Abstract: Methods and apparatus for sensor-based part development are disclosed. An example apparatus includes at least one memory, instructions in the apparatus, and processor circuitry to execute the instructions to identify a reference process observable of a computer-generated part, receive input from at least one sensor during three-dimensional printing to identify an estimated process observable using feature extraction, and adjust at least one three-dimensional printing process parameter to reduce an error identified from a mismatch between the estimated process observable and the reference process observable.

Abstract: A method for performing a fault estimation based on residuals of detected signals includes: determining an operating regime based on a plurality of parameters; extracting predetermined noise standard deviations of the residuals corresponding to said operating regime and scaling the residuals; calculating a magnitude of a measurement vector of the scaled residuals and comparing the magnitude to a decision threshold value; extracting a mean direction and a fault level mapping for each of a plurality of fault types, based on the operating regime; calculating a projection of the measurement vector onto the mean direction of each of the plurality of fault types; determining a fault type based on which projection is maximum; and mapping the projection to a continuous-valued fault level using a lookup table.

Abstract: A method and system of controlling a gas turbine engine is disclosed. The engine has sensors to detect one or more parameters and actuators adapted to respond to commands. The method includes receiving data from the sensors of the engine for one or more measured or sensed parameters, estimating a state of the engine by estimating one or more unmeasured or unsensed parameters using the data from the sensors and a predictive model of the engine, generating commands for the actuators based on the state using an optimization algorithm; and transmitting the commands to the engine. The system includes a state estimator adapted to estimate a state of the engine by estimating one or more unmeasured or unsensed parameters using data from the sensors of the engine for one or more measured or sensed parameters. The estimator includes a model of the engine. The system also includes a control module adapted to generate commands for the actuators based on the state.