High-speed thermal video data in L-PBF on copper-ceramic substrates

This dataset comprises high-speed thermal video recordings acquired during Laser Powder Bed Fusion (L-PBF) of pure copper components manufactured on Direct Bonded Copper (DBC) substrates, consisting of a ceramic layer sandwiched between copper sheets. The application targets the fabrication of additively manufactured features directly on electronic substrates, a scenario characterized by reduced heat dissipation and pronounced thermal instabilities, making it particularly relevant for in-situ monitoring and process analysis. All details about the study can be found in Zheng et al. (2026a).

Experiments were performed using a 3D-NT LLA150 L-PBF system equipped with a 600 W fiber laser. Two builds were conducted under different process conditions: a standard infill scanning strategy and a modified strategy including a new spatter mitigation strategy based on contour pre-sintering (Zheng et al. 2026a). High-speed thermal imaging was carried out using a FLIR 6900sc MWIR camera (3–5 µm spectral range) at 500 fps, capturing spatially and temporally resolved radiometric signals of the process. The camera was mounted above the build chamber and observed the process through a sapphire window.

The dataset includes raw thermal videos in .ats format (which can be converted and exported by means of the Software Development Kit (SDK) provided for free by FLIR), containing raw (irradiance) measurements, along with supplementary data to support interpretation and reuse. These include spatial masks defining regions of interest (ROIs), perspective-corrected reference masks derived from the nominal geometry, and tabular data in .csv format providing temporal labeling of individual scan tracks (start and end frames) for each layer and ROI. In addition, post-process micrographs of sample cross-sections are provided.

Full details about the dataset can be found in Zheng et al. (2026b)

The dataset enables the analysis of thermal process signatures at high temporal resolution and supports applications such as machine learning, thermal modeling, spatter analysis, and process monitoring in additive manufacturing.

References:

Zheng, H., Bugatti, M. Grasso, M., Sarfert, F. and Colosimo, B.M., (2026a) A new strategy for spatter mitigation in L-PBF with application in direct manufacturing on multimaterial substrates, submitted to Additive Manufacturing. Available at SSRN: https://ssrn.com/abstract=6754398 or http://dx.doi.org/10.2139/ssrn.6754398

Zheng, H., Bugatti, M., Tsiamyrtzis, P., Sarfert, F., Grasso, M., and Colosimo, B.M., (2026b) In-situ high-speed thermal video data in Laser Powder Bed Fusion on copper–ceramic substrates, submitted to Scientific Data