Abstract: Process control parameters are predicted to fabricate an object using deposition. An input design geometry is provided for the object. A training data set includes past post-build physical inspection data for a plurality of objects that comprise at least one object that is different from the object to be physically fabricated; and training data generated through a repetitive process of randomly choosing values for each of multiple process control parameters and scoring adjustments to the multiple process control parameters as leading to either undesirable or desirable outcomes, the outcomes based respectively on the presence or absence of defects detected in a fabricated object arising from the process control parameter adjustments. A machine learning algorithm is trained using the provided training data set and a predicted optimal set of the multiple process control parameters is generated for initiating and performing the deposition process to fabricate the object.

Abstract: Systems and methods for deliberate defect introduction in additive manufacturing are disclosed. In one embodiment, a robotic additive manufacturing system includes an additive manufacturing robot, the additive manufacturing robot including a robotic arm, a welder system mounted to the robotic arm and including a welding tip configured to deposit a consumable electrode wire onto an additively-manufactured article, a signals data storage system configured to receive from the welder system one or more signals indicative of a voltage and a current and to store the signals as a time series, a defect introduction system configured to receive an interrupt signal and to trigger a release mechanism configured to disrupt shielding gas around the welding tip based upon the interrupt signal, and a clock configured to provide a clock signal to the signals data storage system and the defect introduction system.

Abstract: Methods, apparatus, and devices for fixturing and alignment of parts and panels for assembly into aerospace components, are provided. These methods and devices are designed for joining together several large part segments into a larger complete component.

Abstract: A torch assembly for additive manufacturing is described. The torch assembly can apply at least two arcs surrounding a feed wire during an additive manufacturing process. The additional arc provides better shielding functions during the process.

Abstract: Disclosed herein are systems and methods for using printing process data to predict quality measures for three-dimensional (3D) printed objects and properties of the materials comprising the 3D objects. Printing may be performed using resistive or Joule printing. The system may include a computer communicatively coupled to a 3D printing apparatus, which may store printing parameters. The 3D printing apparatus may be able to take measurements during a print job, and record those measurements in memory. The 3D printing apparatus may also be able to record printing states before, during, and/or after printing. A combination of printing states, printing parameters, and measurements may be analyzed, for example, by a machine learning algorithm, in order to predict material properties and quality measures.

Abstract: Methods, apparatus, and devices for fixturing and alignment of parts and panels for assembly into aerospace components, are provided. These methods and devices are designed for joining together several large part segments into a larger complete component.

Abstract: The disclosure presents a combination of additive manufacturing processes that could be used to produce different portions or features of a hybrid structure, such that a first additive manufacturing process could be used to form a complex seed part or first section of the hybrid component, and a different additive manufacturing component could be used to form a second section of the hybrid component. When two components are manufactures, a mandrel could be assembled into the first component to provide rigidity and resistance to deformation of the first component, even during and after formation of the second component on the interface surface of the first component using a second additive manufacturing process. Finally, struts could be formed directly on a base plate and before formation of the component so that the base plate temperature could increase to be in equilibrium with the temperature of the newly deposited material.

Abstract: The disclosure presents a combination of additive manufacturing processes that could be used to produce different portions or features of a hybrid structure, such that a first additive manufacturing process could be used to form a complex seed part or first section of the hybrid component, and a different additive manufacturing component could be used to form a second section of the hybrid component. When two components are manufactures, a mandrel could be assembled into the first component to provide rigidity and resistance to deformation of the first component, even during and after formation of the second component on the interface surface of the first component using a second additive manufacturing process. Finally, struts could be formed directly on a base plate and before formation of the component so that the base plate temperature could increase to be in equilibrium with the temperature of the newly deposited material.

Abstract: A process can obtain a RT image of an article from the RT imaging system, the article comprising a reference feature, identify a first portion and a second portion of the first RT image, wherein the first portion and the second portion overlap, and classify each pixel in the first portion and the second portion using a pore classification model. A pore map can then be generated and mapped onto the article based on data received from the at least one sensor. A process can identify rejected regions on the pore map, wherein the rejected regions exceed a rejection threshold based on predefined rules. These rejected regions can then be displayed.

Abstract: Process control parameters are predicted to fabricate an object using deposition. An input design geometry is provided for the object. A training data set includes past post-build physical inspection data for a plurality of objects that comprise at least one object that is different from the object to be physically fabricated; and training data generated through a repetitive process of randomly choosing values for each of multiple process control parameters and scoring adjustments to the multiple process control parameters as leading to either undesirable or desirable outcomes, the outcomes based respectively on the presence or absence of defects detected in a fabricated object arising from the process control parameter adjustments. A machine learning algorithm is trained using the provided training data set and a predicted optimal set of the multiple process control parameters is generated for initiating and performing the deposition process to fabricate the object.

Abstract: Methods, apparatus, and devices for fluid flushing systems to remove foreign object debris (FOD) are provided. These methods and devices are designed to flush and transport FOD away from machined parts. Foreign object debris refers to any unintended material such as tiny particles, chips that enters a part during a manufacturing process. FOD can have significant effects, compromising the quality and functionality of manufactured items. This can lead to costly consequences such as rework, scrapped parts, and production delays. FOD prevention is essential for improving safety, reliability, and efficiency.

Abstract: Systems and methods for additive manufacturing robotic systems in accordance with embodiments of the invention are illustrated. One embodiment includes a method for visualizing a space. The method includes steps for receiving, at a set of one or more processors, a set of print data, wherein the set of print data comprises a first set of data for a first visualization, wherein the first set of data is received from a control system that controls a set of one or more robots for a print job to print a part, and a second set of data for a second visualization associated with the part, rendering, at the set of processors, the first and second visualizations based on the print data, wherein the first visualization includes a visualization of the print job, and displaying the rendered first and second visualizations.

Abstract: Systems and methods for nozzles that can provide cryogenic shielding during wire-based additive manufacturing are described. Cryogenic fluid supplied by the cryogenic nozzles can provide ample coverage, great shielding, and efficient cooling during additive manufacturing processes.

Abstract: Systems of weldable wires, powder, and materials comprising an aluminum-magnesium-scandium alloy, and methods for additive manufacturing the alloy are described. The alloy can be utilized in additive manufacturing to additively manufacture at industrial scales. With post treatment, the additive manufactured alloys can have advantageous properties for aerospace applications.

Abstract: Systems and methods for implementing weaving in additive manufacturing are described. The weaving can be controlled by a localized system to achieve fine movement accuracy. The system can include a motor to move the print head in a multi axes motion. The system can improve print consistency and quality.

Abstract: The present disclosure provides a system for printing a three-dimensional object. The system may comprise a support for holding a portion of the object and a wire(s) source configured to hold a wire(s) of substantially the same or different diameters. The system may also comprise a print head. The print head may comprise a guide for directing the wire to the support. The system may also comprise a driver roller comprising a groove configured to contact a portion of the wire and direct the wire to the guide, and a power source in electrical communication with the wire and the support. The system may also comprise a controller configured to direct the power source to supply electrical current to the wire and the support. The electrical current may be sufficient to melt the wire when the wire is in contact with the support or the portion of the object.

Abstract: Additively manufactured thrust chambers and thrust chambers with integral fluid manifolds, and hybrid additive manufacturing methods for their production, are provided. Hybrid additive manufacturing techniques may combine a variety of processes including, WAAM, PBF, cold spray and DED, for example, to produce objects with variant dimensional requirements, i.e., large overall size and small features. Hybrid additive manufacturing may be defined as provide various process layers within any manufactured object. These process layers in turn allow for the introduction of variable feature and size distribution throughout the manufactured object. Hybrid process layers according to aspects may also allow the use of a variety of materials or may use a single material across the various process layers.