Property Connection
Thursday, October 1
3:25 p.m. EDT
Celebration 5/6
Presenter: Jacob Swanson, Deputy General Manager, ASTRO Midwest
Additive Friction Stir Deposition is a solid-state additive manufacturing process that uses metal rod feedstock, high-speed rotation, and plastic deformation to build uniform layers. The process enables large-scale metallic structures and geometries that have historically relied on casting, rolling, or forging.
This presentation will explore ASTRO Midwest’s work to connect processing conditions, microstructure, and mechanical performance in AFSD. Using a Design of Experiments approach, the team has printed more than 100 builds and worked with university researchers, industry labs, Army partner organizations, and technical specialists to establish mechanical property baselines, develop thermal models, characterize materials, and support non-destructive evaluation methods. With several phases of printing and analysis complete, ASTRO is now working to bring these fields together into a Technical Data Package to support industrial qualification and eventual part production.
Bent Out of Shape: Perspectives on State-of-the-Art Distortion Prediction and Compensation Tools
Thursday, October 1
4:05 p.m. EDT
Regency Ballroom V
Presenter: Alex Riensche, Advanced Research Scientist, ASTRO South
Many software tools claim to predict and correct component distortion in laser-based powder bed fusion. However, without costly trials, end users often lack clear visibility into how these tools perform under realistic production conditions.
This presentation will share insights from the ASTRO-InSPIRE challenge on distortion prediction and compensation in PBF-LB, where seven leading commercial solutions were assessed using real-world components. Each solution was independently demonstrated using complex parts with defined geometric requirements, vendor-specified calibration procedures, and actual build measurements. The presentation will discuss how the tools performed, including their accuracy, value, and practical relevance for end users seeking more predictable additive manufacturing outcomes.
Smoke, Mirrors, and Melt Pools: Insights from Inaugural ASTRO-InSPIRE-ASTM In-Situ Awareness Challenge
Friday, October 2
8:50 a.m. EDT
Regency Ballroom P
Presenter: Abdalla Nassar, Vice President and General Manager, ASTRO South
The inaugural ASTRO-InSPIRE-ASTM In-Situ Awareness Challenge showcased the progress being made in in-situ monitoring for metal LPBF additive manufacturing. Five commercial solutions, including Addiguru, Additive Assurance, Applied Optimization, JENTEK Sensors, and Phase3D, were evaluated on a production LPBF system building aerospace-relevant parts.
This presentation will highlight the core principles behind today’s monitoring technologies and offer practical insight into their current capabilities and future potential. The session will also examine how in-situ monitoring can help detect process drift and identify flaws in real time, supporting the broader goal of making additive manufacturing more reliable, repeatable, and production-ready.
Comparing In-Situ Monitoring Sensors with Model-Based Approach for Industrial Laser Metal Powder Bed Fusion Additive Manufacturing
Friday, October 2
10:55 a.m. EDT
Regency Ballroom P
Presenter: Jared Blecher, Director and General Manager, ASTRO Mid-Atlantic
In-situ process monitoring sensors can help accelerate the adoption and acceptance of laser metal powder bed fusion additive manufacturing, particularly in aviation and other highly regulated industries. However, comparing different sensors across printers, materials, and parts can be expensive and time-consuming.
This presentation will examine a model-based approach that simulates sensor responses under nominal and off-nominal conditions, allowing for direct comparison of sensor modalities. The work compares a scientific CMOS camera imaging the full powder bed and a coaxial photodiode capturing light emissions near the laser-material interaction. Results suggest that the camera-based approach may be more effective for industrial applications, offering insight into how modeling and sensor comparison can support more informed monitoring decisions.
Advancing Production-Ready Additive Manufacturing
Across these presentations, ASTRO’s ICAM 2026 lineup reflects a common theme: advanced manufacturing requires data, testing, monitoring, inspection, process control, and qualification pathways that give end users confidence in the parts and processes they adopt.
From LPBF monitoring and distortion compensation to AFSD process development and lattice flaw detection, ASTRO’s work is helping address the practical barriers standing between innovative manufacturing technologies and real-world production.
We look forward to joining partners, researchers, and industry leaders at ICAM 2026. See you in Orlando! 🌴