Abstract: A method for optimizing one or more process parameters of an additive manufacturing process. The method includes, a. manufacturing a set of test samples (c1 . . . c1 . . . cn) on a build platform (P) of an additive manufacturing system, each test sample (c1 . . . c1 . . . cn) being monitored by at least one electromagnetic sensor for obtaining at least one optimized set of process parameters (pi,opt), and storing the at least one optimized set of process parameters (pi,opt) for subsequent use during the building process of the said at least one AM part, which is representative of a test coupon (ci,j) of a given acceptable quality factor. The at least one optimized set of process parameters (pi,opt) is obtained by carrying out the following steps: i. manufacturing at least two test coupons (c1,1 . . . ci,1 . . . cn,1) with two different sets of guess process parameters (p1,1 . . . pi,1 . . . pn,1), ii. sensing the two test coupons (c1,1 . . . ci,1 . . . cn,1) with the at least one electromagnetic sensor, iii.

Abstract: The present invention relates to a method for manufacturing, monitoring and classifying an AM metal part. The AM part is manufactured by a powder-bed additive manufacturing machine comprising a build plate (BP), a recoater (RC) and at least one electromagnetic sensor (ECS) mounted on the recoater.