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 algebraic connectivity of the melt pool; and controlling at least one aspect of the additive manufacturing process with reference to the algebraic connectivity.

Abstract: A system and method for authenticating an additively manufactured component is provided. The method includes locating an identifying region of the component that includes localized density variations that define a component identifier. The method further includes interrogating the identifying region of the component using a scanning device such as an x-ray computed tomography device to obtain the component identifier. The method further includes obtaining a reference identifier from a database, comparing the component identifier to the reference identifier, and determining that the component is authentic if the component identifier matches the reference identifier.

Abstract: A system and method for authenticating an additively manufactured component are provided. The method includes locating an identifying region on the component which may be positioned at a predetermined location relative to an identifiable datum feature. The identifying region may be scanned to determine a component identifier of the component. A reference identifier may be obtained from a database and compared to the component identifier to determine whether the component is authentic.

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; using a software machine learning algorithm to classify each image as acceptable or unacceptable; and controlling at least one aspect of the additive manufacturing process with reference to the image classification.

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: 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 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: 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 algebraic connectivity of the melt pool; and controlling at least one aspect of the additive manufacturing process with reference to the algebraic connectivity.

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: A method and apparatus for additive manufacturing is provided whereby a curtain of powder is provided adjacent a vertically oriented build plate, and a laser melts or sinters the powder over a region of the build plate. The curtain of powder is moved relative to the build plate to maintain the same distance between the curtain and the previously deposited layer, and the process repeated to provide a three dimensional structure on the build plate.

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: The present invention is related to additive manufacturing methods and systems using a recoater with in-situ exchangeable recoater blades. Being able to switch out recoater blades in situ, i.e. without stopping the build and opening up the build chamber, is advantageous, especially for larger, more complicated, and/or longer builds. For instance, if a recoater blade becomes damaged, a new one can be readily swapped in. Or if a different material for the object(s) is used during the build, it may be advantageous to switch in a new recoater blade that is made of the new, different material.

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: 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: 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 for authenticating an additively manufactured component are provided. The method includes locating an identifying region on the component which may be positioned at a predetermined location relative to an identifiable datum feature. The identifying region may be scanned to determine a component identifier of the component. A reference identifier may be obtained from a database and compared to the component identifier to determine whether the component is authentic.

Abstract: A system and method for manufacturing and authenticating an additively manufactured component are provided. The method includes additively manufacturing the component including a first component identifier. A second component identifier is generated using the first component identifier and an encryption key. The second component identifier is additively manufactured onto the component and the first and second component identifiers are stored in a database as an authenticating pair. An end user may determine that a component is authentic if it contains a first component identifier and a second component identifier that match an authenticating pair from the database.

Abstract: A method for additively manufacturing a component is provided. The method includes additively manufacturing an identifying region of the component including localized density variations that define a component identifier of the component. The localized density variations may be formed using two materials having different densities, by manipulating an energy source to underexpose or overexpose a layer of powder, or by laser shock peening the component during the additive manufacturing process. This method generates a three-dimensional unique component identifier that may be invisible to the naked eye and detectable only through interrogation by a scanning device, such as an x-ray computed tomography device. The component identifier may be stored in a database as a reference identifier and may be used for authenticating components.

Abstract: A system and method for authenticating an additively manufactured component is provided. The method includes locating an identifying region of the component that includes localized density variations that define a component identifier. The method further includes interrogating the identifying region of the component using a scanning device such as an x-ray computed tomography device to obtain the component identifier. The method further includes obtaining a reference identifier from a database, comparing the component identifier to the reference identifier, and determining that the component is authentic if the component identifier matches the reference identifier.

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.