A set of multi-mode elastic wave generating and detecting devices and field sensors are utilized in a real-time in-situ monitoring system based on the quality assessment of a specially designed article made by an additive manufacturing machine. The original invention disclosed in U.S. patent application Ser. No. 15/731,366 involves the transmission and reception of waves into a periodic test artifact while it is being built. The current invention involves the transmission and reception of multi-mode waves into a test artifact, the processing of data from narrow and wide field-of-view sensors, and correlating and relating the waveforms and sensor data while it is being built using physics-based and machine learning models. The disclosed system may initiate control and real-time corrective actions based on the properties and characteristics of the obtained waveforms and sensor data and their correlations and functional relationships.

A powder dispensing assembly for an additive manufacturing machine is provided. The powder dispensing assembly includes a housing that defines a powder reservoir that receives additive powder; a first plate removably connectable to the housing, the first plate defining a first discharge orifice having a first discharge orifice geometry; and a second plate removably connectable to the housing, the second plate defining a second discharge orifice having a second discharge orifice geometry different than the first discharge orifice geometry, wherein with the first plate connected to the housing, the additive powder flows out of the first discharge orifice at a first dosing rate, and wherein with the second plate connected to the housing, the additive powder flows out of the second discharge orifice at a second dosing rate different than the first dosing rate.

A powder dispensing assembly for an additive manufacturing machine is provided. The powder dispensing assembly includes a housing that defines a powder reservoir that receives additive powder; a first plate removably connectable to the housing, the first plate defining a first discharge orifice having a first discharge orifice geometry; and a second plate removably connectable to the housing, the second plate defining a second discharge orifice having a second discharge orifice geometry different than the first discharge orifice geometry, wherein with the first plate connected to the housing, the additive powder flows out of the first discharge orifice at a first dosing rate, and wherein with the second plate connected to the housing, the additive powder flows out of the second discharge orifice at a second dosing rate different than the first dosing rate.

An additive manufacturing machine is provided. The additive manufacturing machine includes a build unit including a powder dispenser assembly defining a powder reservoir that receives additive powder; a dosing rate measurement device in communication with the powder dispenser assembly, wherein the dosing rate measurement device measures a dosing rate of the additive powder in-situ; and a controllable device operably coupled to the build unit and including one or more processors configured to execute a program to cause the controllable device to adjust the dosing rate of the additive powder based on the dosing rate measured by the dosing rate measurement device.

An additive manufacturing machine is provided. The additive manufacturing machine includes a build unit including a powder dispenser assembly defining a powder reservoir that receives additive powder; a dosing rate measurement device in communication with the powder dispenser assembly, wherein the dosing rate measurement device measures a dosing rate of the additive powder in-situ; and a controllable device operably coupled to the build unit and including one or more processors configured to execute a program to cause the controllable device to adjust the dosing rate of the additive powder based on the dosing rate measured by the dosing rate measurement device.

An additive manufacturing machine is provided. The additive manufacturing machine includes a build unit including a powder dispenser assembly defining a powder reservoir that receives additive powder; a dosing rate measurement device in communication with the powder dispenser assembly, wherein the dosing rate measurement device measures a dosing rate of the additive powder in-situ; and a controllable device operably coupled to the build unit and including one or more processors configured to execute a program to cause the controllable device to adjust the dosing rate of the additive powder based on the dosing rate measured by the dosing rate measurement device.

An additive manufacturing machine having a build vessel defining a work surface is provided. The additive manufacturing machine includes a build unit including a powder dispenser assembly defining a powder reservoir that receives additive powder; a positioning system adapted to provide independent movement of at least one of the build unit and the work surface with respect to one another in at least two dimensions; and a dosing rate measurement device in communication with the powder dispenser assembly, wherein the dosing rate measurement device measures a dosing rate of the additive powder in-situ.

An additive manufacturing machine having a build vessel defining a work surface is provided. The additive manufacturing machine includes a build unit including a powder dispenser assembly defining a powder reservoir that receives additive powder; a positioning system adapted to provide independent movement of at least one of the build unit and the work surface with respect to one another in at least two dimensions; and a dosing rate measurement device in communication with the powder dispenser assembly, wherein the dosing rate measurement device measures a dosing rate of the additive powder in-situ.

An additive manufacturing machine having a build vessel defining a work surface is provided. The additive manufacturing machine includes a build unit including a powder dispenser assembly defining a powder reservoir that receives additive powder; a positioning system adapted to provide independent movement of at least one of the build unit and the work surface with respect to one another in at least two dimensions; and a dosing rate measurement device in communication with the powder dispenser assembly, wherein the dosing rate measurement device measures a dosing rate of the additive powder in-situ.

A method of additive manufacture is disclosed. The method may include providing a powder bed and directing a shaped laser beam pulse train consisting of one or more pulses and having a flux greater than 20 kW/cm.sup.2 at a defined two dimensional region of the powder bed. This minimizes adverse laser plasma effects during the process of melting and fusing powder within the defined two dimensional region.