Abstract: A powder bed additive manufacturing apparatus includes a build sleeve, a build platform for supporting a powder bed and object during a build, the build platform lowerable in the build sleeve, and at least one acoustic sensing system. The acoustic sensing system includes an acoustic emission sensor and an acoustic waveguide. The acoustic waveguide extends through the build platform such that a receiving end of the acoustic waveguide distal from the acoustic emission sensor abuts a surface of a build substrate removable mounted to the build platform to transmit structure-borne acoustic waves from the build substrate to the acoustic emission sensor.

Abstract: A method of monitoring an additive manufacturing apparatus. The method includes receiving one or more sensor signals from the additive manufacturing apparatus during a build of a workpiece, comparing the one or more sensor signals to a corresponding acceptable process variation of a plurality of acceptable process variations and generating a log based upon the comparisons. Each acceptable process variation of the plurality of acceptable process variations is associated with at least one state of progression of the build of the workpiece and the corresponding acceptable process variation is the acceptable process variation associated with the state of progression of the build when the one or more sensor signals are generated.

Abstract: A powder bed additive manufacturing apparatus includes a build sleeve, a build platform for supporting a powder bed and object during a build, the build platform lowerable in the build sleeve, and at least one acoustic sensing system. The acoustic sensing system includes an acoustic emission sensor and an acoustic waveguide. The acoustic waveguide extends through the build platform such that a receiving end of the acoustic waveguide distal from the acoustic emission sensor abuts a surface of a build substrate removable mounted to the build platform to transmit structure-borne acoustic waves from the build substrate to the acoustic emission sensor.

Abstract: This invention concerns a method of monitoring an additive manufacturing apparatus. The method comprises receiving one or more sensor signals from the additive manufacturing apparatus during a build of a workpiece, comparing the one or more sensor signals to a corresponding acceptable process variation of a plurality of acceptable process variations and generating a log based upon the comparisons. Each acceptable process variation of the plurality of acceptable process variations is associated with at least one state of progression of the build of the workpiece and the corresponding acceptable process variation is the acceptable process variation associated with the state of progression of the build when the one or more sensor signals are generated.

Abstract: A method of monitoring an additive manufacturing apparatus. The method includes receiving one or more sensor signals from the additive manufacturing apparatus during a build of a workpiece, comparing the one or more sensor signals to a corresponding acceptable process variation of a plurality of acceptable process variations and generating a log based upon the comparisons. Each acceptable process variation of the plurality of acceptable process variations is associated with at least one state of progression of the build of the workpiece and the corresponding acceptable process variation is the acceptable process variation associated with the state of progression of the build when the one or more sensor signals are generated.

Abstract: A method of generating a spatial map of sensor data collected during additive manufacturing, in which a plurality of layers of powder are selectively melted with an energy beam to form an object. The method includes receiving sensor data collected during additive manufacturing of an object, the sensor data including sensor values, the sensor values captured for different coordinate locations of the energy beam during the additive manufacturing of the object, and generating cell values for a corresponding cell-based spatial mapping of the sensor data. Each of the cell values is determined from a respective plurality of the sensor values extending over an area/volume comparable to an extent of the melt pool or the energy beam spot.

Abstract: A method of monitoring an additive manufacturing apparatus. The method includes receiving one or more sensor signals from the additive manufacturing apparatus during a build of a workpiece, comparing the one or more sensor signals to a corresponding acceptable process variation of a plurality of acceptable process variations and generating a log based upon the comparisons. Each acceptable process variation of the plurality of acceptable process variations is associated with at least one state of progression of the build of the workpiece and the corresponding acceptable process variation is the acceptable process variation associated with the state of progression of the build when the one or more sensor signals are generated.