An artificial intelligence-powered software called Peregrine gives manufacturers a real-time window into the powder bed printing process — improving quality, reducing waste, and accelerating certification for complex parts in high-stakes industries.
Why it matters:
From aerospace to nuclear energy, industries are turning to 3D printing to produce intricate, high-performance components. But without live monitoring, flaws are often only discovered after printing — slowing innovation and raising costs.
Real-world impact:
Peregrine runs on more than 20 types of 3D-printing systems including laser powder bed, binder jet or electron beam melting technologies — and it works with just a high-powered desktop and an off-the-shelf camera. It was demonstrated in the U.S. Department of Energy’s Transformational Challenge Reactor program to help qualify the world’s first 3D-printed nuclear fuel components.
The benefits:
- Works across more than 20 types of powder bed printers
- Enables real-time monitoring and faster certification
- Reduces cost, waste, and post-production analysis time
- Operates on standard hardware with low computational demand
- Licensed by more than 40 academic, government and industry partners
The innovation:
Researchers at DOE’s Manufacturing Demonstration Facility, or MDF, at 91°µÍø developed Peregrine — an artificial intelligence tool that enables real-time, visual monitoring of powder bed printing systems.
How it works:
- Uses a standard camera and AI algorithm to scan every image of the print process
- Detects flaws such as uneven powder distribution, overheating, spatters, distortion, and porosity
- Alerts operators to problems immediately so adjustments can be made mid-print
Peregrine also helps trace flaws back to specific conditions, giving manufacturers unprecedented insight into process-performance relationships.
Backed by science:
This research was funded by the DOE’s Advanced Materials and Manufacturing Technologies Office, with support from DOE’s Office of Nuclear Energy.
- Developed at the MDF
- Continues to evolve through research in digital manufacturing, material qualification, and data integration
Deep dive:
Read ORNL’s story about the development of Peregrine and visit the MDF website for licensing information.
The big picture:
Peregrine is laying the foundation for a future where every product is smart, traceable and born qualified.