Additive manufacturing is a modern fabrication process by which three dimensional components are built up layer-by-layer. Each layer corresponds to a cross-section of a 3D CAD model of the product. LPT proposes an active machine vision, based on a monitoring system to improve Electron Beam Freeform Fabrication (EBF3) processes, by measuring spatial, spectral, thermal and temporal information of the melt pool and element compositions of materials. The proposed technology will provide clear and accurate information of the melting pool during the metal deposition processes in order to control operation and correct defects. LPT has extensive expertise in monitoring laser machining processes using various optical sensing technologies. These sensing technologies have shown significant promise for developing a sensing system to monitor EBF3 processes. During Phase I, LPT will complete the theoretical design of the active machine vision system. The proof-of-concept tests will be performed in lab conditions to demonstrate the feasibility of the proposed approach. The research and development efforts in Phase I will provide a solid base for implementing a prototype during Phase II and commercializing this technology during Phase III.