Abstract: An additive manufacturing machine may include a beam source, a process chamber, a beam column operably coupled to the process chamber and/or defining a portion of the process chamber, and a gaseous ionization detector disposed about the beam column. The gaseous ionization detector may be configured to detect elementary particles corresponding to an ionizing gas ionized by an energy beam from the beam source. A method of additively manufacturing a three-dimensional object may include determining data from a gaseous ionization detector disposed about a beam column of an additive manufacturing machine, and additively manufacturing a three-dimensional object using the additive manufacturing machine based at least in part on the data from the gaseous ionization detector.

Abstract: An additively manufactured component and a method for manufacturing the same are provided. The additively manufactured component includes a cross sectional layer having a surface surrounding the cross sectional layer. The cross sectional layer is formed by moving a focal point of an energy source over a bed of additive material. A surface irregularity is formed on the surface by manipulating the energy level of the energy source. The surface may include a datum feature positioned at a predetermined location relative to the surface irregularity and the surface irregularity may be greater than a surface roughness of the surface but less than one millimeter.

Abstract: A system and method of monitoring a powder-bed additive manufacturing process is provided where a layer of additive powder is fused using an energy source and electromagnetic emission signals are measured by a melt pool monitoring system to monitor the print process. The measured emission signals are analyzed to identify outlier emissions and clusters of outliers are identified by assessing the spatial proximity of the outlier emissions, e.g., using clustering algorithms, spatial control charts, etc. An alert may be provided or a process adjustment may be made when a cluster is identified or when a magnitude of a cluster exceeds a predetermined cluster threshold.

Abstract: A method, apparatus, and program for additive manufacturing. The additive manufacturing method may include solidifying at least a portion of a first layer (601) of build material (416) within a first scan region (902A). At least one of a build unit (400) and a build platform (310) may be moved to solidify at least a portion of the first layer (601) of build material (416) within a second scan region (902B). A second layer (602) of build material (416) may be provided over at least a portion of the first scan region (902A) and the second scan region (902B). A second layer (602) of build material (416) may be solidified within at least a portion of the third scan region (902C), the third scan region (902C) may at least partially overlap and may be offset with relation to the first scan region (902A).

Abstract: A method of controlling a manufacturing process in which directed energy selectively melts material, forming a melt pool. The method includes: generating an image having an array of individual image elements, the image including measurement, for each image element, of two or more physical properties from the group including: color, emission frequency, and sheen, the measurements collectively indicating presence of: liquid phase, melting, or incipient melting; from the measurements, mapping a boundary of the melt pool, wherein for each of the measurements that indicate liquid phase, melting, or incipient melting, corresponding image elements are defined to be inside the boundary, and wherein for each of the measurements that do not indicate liquid phase, melting, or incipient melting, the corresponding image elements are defined to be outside of the boundary; and controlling at least one aspect of the additive manufacturing process with reference to the boundary.

Abstract: A system and method of monitoring a powder-bed additive manufacturing process is provided where a layer of additive powder is fused using an energy source and electromagnetic emission signals are measured by a melt pool monitoring system to monitor the print process. The measured emission signals are analyzed to identify outlier emissions and clusters of outliers are identified by assessing the spatial proximity of the outlier emissions, e.g., using clustering algorithms, spatial control charts, etc. An alert may be provided or a process adjustment may be made when a cluster is identified or when a magnitude of a cluster exceeds a predetermined cluster threshold.

Abstract: A system and method of monitoring a powder-bed additive manufacturing process is provided where a layer of additive powder is fused using an energy source and electromagnetic emission signals are measured by a melt pool monitoring system to monitor the print process. The measured emission signals are analyzed to identify outlier emissions and clusters of outliers are identified by assessing the spatial proximity of the outlier emissions, e.g., using clustering algorithms, spatial control charts, etc. An alert may be provided or a process adjustment may be made when a cluster is identified or when a magnitude of a cluster exceeds a predetermined cluster threshold.

Abstract: An additive manufacturing machine may include a beam source, a process chamber, a beam column operably coupled to the process chamber and/or defining a portion of the process chamber, and a gaseous ionization detector disposed about the beam column. The gaseous ionization detector may be configured to detect elementary particles corresponding to an ionizing gas ionized by an energy beam from the beam source. A method of additively manufacturing a three-dimensional object may include determining data from a gaseous ionization detector disposed about a beam column of an additive manufacturing machine, and additively manufacturing a three-dimensional object using the additive manufacturing machine based at least in part on the data from the gaseous ionization detector.

Abstract: A method of controlling an additive manufacturing process in which a directed energy source is used to selectively melt material to form a workpiece, forming a melt pool in the process of melting. The method includes: using an imaging apparatus to generate an image of the melt pool comprising an array of individual image elements, the image including a measurement of at least one physical property for each of the individual image elements; from the measurements, mapping a melt pool boundary of the melt pool; applying Green's theorem to the melt pool boundary; and controlling at least one aspect of the additive manufacturing process with reference to the Green's theorem application.

Abstract: An additively manufactured component and a method for manufacturing the same are provided. The additively manufactured component includes a cross sectional layer having a surface surrounding the cross sectional layer. The cross sectional layer is formed by moving a focal point of an energy source over a bed of additive material. A surface irregularity is formed on the surface by manipulating the energy level of the energy source. The surface may include a datum feature positioned at a predetermined location relative to the surface irregularity and the surface irregularity may be greater than a surface roughness of the surface but less than one millimeter.

Abstract: An additively manufactured component and a method for manufacturing the same are provided. The additively manufactured component includes a cross sectional layer having a surface surrounding the cross sectional layer. The cross sectional layer is formed by moving a focal point of an energy source over a bed of additive material. A surface irregularity is formed on the surface by manipulating the energy level of the energy source. The surface may include a datum feature positioned at a predetermined location relative to the surface irregularity and the surface irregularity may be greater than a surface roughness of the surface but less than one millimeter.

Abstract: A method, apparatus, and program for additive manufacturing. The additive manufacturing method may include solidifying at least a portion of a first layer (601) of build material (416) within a first scan region (902A). At least one of a build unit (400) and a build platform (310) may be moved to solidify at least a portion of the first layer (601) of build material (416) within a second scan region (902B). A second layer (602) of build material (416) may be provided over at least a portion of the first scan region (902A) and the second scan region (902B). A second layer (602) of build material (416) may be solidified within at least a portion of the third scan region (902C), the third scan region (902C) may at least partially overlap and may be offset with relation to the first scan region (902A).

Abstract: A method of controlling an additive manufacturing process in which a directed energy source is used to selectively melt material to form a workpiece, forming a melt pool in the process of melting, the method comprising: using an imaging apparatus to generate an image of the melt pool comprising an array of individual image elements, the image including a measurement of at least one physical property for each of the individual image elements; from the measurements, mapping a melt pool boundary of the melt pool; computing a fractal dimension of the melt pool; and controlling at least one aspect of the additive manufacturing process with reference to the fractal dimension.

Abstract: A system and method for additively manufacturing a component including features for part identification are provided. The method includes selectively depositing a contrast agent on a cross sectional layer to define a component identifier of the component and directing energy from an energy source onto the contrast agent to fuse the contrast agent and the cross sectional layer. The contrast agent may be an x-ray emission contrast agent that is read using an x-ray emission spectroscopy method, an infrared contrast agent that is read using an infrared camera or an infrared scanner, or a radioactive contrast agent that is read using a gamma ray spectrometer.

Abstract: A method of controlling a manufacturing process in which directed energy selectively melts material, forming a melt pool. The method includes: generating an image having an array of individual image elements, the image including measurement, for each image element, of two or more physical properties from the group including: color, emission frequency, and sheen, the measurements collectively indicating presence of: liquid phase, melting, or incipient melting; from the measurements, mapping a boundary of the melt pool, wherein for each of the measurements that indicate liquid phase, melting, or incipient melting, corresponding image elements are defined to be inside the boundary, and wherein for each of the measurements that do not indicate liquid phase, melting, or incipient melting, the corresponding image elements are defined to be outside of the boundary; and controlling at least one aspect of the additive manufacturing process with reference to the boundary.

Abstract: A system and method for calibrating a melt pool monitoring system of an additive manufacturing machine includes installing a calibration system on the machine and performing a calibration process. Specifically, the calibration system includes a calibration platform removably mountable to a build platform of the additive manufacturing machine and having calibrated electromagnetic energy sources mounted thereon for defining a measurement standard. The electromagnetic energy generated is measured by the melt pool monitoring system and compared to the known measurement standard to determine whether system adjustments would improve process tolerances or uniformity.

Abstract: A method of controlling an additive manufacturing process in which a directed energy source is used to selectively melt material to form a workpiece, forming a melt pool in the process of melting, the method comprising: using an imaging apparatus to generate an image of the melt pool comprising an array of individual image elements, the image including a measurement of at least one physical property for each of the individual image elements; from the measurements, mapping a melt pool boundary of the melt pool; computing a geometric length of the melt pool boundary; and controlling at least one aspect of the additive manufacturing process with reference to the geometric length.

Abstract: The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials.

Abstract: A method of controlling an additive manufacturing process in which a directed energy source is used to selectively melt material to form a workpiece, forming a melt pool in the process of melting, the method including: using an imaging apparatus to generate an image of the melt pool comprising an array of individual image elements, the image including a measurement of at least one physical property for each of the individual image elements; from the measurements, mapping a melt pool boundary of the melt pool; and controlling at least one aspect of the additive manufacturing process with reference to the melt pool boundary.

Abstract: The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials, in-process monitoring, and closed loop control.