Abstract: Systems and methods involved in additive manufacturing are disclosed. Calibrating one or more optical cameras of an additive manufacturing system includes controlling one or more laser energy sources to form a design on a surface. The design is a two-dimensional array of elements, at least two elements of the array differing in shape and/or orientation from each other. The method also includes obtaining one or more images of the design based on using the one or more cameras, and analyzing the one or more images by implementing one or more algorithms to determine or update parameters for each of the one or more cameras. The parameters of each of the one or more cameras include extrinsic parameters relating a printer coordinate system of the one or more laser energy sources and an image coordinate system of the camera, intrinsic parameters controlling image distortion resulting from lens properties, or both.

Abstract: Systems and methods for predicting weld and/or part defects during additive manufacturing process are disclosed. Additionally, systems and methods related to controlling an additive manufacturing process using predicted weld and/or build defects are disclosed.