Abstract: A joined part comprises a first portion and a second portion. The first portion comprises a guide slot at least partially defined by a porous structure. A joint material is disposed within the porous structure. The second portion is disposed within the guide slot and contacts the porous structure and the joint material disposed therein to form an interfacial joint between the first portion and the second portion. A method of manufacturing the joined part includes disposing a joint material into a porous structure of a guide slot of a first portion, inserting a second portion into the guide slot, and contacting the porous structure and the joint material disposed therein to form an interfacial joint between the first portion and the second portion.

Abstract: Methods of additively manufacturing a three-dimensional object include irradiating a first build plane region using a first energy beam defining a beam diameter, the first energy beam travelling along a first oscillating path in a first direction to consolidate a first wall defining a thickness perpendicular to the first direction, wherein a build material adjacent a first side of the first wall and the build material adjacent a second side of the first wall, opposite the first side of the first wall, remains unconsolidated; and wherein the thickness of the first wall is greater than the beam diameter.

Abstract: A cascade thrust reverser assembly for a gas turbine engine includes a nacelle assembly defining a bypass passage. The cascade thrust reverser assembly includes a cascade assembly configured to be at least partially enclosed by the nacelle assembly, the cascade assembly comprising one or more cascade members, the one or more cascade members movable between a stowed configuration wherein the one or more cascade members define a first radial extent and a deployed configuration wherein the one or more cascade members define a second radial extent, wherein the one or more cascade members form a cascade segment in the deployed configuration, and wherein the second radial extent is greater than the first radial extent.

Abstract: An apparatus may include a processor, memory modules, and machine-readable instructions stored in the memory modules. When executed by the processor, the instructions may cause the apparatus to receive image data of one or more laser strikes on a build plane, the image data indicating positions of a first set of fiducial strikes made by a first laser on the build plane and positions of a second set of fiducial strikes made by a second laser on the build plane, determine relative positions of the first set of fiducial strikes and the second set of fiducial strikes with respect to each other from the received image data, compare the determined relative positions of the first and second sets of fiducial strikes with respect to each other to expected relative positions of the first and second sets of fiducial strikes with respect to each other, and determine whether the first laser and the second laser are misaligned with respect to each other based on the comparison.

Abstract: A cascade thrust reverser assembly for a gas turbine engine includes a nacelle assembly defining a bypass passage. The cascade thrust reverser assembly includes a cascade assembly configured to be at least partially enclosed by the nacelle assembly, the cascade assembly comprising one or more cascade members, the one or more cascade members movable between a stowed configuration wherein the one or more cascade members define a first radial extent and a deployed configuration wherein the one or more cascade members define a second radial extent, wherein the one or more cascade members form a cascade segment in the deployed configuration, and wherein the second radial extent is greater than the first radial extent.

Abstract: According to some embodiments, system and methods are provided comprising receiving, via a communication interface of a parameter development module comprising a processor, a defined geometry for one or more parts, wherein the parts are manufactured with an additive manufacturing machine, and wherein a stack is formed from one or more parts; fabricating the one or more parts with the additive manufacturing machine based on a first parameter set; collecting in-situ monitoring data from one or more in-situ monitoring systems of the additive manufacturing machine for one or more parts; determining whether each stack should receive an additional part based on an analysis of the collected in-situ monitoring data; and fabricating each additional part based on the determination the stack should receive the additional part. Numerous other aspects are provided.

Abstract: An additive manufacturing system including a housing configured to contain a powder bed of material, and an array of laser emitters having a field of view. The array is configured to melt at least a portion of the powder bed within the field of view as the array translates relative to the powder bed. The system further includes a spatter collection device including a diffuser configured to discharge a stream of gas across the powder bed, and a collector configured to receive the stream of gas and contaminants entrained in the stream of gas. The collector is spaced from the diffuser such that a collection zone is defined therebetween, and the spatter collection device is configured to translate relative to the powder bed such that the collection zone overlaps with the field of view of the array.

Abstract: An additive manufacturing system including a housing configured to contain a powder bed of material, and an array of laser emitters having a field of view. The array is configured to melt at least a portion of the powder bed within the field of view as the array translates relative to the powder bed. The system further includes a spatter collection device including a diffuser configured to discharge a stream of gas across the powder bed, and a collector configured to receive the stream of gas and contaminants entrained in the stream of gas. The collector is spaced from the diffuser such that a collection zone is defined therebetween, and the spatter collection device is configured to translate relative to the powder bed such that the collection zone overlaps with the field of view of the array.

Abstract: According to some embodiments, system and methods are provided comprising receiving, via a communication interface of a parameter development module comprising a processor, a defined geometry for one or more parts, wherein the parts are manufactured with an additive manufacturing machine, and wherein a stack is formed from one or more parts; fabricating the one or more parts with the additive manufacturing machine based on a first parameter set; collecting in-situ monitoring data from one or more in-situ monitoring systems of the additive manufacturing machine for one or more parts; determining whether each stack should receive an additional part based on an analysis of the collected in-situ monitoring data; and fabricating each additional part based on the determination the stack should receive the additional part. Numerous other aspects are provided.

Abstract: An additive manufacturing system includes a first laser device configured to generate a first laser beam and a second laser device configured to generate a second laser beam. The laser scanning devices include a first laser scanning device and a second laser scanning device. The first laser scanning device is configured to selectively direct the first laser beam from the first laser devices across a powder bed along a plurality of first hatching paths and a first contour path along a contour of the solid component. The second laser scanning device is configured to selectively direct the second laser beam from the second laser devices across the powder bed along a plurality of second hatching paths and a second contour path along the contour of the solid component. The first contour path includes a first hook extending into the plurality of second hatching paths.

Abstract: A method of additive manufacturing machine (AMM) build process control includes obtaining AMM machine and process parameter settings, accessing sensor data for monitored physical conditions in the AMM, calculating a difference between expected AMM physical conditions and elements of the monitored conditions, providing the machine and process parameter settings, monitored conditions, and differences to one or more material property prediction models, computing a predicted value or range for the monitored conditions, comparing the predicted value or range to a predetermined target range, based on a determination that predicted value(s) are within the predetermined range, maintaining the machine and process parameter settings, or based on a determination that one or more of the predicted value(s) is outside the predetermined range, generating commands to compensate the machine and process parameter settings, and repeating the closed feedback loop at intervals of time during the build process.

Abstract: An additive manufacturing system includes a first laser device configured to generate a first laser beam and a second laser device configured to generate a second laser beam. The laser scanning devices include a first laser scanning device and a second laser scanning device. The first laser scanning device is configured to selectively direct the first laser beam from the first laser devices across a powder bed along a plurality of first hatching paths and a first contour path along a contour of the solid component. The second laser scanning device is configured to selectively direct the second laser beam from the second laser devices across the powder bed along a plurality of second hatching paths and a second contour path along the contour of the solid component. The first contour path includes a first hook extending into the plurality of second hatching paths.

Abstract: An additive manufacturing system configured to manufacture a component including scan strategies for efficient utilization of one or more laser arrays. The additive manufacturing system includes at least one laser device, each configured as a laser array, and a build platform. Each laser device is configured to generate a plurality of laser beams. The component is disposed on the build platform. The at least one laser device is configured to sweep across the component and the build platform in at least one of a radial direction, a circumferential direction or a modified zig-zag pattern and simultaneously operate the one or more of the plurality of individually operable laser beams corresponding to a pattern of the layer of a build to generate successive layers of a melted powdered material on the component and the build platform corresponding to the pattern of the layer of the build. A method of manufacturing a component with the additive manufacturing system is also disclosed.

Abstract: According to some embodiments, system and methods are provided comprising receiving, via a communication interface of a platform comprising a segmentation module and a processor, a defined geometry for one or more geometric structures forming one or more parts, wherein the parts are manufactured with an additive manufacturing machine; generating a build file including an initial parameter set to fabricate each part; fabricating the part based on the build file; receiving sensor data for the fabricated part; generating a parameter set for each layer that forms the part, via execution of an iterative learning control process for each layer; generating raw power data for each layer that forms the part, using the processor, based on the generated parameter set; applying a noise reduction process to the raw power data; and generating a segmented build file, using the segmentation module, via application of the noise reduction process on the raw power data. Numerous other aspects are provided.

Abstract: Methods and systems for fabricating a component include a build platform configured to receive a particulate, a consolidation device configured to consolidate the particulate to form a component, and a gas supply configured to provide a gas flow across the build platform. The additive manufacturing system also includes at least one vane positionable in a plurality of orientations relative to the gas flow. The additive manufacturing system further includes an actuator system coupled to the at least one vane and configured to move the at least one vane between the plurality of orientations. The additive manufacturing system also includes at least one sensor and a control system configured to receive information from the at least one sensor and cause the at least one vane to move between the plurality of orientations based on the information received from the at least one sensor.

Abstract: A method of additive manufacturing machine (AMM) build process control includes obtaining AMM machine and process parameter settings, accessing sensor data for monitored physical conditions in the AMM, calculating a difference between expected AMM physical conditions and elements of the monitored conditions, providing the machine and process parameter settings, monitored conditions, and differences to one or more material property prediction models, computing a predicted value or range for the monitored conditions, comparing the predicted value or range to a predetermined target range, based on a determination that predicted value(s) are within the predetermined range, maintaining the machine and process parameter settings, or based on a determination that one or more of the predicted value(s) is outside the predetermined range, generating commands to compensate the machine and process parameter settings, and repeating the closed feedback loop at intervals of time during the build process.

Abstract: An additive manufacturing system includes a laser device, a build plate, a first scanning device, and an alignment system. The laser device is configured to generate a laser beam. The build plate has a position relative to the laser device. The first scanning device is configured to selectively direct the laser beam across the build plate. The laser beam generates a melt pool on the build plate. The alignment system includes a fiducial marks projector configured to project a plurality of fiducial marks across the build plate. Each fiducial mark has a location on the build plate. The alignment system also includes an optical detector configured to detect the location of each of the fiducial marks on the build plate. The alignment system is configured to detect the position of the build plate relative to the laser device.

Abstract: According to some embodiments, system and methods are provided comprising receiving, via a communication interface of a parameter development module comprising a processor, a defined geometry for one or more parts, wherein the parts are manufactured with an additive manufacturing machine, and wherein a stack is formed from one or more parts; fabricating the one or more parts with the additive manufacturing machine based on a first parameter set; collecting in-situ monitoring data from one or more in-situ monitoring systems of the additive manufacturing machine for one or more parts; determining whether each stack should receive an additional part based on an analysis of the collected in-situ monitoring data; and fabricating each additional part based on the determination the stack should receive the additional part. Numerous other aspects are provided.

Abstract: According to some embodiments, system and methods are provided comprising receiving, via a communication interface of a platform comprising a segmentation module and a processor, a defined geometry for one or more geometric structures forming one or more parts, wherein the parts are manufactured with an additive manufacturing machine; generating a build file including an initial parameter set to fabricate each part; fabricating the part based on the build file; receiving sensor data for the fabricated part; generating a parameter set for each layer that forms the part, via execution of an iterative learning control process for each layer; generating raw power data for each layer that forms the part, using the processor, based on the generated parameter set; applying a noise reduction process to the raw power data; and generating a segmented build file, using the segmentation module, via application of the noise reduction process on the raw power data. Numerous other aspects are provided.

Abstract: A component is fabricated in a powder bed by moving a laser array across the powder bed. The laser array includes a plurality of laser devices. The power output of each laser device of the plurality of laser devices is independently controlled. The laser array emits a plurality of energy beams from a plurality of selected laser devices of the plurality of laser devices to generate a melt pool in the powder bed. A non-uniform energy intensity profile is generated by the plurality of selected laser devices. The non-uniform energy intensity profile facilitates generating a melt pool that has a predetermined characteristic.