Abstract: Systems, apparatus, computer-readable medium, and associated methods to monitor, analyze, and adjust at least one of a build and/or an additive manufacturing machine configuration are disclosed. An example apparatus includes memory circuitry, instructions, and processor circuitry to execute the instructions to implement at least a feature extractor, a variability analyzer, and an output generator. The feature extractor is to: i) group data for a plurality of builds associated with one or more additive manufacturing machines; and ii) extract features from the grouped data. The variability analyzer is to: i) process the grouped data with respect to the features to determine a measure of variability for each feature; and ii) compare the measure of variability for each feature to a respective allowable limit associated with the respective feature. The output generator is to provide actionable output to adjust at least a first additive manufacturing machine.

Abstract: An apparatus for additively manufacturing three-dimensional objects may include at least one calibration unit, at least one irradiation device, and a determination device. The least one calibration unit may include at least one calibration region arranged in the beam guiding plane, and the at least one calibration region may include a plurality of sub-regions differing in respect of at least one optical property. The at least one irradiation device may be configured to guide a plurality of energy beams across the at least one calibration region comprising the plurality of sub-regions, and a plurality of calibration signals may be generated by the plurality of sub-regions being irradiated with the plurality of energy beams. The determination device may be configured to determine the plurality of calibration signals and to determine a calibration status of the irradiation device based at least in part on the determined plurality of calibration signals.

Abstract: An apparatus for additively manufacturing three-dimensional objects may include at least one calibration unit, at least one irradiation device, and a determination device. The least one calibration unit may include at least one calibration region arranged in the beam guiding plane, and the at least one calibration region may include a plurality of sub-regions differing in respect of at least one optical property. The at least one irradiation device may be configured to guide a plurality of energy beams across the at least one calibration region comprising the plurality of sub-regions, and a plurality of calibration signals may be generated by the plurality of sub-regions being irradiated with the plurality of energy beams. The determination device may be configured to determine the plurality of calibration signals and to determine a calibration status of the irradiation device based at least in part on the determined plurality of calibration signals.

Abstract: A method of additively manufacturing three-dimensional objects may include determining an irradiation regime for a plurality of object elements of a layer of an object to be additively manufactured, and forming the plurality of object elements at least in part by irradiating a layer of a build plane with one or more irradiation devices of the additive manufacturing machine. The plurality of object elements may include a core region and a shell region. The shell region may at least partially surround the core region. The irradiation regime for at least one of the plurality of object elements may include a core-shell irradiation regime. Additionally, or in the alternative, the irradiation regime for at least one of the plurality of object elements may include a core-shell apportioned irradiation regime.

Abstract: An apparatus for additively manufacturing three-dimensional objects may include at least one calibration unit, at least one irradiation device, and a determination device. The least one calibration unit may include at least one calibration region arranged in the beam guiding plane, and the at least one calibration region may include a plurality of sub-regions differing in respect of at least one optical property. The at least one irradiation device may be configured to guide a plurality of energy beams across the at least one calibration region comprising the plurality of sub-regions, and a plurality of calibration signals may be generated by the plurality of sub-regions being irradiated with the plurality of energy beams. The determination device may be configured to determine the plurality of calibration signals and to determine a calibration status of the irradiation device based at least in part on the determined plurality of calibration signals.

Abstract: A method of controlling an additive manufacturing process in which a directed energy source is used to selectively fuse powdered material to form a workpiece, in the presence of a gas flow, the method including: using at least one gas flow sensor to generate at least one gas flow measurement; and controlling at least one aspect of the additive manufacturing process in response to the at least one gas flow measurement.

Abstract: A method of controlling an additive manufacturing process in which a directed energy source is used to selectively fuse powdered material to form a workpiece, in the presence of a gas flow, the method including: using at least one gas flow sensor to generate at least one gas flow measurement; and controlling at least one aspect of the additive manufacturing process in response to the at least one gas flow measurement.