A Ray Tracing Model for Electron Optical Imaging in Electron Beam Powder Bed Fusion

The recent success of the process monitoring method Electron Optical Imaging, applied in the additive manufacturing process Electron Beam Powder Bed Fusion, necessitates a clear understanding of the underlying image formation process. Newly developed multi-detector systems enable the reconstruction of the build surface topography in-situ but add complexity to the method. This work presents a physically based raytracing model, which rationalises the effect of detector positioning on image contrast development and masking. The model correctly describes the effect of multiple scattering events on vacuum chamber walls or heat shields and represents, therefore, a predictive tool for designing future detector systems. Most importantly, this work provides a validated method to compute build surface height gradients directly from experimentally recorded electron-optical images of a multi-detector system without any calibration steps. The computed surface height gradients can be used subsequently as input of normal integration algorithms aiming at the in-situ reconstruction of the build surface topography.