Roadmapping In-Situ Metrology for Metal Alloy Additive Manufacturing

Metal-based additive manufacturing (AM) has the potential to transform critical industries including aerospace, defense, energy, and medical devices. However, widespread adoption remains limited by challenges in process understanding, qualification, and certification. A key barrier is the lack of reliable and validated in situ measurements capable of monitoring structural and microstructural evolution during AM processes.

In situ metrology enables real-time observation of thermal, structural, and material phenomena during metal AM fabrication, providing critical data to link process conditions with material structure and performance. This workshop will emphasize structural measurements during fabrication and processing, including measurements of phase evolution, microstructure development, and residual stress—information essential for model validation and process qualification.

This NIST workshop will bring together stakeholders from industry, academia, government, and national laboratories to identify key measurement science gaps and develop a community-informed roadmap for advancing in situ metrology in metal additive manufacturing. Outcomes will inform a NIST Special Publication outlining research priorities across metrology, data, artificial intelligence, and standards to support qualification-ready manufacturing and accelerate industrial adoption.