Abstract: Methods for anomaly detection in additive manufacture using meltpool monitoring are disclosed. A method includes obtaining a process model representative of an object to be generated through additive manufacture. The method also includes generating, based on the process model and using a hybrid machine-learning model, an instruction for generating the object through additive manufacture. Another method includes generating a layer of an object, and taking a reading relative to the generation of the layer. The other method also includes updating, based on the reading and using a hybrid machine-learning model, a process model, the process model representative of the object. The other method also includes generating, based on the updated process model and using the hybrid machine-learning model, an instruction for generating a subsequent layer of the object through additive manufacture. Related systems and devices are also disclosed.

Abstract: A process for producing a powder witness coupon including additively manufacturing a container simultaneously with a primary part, filling at least a portion of the container with a feed material employed for the part simultaneously with the additive manufacturing of the primary part, and sealing the container during the additive manufacturing of the primary part. An in-situ feed material powder witness coupon including a container additively manufactured simultaneously with a primary part, and a plurality of individual chambers within the container, at least one of the chambers being removable intact from the container. Further, a method for enhancing examination of feed material in an additively manufactured part including additively manufacturing a container simultaneously with a primary part, capturing feed material, density and environment in the container, and sealing the container.

Abstract: An additive manufacturing system includes an additive manufacturing apparatus and control circuitry. The apparatus includes a build chamber, a platform, a material delivery system, a laser system, and a contaminant remover. The platform is positioned in the build chamber and is configured to support one or more objects being manufactured. The material delivery system is configured to provide feedstock material to the build chamber. The laser system is configured to melt the feedstock material to form the one or more objects being manufactured. The contaminant remover is configured to remove contaminants from a top layer of the one or more objects being manufactured prior to the material delivery system depositing a layer of the feedstock material thereon. The control circuitry is configured to control at least a portion of operation of the additive manufacturing apparatus. Contaminants may be removed from an object during manufacture of the object with the system.

Abstract: Methods for anomaly detection in additive manufacture using meltpool monitoring are disclosed. A method includes obtaining a process model representative of an object to be generated through additive manufacture. The method also includes generating, based on the process model and using a hybrid machine-learning model, an instruction for generating the object through additive manufacture. Another method includes generating a layer of an object, and taking a reading relative to the generation of the layer. The other method also includes updating, based on the reading and using a hybrid machine-learning model, a process model, the process model representative of the object. The other method also includes generating, based on the updated process model and using the hybrid machine-learning model, an instruction for generating a subsequent layer of the object through additive manufacture. Related systems and devices are also disclosed.

Abstract: A method of calibrating a laser of an additive manufacturing system involves processing a test pattern with the laser while varying one or more of laser power and/or scan speed. Thermal energy emitted from the resulting meltpool is measured while processing the test pattern. The power of the laser is calculated using a relationship between volumetric energy density and the thermal emissions, and the laser power is adjusted based on the calculated laser power. An additive manufacturing system for performing such a method may include a laser, a thermal sensor configured to measure meltpool thermal emissions, a processor configured to calculate a laser power based on the measured meltpool thermal emissions of the test pattern, and a controller configured to adjust the laser power based on the calculated laser power.

Abstract: A process for producing a powder witness coupon including additively manufacturing a container simultaneously with a primary part, filling at least a portion of the container with a feed material employed for the part simultaneously with the additive manufacturing of the primary part, and sealing the container during the additive manufacturing of the primary part. An in-situ feed material powder witness coupon including a container additively manufactured simultaneously with a primary part, and a plurality of individual chambers within the container, at least one of the chambers being removable intact from the container. Further, a method for enhancing examination of feed material in an additively manufactured part including additively manufacturing a container simultaneously with a primary part, capturing feed material, density and environment in the container, and sealing the container.

Abstract: Additive manufacturing systems and related systems, methods, and devices are disclosed. An additive manufacturing system includes an additive manufacturing apparatus configured to manufacture an object using additive manufacturing. The additive manufacturing system also includes control circuitry configured to correlate input factors related to manufacturing of the object to manufacturing outcomes.