Abstract: A laser power control method for additive manufacturing includes a pre-processing component and an intra-processing component. The pre-processing component creates in the system controller a machine code expressed additive-path-with-geometry-metadata that includes a path description. The path description represents the path of the beam source on the build and includes a geometry index for the build. The intra-processing component calculates required power for the beam at intervals and events on the beam path based upon the additive-path-with-geometry-metadata and calculations of the energy balance at the melt pool and the total energy for each point P(s) on the path.

Abstract: A power schedule calculation method utilizes an idealized geometry to predict laser power levels on an additive path during laser deposition. The method calculates beam power for any point along the path traveled to form a build having a geometry. Each point along the path has associated with it an idealized geometry comprising a melt pool, hot zone and bulk portion. The method comprises creating a geometric description representing the geometry of the build during the process, creating a path description representing the path of the beam source through space during the process, calculating the idealized geometry for the point on the path based upon the geometric description and path description, calculating an energy balance at the melt pool for the point on the path, calculating total energy needed at the point on the path and calculating optimum beam source power. In the calculations, build temperature is based upon a calculation of hot zone temperature derived from the idealized geometry.

Abstract: A method for detecting a subsurface defect in a workpiece undergoing processing includes directing focused heat energy from an energy point source on to the workpiece to generate a melt pool and cause a solid portion of the workpiece to emit incandescent radiation. The incandescent radiation emitted by the solid portion of the workpiece is captured and a signal based upon the color or intensity of the captured incandescent radiation is output. A processor receives the output signal and analyzes it for any variance. If any variance is detected, the region associated with the variance is determined. In this fashion, gradients in the color or intensity distribution reveal subsurface defects.

Abstract: A power schedule calculation method utilizes an idealized geometry to predict laser power levels on an additive path during laser deposition. The method calculates beam power for any point along the path traveled to form a build having a geometry. Each point along the path has associated with it an idealized geometry comprising a melt pool, hot zone and bulk portion. The method comprises creating a geometric description representing the geometry of the build during the process, creating a path description representing the path of the beam source through space during the process, calculating the idealized geometry for the point on the path based upon the geometric description and path description, calculating an energy balance at the melt pool for the point on the path, calculating total energy needed at the point on the path and calculating optimum beam source power. In the calculations, build temperature is based upon a calculation of hot zone temperature derived from the idealized geometry.

Abstract: Methods and systems of detecting one or more characteristics of a load are disclosed. One or more characteristics of a first signal may be detected at the output of a Radio Frequency (RF) power generator. The first signal may have a fundamental frequency. The one or more characteristics of the first signal may be sampled at a sampling frequency to produce a digital sampled signal. The sampling frequency may be determined based on a function of the fundamental frequency of the first signal. One or more characteristics of a load in communication with the RF power generator may then be determined from the digital sampled signal.

Abstract: A capacitor array may include a bottom electrode, a plurality of top electrodes, at least one dielectric medium and a plurality of switching mechanisms. Each switching mechanism may separably electronically connect two or more top electrodes. The at least one dielectric medium may include a plurality of discrete capacitors each in contact with a top electrode and the bottom electrode.