Abstract: Sensor values captured by a sensor device are determined, one or more regions of a three-dimensional component having a deviation from an intended value are determined based at least in part on build coordinates for additively manufacturing the three-dimensional component corresponding to the sensor values, and a quality of the three-dimensional component is evaluated based at least in part on the one or more regions of the three-dimensional component having a deviation from the intended value. The sensor values correspond to an electromagnetic spectrum emitted by a melt pool formed by exposing a powder bed to a beam of radiation emitted from a laser apparatus, with the beam of radiation generating the melt pool in a melt region of the powder bed.

Abstract: A method for producing a three-dimensional component by means of a laser melting process, in which the component is produced by consecutively solidifying individual layers made of building material by melting the building material, wherein said building material can be solidified by the action of radiation, wherein the melting area produced by a punctiform and/or linear energy input is detected by a sensor device and sensor values are derived therefrom in order to evaluate the component quality. The sensor values detected in order to evaluate the component quality are stored together with the coordinate values that locate the sensor values in the component and are displayed by means of a visualization unit in two- and/or multi-dimensional representation with respect to the detection location of the sensor values in the component.

Abstract: Sensor values captured by a sensor device are determined, one or more regions of a three-dimensional component having a deviation from an intended value are determined based at least in part on build coordinates for additively manufacturing the three-dimensional component corresponding to the sensor values, and a quality of the three-dimensional component is evaluated based at least in part on the one or more regions of the three-dimensional component having a deviation from the intended value. The sensor values correspond to an electromagnetic spectrum emitted by a melt pool formed by exposing a powder bed to a beam of radiation emitted from a laser apparatus, with the beam of radiation generating the melt pool in a melt region of the powder bed.

Abstract: Additive manufacturing systems may include a laser melting apparatus, a sensor device, and a visualization apparatus. A laser melting apparatus may form a three-dimensional component by exposing a powder bed to a beam of radiation based on build coordinates, with the beam of radiation providing an energy influx that generates a melt pool in a melt region of the powder bed. A sensor device may capture sensor values corresponding to the melt pool and/or the melt region. A visualization apparatus may display a representation of the three-dimensional component, with the display including the build coordinates and the sensor values in respect of a capture location thereof in the three-dimensional component. The displayed representation may be based on a display output that includes sensor values correlated with build coordinates.

Abstract: Systems and methods for generating an energy density map of an object to be built in an additive manufacturing environment are provided. Certain embodiments provide a method for building an object utilizing additive manufacturing, the method including: receiving a job file for building the object, wherein the job file includes a plurality of slices of the object, and wherein a first slice of the object indicates scanning lines for applying an energy source to build material to build the first slice of the object; determining operation parameters of the energy source; and generating a first energy density map of the first slice of the object based on the job file and the operation parameters of the energy source, wherein the first energy density map indicates an amount of energy from the energy source per area of build material applied to the build material for the first slice of the object.

Abstract: The present disclosure relates to computer-implemented methods for tuning parameters associated with powder bed fusion processes of additive manufacturing, such as laser sintering. Disclosed herein are methods for determining scanning strategies on the basis of information about the build material, additive manufacturing apparatus, and desired or intended features of the part.

Abstract: A system (100) and method for monitoring a recoating mechanism (415A, 415B) in an additive manufacturing environment is provided. Various embodiments involve the use of a control computer (102a-102d) to receive data based on a thermal image of a recoating mechanism (415A, 415B) from an imaging device (436) configured to capture thermal image. The control computer (102a-102d) further determines a value of a property of the thermal image, wherein the property is related to an amount of powder in the recoating mechanism. The control computer (102a-102d) further determines at least one of if the value indicates an error related to the amount of powder in the recoating mechanism (415A, 415B), and an action to take with respect to the recoating mechanism (415A, 415B) that is based on the value.

Abstract: Additive manufacturing systems may include a laser melting apparatus, a sensor device, and a visualization apparatus. A laser melting apparatus may form a three-dimensional component by exposing a powder bed to a beam of radiation based on build coordinates, with the beam of radiation providing an energy influx that generates a melt pool in a melt region of the powder bed. A sensor device may capture sensor values corresponding to the melt pool and/or the melt region. A visualization apparatus may display a representation of the three-dimensional component, with the display including the build coordinates and the sensor values in respect of a capture location thereof in the three-dimensional component. The displayed representation may be based on a display output that includes sensor values correlated with build coordinates.

Abstract: A method for producing a three-dimensional component by means of a laser melting process, in which the component is produced by consecutively solidifying individual layers made of building material by melting the building material, wherein said building material can be solidified by the action of radiation, wherein the melting area produced by a punctiform and/or linear energy input is detected by a sensor device and sensor values are derived therefrom in order to evaluate the component quality. The sensor values detected in order to evaluate the component quality are stored together with the coordinate values that locate the sensor values in the component and are displayed by means of a visualization unit in two- and/or multi-dimensional representation with respect to the detection location of the sensor values in the component.

Abstract: The present disclosure relates to the prediction of part and material quality of Additive Manufacturing (AM) processes using layer based images. Described herein are methods and systems for detection of errors in parts built by AM processes such as Selective Laser Melting (SLM). The detection comprises analysis of optical images to identify errors which appear in layers during the AM build process. Errors include but are not limited to warpage of parts and dross formation of overhang surfaces.

Abstract: Systems and methods for generating an energy density map of an object to be built in an additive manufacturing environment are provided. Certain embodiments provide a method for building an object utilizing additive manufacturing, the method including: receiving a job file for building the object, wherein the job file includes a plurality of slices of the object, and wherein a first slice of the object indicates scanning lines for applying an energy source to build material to build the first slice of the object; determining operation parameters of the energy source; and generating a first energy density map of the first slice of the object based on the job file and the operation parameters of the energy source, wherein the first energy density map indicates an amount of energy from the energy source per area of build material applied to the build material for the first slice of the object.

Abstract: This disclosure relates to a hybrid support system for supporting an object formed by three dimensional printing. In some embodiments, a hybrid support system includes one or more volume support structures, a first volume support structure of the one or more volume support structures being coupled to a base plate and to a first portion of the object. The hybrid support system further includes a partially solidified support structure coupled to a second portion of the object. The hybrid support system further includes one or more reinforcement support structures, a first reinforcement support structure of the one or more reinforcement support structures being coupled to the base plate and to at least one of a portion of the partially solidified support structure and a third portion of the object.

Abstract: A method for producing a three-dimensional component by means of a laser melting process, in which the component is produced by consecutively solidifying individual layers made of building material by melting the building material, wherein said building material can be solidified by the action of radiation, wherein the melting area produced by a punctiform and/or linear energy input is detected by a sensor device and sensor values are derived therefrom in order to evaluate the component quality. The sensor values detected in order to evaluate the component quality are stored together with the coordinate values that locate the sensor values in the component and are displayed by means of a visualization unit in two- and/or multi-dimensional representation with respect to the detection location of the sensor values in the component.

Abstract: A method for producing a three-dimensional component by means of a laser melting process, in which the component is produced by consecutively solidifying individual layers made of building material by melting the building material, wherein said building material can be solidified by the action of radiation, wherein the melting area produced by a punctiform and/or linear energy input is detected by a sensor device and sensor values are derived therefrom in order to evaluate the component quality. The sensor values detected in order to evaluate the component quality are stored together with the coordinate values that locate the sensor values in the component and are displayed by means of a visualization unit in two- and/or multi-dimensional representation with respect to the detection location of the sensor values in the component.

Abstract: The present disclosure relates to the prediction of part and material quality of Additive Manufacturing (AM) processes using layer based images. Described herein are methods and systems for detection of errors in parts built by AM processes such as Selective Laser Melting (SLM). The detection comprises analysis of optical images to identify errors which appear in layers during the AM build process. Errors include but are not limited to warpage of parts and dross formation of overhang surfaces.

Abstract: A method for producing a three-dimensional component by means of a laser melting process, in which the component is produced by consecutively solidifying individual layers made of building material by melting the building material, wherein said building material can be solidified by the action of radiation, wherein the melting area produced by a punctiform and/or linear energy input is detected by a sensor device and sensor values are derived therefrom in order to evaluate the component quality. The sensor values detected in order to evaluate the component quality are stored together with the coordinate values that locate the sensor values in the component and are displayed by means of a visualization unit in two- and/or multi-dimensional representation with respect to the detection location of the sensor values in the component.

Abstract: Embodiments set forth in this application relate to systems and methods by which parts produced by additive manufacturing can be reliably assessed for conformity to a known master model which has quality conforming to the desired specifications. These systems and methods involve recording a thermal history of the manufacturing process of each part. The recorded thermal history is then compared to the previously-recorded thermal history of the master model. Significant deviations in thermal history are indicative of irregularities in the manufacturing build, and the part quality may then be assessed in view of those irregularities.

Abstract: A system (100) and method for monitoring a recoating mechanism (415A, 415B) in an additive manufacturing environment is provided. Various embodiments involve the use of a control computer (102a-102d) to receive data based on a thermal image of a recoating mechanism (415A, 415B) from an imaging device (436) configured to capture thermal image. The control computer (102a-102d) further determines a value of a property of the thermal image, wherein the property is related to an amount of powder in the recoating mechanism. The control computer (102a-102d) further determines at least one of if the value indicates an error related to the amount of powder in the recoating mechanism (415A, 415B), and an action to take with respect to the recoating mechanism (415A, 415B) that is based on the value.

Abstract: This disclosure relates to a hybrid support system for supporting an object formed by three dimensional printing. In some embodiments, a hybrid support system includes one or more volume support structures, a first volume support structure of the one or more volume support structures being coupled to a base plate and to a first portion of the object. The hybrid support system further includes a partially solidified support structure coupled to a second portion of the object. The hybrid support system further includes one or more reinforcement support structures, a first reinforcement support structure of the one or more reinforcement support structures being coupled to the base plate and to at least one of a portion of the partially solidified support structure and a third portion of the object.

Abstract: A method for producing a three-dimensional component by means of a laser melting process, in which the component is produced by consecutively solidifying individual layers made of building material by melting the building material, wherein said building material can be solidified by the action of radiation, wherein the melting area produced by a punctiform and/or linear energy input is detected by a sensor device and sensor values are derived therefrom in order to evaluate the component quality. The sensor values detected in order to evaluate the component quality are stored together with the coordinate values that locate the sensor values in the component and are displayed by means of a visualization unit in two- and/or multi-dimensional representation with respect to the detection location of the sensor values in the component.