WELDING & ADDITIVE MANUFACTURING

Why Choose NIT HDR & SWIR Cameras?

NIT’s HDR technology enables simultaneous visualization of extremely bright and darker areas within the same image, significantly reducing saturation issues commonly encountered in welding applications.

The NIT MAGIC CAMERAS solves this lack of efficiency and robustness by offering high-quality images of the melt-pool, without any saturation and disturbing circle of light. Filters are not necessary anymore. Thanks to the native High Dynamic Range of the product – up to 140 dB or 120dB for the SWIR products – the welding arc, as well as the bevels, can be seen at the same time in one single image. All the relevant parameters can be monitored without any image processing.

The use of our SWIR Camera brings even more valuable information for additive manufacturing processes thanks to the Infrared band, i.e: 900nm-1700nm. Temperature homogeneity and geometry of the melt pool could then be monitored.

• White paper – Welding
• Laser additive manufacturing

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Why Welding & Additive Manufacturing Imaging Is Challenging

Manufacturing processes involving lasers and electric arcs create extreme imaging conditions.

Common challenges include:

• Very bright welding arcs
• Rapidly changing melt pool dynamics
• Strong contrast between illuminated and surrounding areas
• Reflections from metallic surfaces
• Smoke, sparks, and process emissions
• High-speed process variations

Traditional imaging systems often struggle to capture both the brightest and darkest areas simultaneously. As a result, critical process information may be lost due to image saturation or insufficient contrast.

For manufacturers seeking to improve quality and repeatability, accurate process visualization is essential.

Why SWIR & HDR Imaging Improve Process Monitoring

SWIR imaging offers a unique perspective on laser-material interactions and melt pool behavior.

Combined with NIT’s patented HDR technology, SWIR cameras can simultaneously image:

• The welding arc
• The melt pool
• Heat-affected zones
• Surrounding material structures

Unlike conventional cameras, HDR SWIR imaging reduces saturation, allowing operators to observe process details that would otherwise be hidden.

Benefits include:

• Improved process understanding
• Better weld quality monitoring
• Enhanced defect detection
• Increased manufacturing repeatability
• Easier integration into automated inspection systems

This makes SWIR imaging an effective tool for both industrial production and research environments.

Why Camera Performance Matters

Manufacturing environments require imaging systems capable of capturing highly dynamic scenes.

Critical camera characteristics include:

• High Dynamic Range (HDR)
• High sensitivity
• Low noise
• Fast acquisition rates
• Reliable industrial interfaces

These features allow engineers to monitor complex processes while maintaining excellent image quality.

Why SWIR Imaging Is Valuable for Additive Manufacturing

As additive manufacturing moves toward higher productivity and increased automation, process monitoring becomes increasingly important.

SWIR imaging enables manufacturers to:

• Improve process understanding
• Monitor melt pool consistency
• Reduce production variability
• Support automated quality control
• Increase confidence in critical parts

These capabilities are particularly important in industries such as:

• Aerospace
• Automotive
• Medical devices
• Energy
• Advanced manufacturing

Choosing the Right Imaging Technology

Key Welding & Additive Manufacturing Applications

Weld Pool Monitoring

The weld pool is one of the most important indicators of process quality.

SWIR imaging enables monitoring of:

• Melt pool geometry
• Weld stability
• Penetration consistency
• Process repeatability

Applications include:

• TIG welding
• MIG welding
• MAG welding
• Laser welding

Real-time visualization helps manufacturers optimize parameters and reduce defects.

Laser Welding Process Monitoring

Laser welding requires precise control of laser-material interaction.

SWIR cameras enable observation of:

• Melt pool evolution
• Laser impact zone
• Weld seam consistency
• Process deviations

Benefits include:

• Improved process stability
• Faster parameter optimization
• Reduced scrap rates
• Enhanced quality control

Additive Manufacturing Monitoring

Additive manufacturing processes rely on stable and repeatable melt pool behavior.

SWIR imaging is particularly valuable for monitoring:

• Laser Powder Bed Fusion (LPBF)
• Selective Laser Melting (SLM)
• Direct Energy Deposition (DED)
• Laser Metal Deposition (LMD)
• Laser Cladding

Engineers can visualize:

• Melt pool dynamics
• Material deposition quality
• Thermal distribution
• Process consistency

This information helps improve part quality and production reliability.

Process Development & Industrial R&D

SWIR cameras are increasingly used in research laboratories and innovation centers to analyze manufacturing processes.

Applications include:

• New material development
• Process optimization
• Laser parameter studies
• High-speed process characterization

Researchers gain access to information that is difficult to observe using visible imaging systems.