Estimation algorithms, methods, and systems are provided that estimate the internal temperatures inside of a part being built using powder bed fusion (PBF). Closed-loop state estimation is applied to the problem of monitoring temperature fields within parts during the PBF build process. A simplified linear time-invariant (LTI) model of PBF thermal physics with the properties of stability, controllability and observability is presented. In some aspects, an Ensemble Kalman Filter is applied to the model. Linear time-varying (LTV) systems are also contemplated.

A novel process for creating porous structures via powder bed fusion additive manufacturing is provided. The process reduces the computational requirement for generation of the porous structure geometry and for processing the porous structure geometry to generate CNC code. The process provides reduced file size for CNC code and avoids large files which may exceed capacity of manufacturing machines. The process also significantly reduces the time required to sinter the porous structure on a powder bed fusion manufacturing machine.

A novel process for creating porous structures via powder bed fusion additive manufacturing is provided. The process reduces the computational requirement for generation of the porous structure geometry and for processing the porous structure geometry to generate CNC code. The process provides reduced file size for CNC code and avoids large files which may exceed capacity of manufacturing machines. The process also significantly reduces the time required to sinter the porous structure on a powder bed fusion manufacturing machine.

The invention relates to a bone implant, comprising a main body, which has, in its outer region, an open-cell porous lattice structure, which is formed from a plurality of regularly arranged elementary cells, the elementary cells being in the form of an assembled structure and each being composed of an interior and of a plurality of interconnected bars surrounding the interior. The porous lattice structure is provided with a bone-growth-promoting coating comprising calcium phosphate, the calcium phosphate coating having a hydroxylapatite proportion forming a pore inner coating extending into the depth of the porous lattice structure.

A supported product manufactured using additive manufacturing, wherein the supported product provides a simplified post processing. The supported product contains a product and a support structure, wherein the supported product has been manufactured using additive manufacturing as a whole, wherein the support structure is adapted to be removed to provide the product, wherein the support structure provides an interface adapted to interact with a counterpart of a tool for removing the support structure.

A supported product manufactured using additive manufacturing, wherein the supported product provides a simplified post processing. The supported product contains a product and a support structure, wherein the supported product has been manufactured using additive manufacturing as a whole, wherein the support structure is adapted to be removed to provide the product, wherein the support structure provides an interface adapted to interact with a counterpart of a tool for removing the support structure.

A method of monitoring an additive manufacturing apparatus. The method includes receiving one or more sensor signals from the additive manufacturing apparatus during a build of a workpiece, comparing the one or more sensor signals to a corresponding acceptable process variation of a plurality of acceptable process variations and generating a log based upon the comparisons. Each acceptable process variation of the plurality of acceptable process variations is associated with at least one state of progression of the build of the workpiece and the corresponding acceptable process variation is the acceptable process variation associated with the state of progression of the build when the one or more sensor signals are generated.

A method of monitoring an additive manufacturing apparatus. The method includes receiving one or more sensor signals from the additive manufacturing apparatus during a build of a workpiece, comparing the one or more sensor signals to a corresponding acceptable process variation of a plurality of acceptable process variations and generating a log based upon the comparisons. Each acceptable process variation of the plurality of acceptable process variations is associated with at least one state of progression of the build of the workpiece and the corresponding acceptable process variation is the acceptable process variation associated with the state of progression of the build when the one or more sensor signals are generated.

Described herein are additive manufacturing methods and products made using such methods. The alloy compositions described herein are specifically selected for the additive manufacturing methods and provide products that exhibit superior mechanical properties as compared to their cast counterparts. Using the compositions and methods described herein, products that do not exhibit substantial coarsening, such as at elevated temperatures, can be obtained. The products further exhibit uniform microstructures along the print axis, thus contributing to improved strength and performance. Additives also can be used in the alloys described herein.

Described herein are additive manufacturing methods and products made using such methods. The alloy compositions described herein are specifically selected for the additive manufacturing methods and provide products that exhibit superior mechanical properties as compared to their cast counterparts. Using the compositions and methods described herein, products that do not exhibit substantial coarsening, such as at elevated temperatures, can be obtained. The products further exhibit uniform microstructures along the print axis, thus contributing to improved strength and performance. Additives also can be used in the alloys described herein.