biostudies-literatureUnknown14(1)Li HLaser powder bed fusion (LPBF) is an additive manufacturing technology with high practical value. In order to improve the quality of the fabricated parts, process monitoring has become a crucial solution, offering the potential to ensure manufacturing stability and repeatability. However, a cardinal challenge involves discerning a precise correlation between process characteristics and potential defects. This paper elucidates the integration of an off-axis vision monitoring mechanism via a high-speed camera focused on capturing the single-track melting phenomenon. An innovative image processing method was devised to segment the plume and spatters, while Kalman filter was employed for multi-object tracking of the spatters. The features of both the plume and spatters were extracted, and theiScientific reports14697https://www.ebi.ac.uk/biostudies/studies/S-EPMC11208593biostudies-literatureData-fusion for in-situ monitoring and molten state identification during LPBF of NiCoCr medium-entropy alloy.PMC11208593Li HFu YYan SfalseData-fusion for in-situ monitoring and molten state identification during LPBF of NiCoCr medium-entropy alloy.Laser powder bed fusion (LPBF) is an additive manufacturing technology with high practical value. In order to improve the quality of the fabricated parts, process monitoring has become a crucial solution, offering the potential to ensure manufacturing stability and repeatability. However, a cardinal challenge involves discerning a precise correlation between process characteristics and potential defects. This paper elucidates the integration of an off-axis vision monitoring mechanism via a high-speed camera focused on capturing the single-track melting phenomenon. An innovative image processing method was devised to segment the plume and spatters, while Kalman filter was employed for multi-object tracking of the spatters. The features of both the plume and spatters were extracted, and thei2024-01-01T00:00:00Z2024 Jun2025-04-04T20:47:19.954Z2024-11-21T05:48:42.977ZS-EPMC112085933892644110.1038/s41598-024-65545-9