Detecting LPBF Part Protrusion Before Build Failure

LIVE ONLINE WEBINAR · 24 September 2026 · 7:00–7:45 pm BST

Part protrusion during laser powder bed fusion (LPBF) can turn a localised component failure into recoater damage, scrapped neighbouring parts and, ultimately, a lost build.

But what if you could see it developing before the recoater hits?

Join Andrew Holliday, Applications Engineering Manager at Phase3D, for a focused technical session examining a recent LPBF part protrusion study.

Using quantitative, layer-by-layer height data from Fringe Inspection™, Andrew will show how a protruding component was identified and tracked as it progressed towards build failure and how in-situ measurement can create an opportunity for earlier, data-driven intervention.

Free online webinar · Live Q&A

Detecting part protrusion during LPBF

A protruding part doesn't only threaten the component itself. As a protrusion develops above the expected powder bed surface, it can eventually come into contact with the recoater. The consequences can extend beyond the original defect potentially affecting neighbouring components, damaging recoater hardware and compromising the wider build. The challenge is identifying that change before contact occurs.

In this webinar, Andrew will explore a recent part protrusion study and show how Fringe Inspection™ captured quantitative surface height data throughout the build, allowing the developing protrusion to be observed layer by layer.

Rather than simply identifying a defect after it has occurred, the data provides a measurable view of how the condition develops over time.

See the failure develop. Layer by layer.

Using data captured during the build, Andrew will walk through the progression of the protruding component and examine what the changing surface height reveals. The session will explore how quantitative in-situ inspection can help manufacturers move beyond simply detecting anomalies towards understanding their severity and progression.

By monitoring changes against measurable thresholds, teams can begin to make earlier, evidence-based decisions about whether a build should continue before a developing issue becomes a much more expensive failure.

What we'll cover

During the 45-minute session, Andrew will explore:

What causes part protrusion in LPBF and why it can escalate into a larger build failure
How Fringe Inspection™ measures surface height throughout the build
What layer-by-layer data can reveal about the progression of a protruding component
How quantitative thresholds can support earlier stop/go decisions
How earlier detection can help protect neighbouring parts, machine time, material and recoater hardware
What this means for the wider use of in-situ monitoring in LPBF
Live Q&A

From anomaly detection to actionable data

Knowing that something unusual has happened is useful. Knowing how far the surface has moved, how quickly it is changing and whether it is approaching a critical threshold gives manufacturers something much more powerful: data they can act on.

Phase3D's Fringe Inspection™ uses structured light measurement to capture objective surface height data during additive manufacturing.

In this session, you'll see how that measurement approach can be applied to a real LPBF failure mechanism and how quantitative build data can support earlier intervention before recoater contact.

Who should attend?

This webinar is designed for teams working with laser powder bed fusion, including engineers and technical leaders involved in:

Additive manufacturing production
LPBF process development
Process monitoring and control
Quality assurance
Applications engineering
Additive manufacturing research

Whether you're running production builds or developing new LPBF processes, the session will provide a practical look at how quantitative, layer-by-layer data can help identify developing problems before they become costly failures.

Meet your presenter

Andrew Holliday

Applications Engineering Manager, Phase3D

Andrew Holliday is the Applications Engineering Manager at Phase3D, where he works closely with manufacturers and researchers to apply quantitative in-process measurement to real additive manufacturing challenges. His work focuses on turning layer-by-layer build data into practical engineering insight, from identifying developing defects to understanding why a process is behaving the way it is. Andrew will walk through the part protrusion study and what the data revealed before the build ultimately failed.

Andrew will present the part protrusion study, walk through the resulting Fringe Inspection™ data and answer questions during a live Q&A at the end of the session.