VertX - In-Process Verification Tool

VertX is a cost-effective, multi-modal in-process verification platform designed to bring scalable monitoring and process intelligence to metal additive manufacturing. Developed by Instruct3D, VertX combines advanced hyperspectral sensing with edge-based data processing to deliver deep process insight without the cost, complexity, or infrastructure burden associated with traditional high-speed monitoring systems.

Unlike conventional approaches that rely on a single high-resolution imaging stream, VertX uses multiple synchronised, lower-cost sensors to capture thermally and optically coupled process signatures in real time. This multi-modal architecture provides a richer and more physically meaningful understanding of melt pool behaviour, thermal evolution, and layer-by-layer build quality — while dramatically reducing data bandwidth and storage requirements.

Designed for seamless integration across existing machine fleets, VertX offers a lightweight and scalable pathway toward in-situ verification without extensive hardware modification or specialised computing infrastructure. On-edge feature extraction enables intelligent data reduction at the source, allowing manufacturers to deploy monitoring capabilities at scale while maintaining operational efficiency.

VertX enables manufacturers to:

• Achieve deeper process observability through fused thermal and optical sensing
• Detect defects and process anomalies layer-by-layer during production
• Correlate in-situ signatures with post-build XCT inspection results for enhanced qualification confidence
• Reduce monitoring costs and data overhead compared to traditional high-speed imaging systems
• Integrate easily into existing additive manufacturing platforms with minimal disruption
• Support physics-informed process optimisation through integration with thermal simulation and AI-driven analytics

By combining low-cost sensing hardware, intelligent edge processing, and physics-informed analytics, VertX provides a practical route toward fleet-wide process verification, adaptive process control, and scalable quality assurance in metal additive manufacturing.