According to some embodiments, system and methods are provided comprising receiving, via a communication interface of a parameter development module comprising a processor, a defined geometry for one or more parts, wherein the parts are manufactured with an additive manufacturing machine, and wherein a stack is formed from one or more parts; fabricating the one or more parts with the additive manufacturing machine based on a first parameter set; collecting in-situ monitoring data from one or more in-situ monitoring systems of the additive manufacturing machine for one or more parts; determining whether each stack should receive an additional part based on an analysis of the collected in-situ monitoring data; and fabricating each additional part based on the determination the stack should receive the additional part. Numerous other aspects are provided.

A method for detecting a position of an energy beam comprises mapping a first density modulated x-ray signal with a plurality of locations on an energy beam target, thereby generating a model of a background x-ray intensity. The method further comprises forming an x-ray signal time series using subsequent intensity modulated x-ray signals, each resulting from scanning the energy beam along the energy beam target in one of a plurality of directions at one of a plurality of speeds, and determining the position of the energy beam based upon a received x-ray signal strength based on the x-ray signal time series and the model of the background x-ray intensity.

A method for detecting a position of an energy beam comprises mapping a first density modulated x-ray signal with a plurality of locations on an energy beam target, thereby generating a model of a background x-ray intensity. The method further comprises forming an x-ray signal time series using subsequent intensity modulated x-ray signals, each resulting from scanning the energy beam along the energy beam target in one of a plurality of directions at one of a plurality of speeds, and determining the position of the energy beam based upon a received x-ray signal strength based on the x-ray signal time series and the model of the background x-ray intensity.

A system for additive metal manufacturing, including a deposition mechanism, a translation mechanism mounting the deposition mechanism to the working volume, and a stage. A method for additive metal manufacturing including: selectively depositing a material carrier within the working volume; removing an additive from the material carrier; and treating the resultant material.

This invention teaches a quality assurance system for additive manufacturing. This invention teaches a multi-sensor, real-time quality system including sensors, affiliated hardware, and data processing algorithms that are Lagrangian-Eulerian with respect to the reference frames of its associated input measurements. The quality system for Additive Manufacturing is capable of measuring true in-process state variables associated with an additive manufacturing process, i.e. those in-process variables that define a feasible process space within which the process is deemed nominal. The in-process state variables can also be correlated to the part structure or microstructure and can then be useful in identifying particular locations within the part likely to include defects.

This invention teaches a quality assurance system for additive manufacturing. This invention teaches a multi-sensor, real-time quality system including sensors, affiliated hardware, and data processing algorithms that are Lagrangian-Eulerian with respect to the reference frames of its associated input measurements. The quality system for Additive Manufacturing is capable of measuring true in-process state variables associated with an additive manufacturing process, i.e. those in-process variables that define a feasible process space within which the process is deemed nominal. The in-process state variables can also be correlated to the part structure or microstructure and can then be useful in identifying particular locations within the part likely to include defects.

Provided is a method for determining the onset of melting of a material and comprising providing a layer of the material; defining a reference area within the layer of material; providing a temperature sensor and a heat source above the reference area, the temperature sensor comprising a plurality of pixels configured to monitor the temperature of the reference area; selecting a first pixel and a second pixel to form a first reference pair of pixels of the temperature sensor to detect the temperature of corresponding first and second regions within the reference area; operating the heat source to heat the reference area over a duration of time, while monitoring, using the reference pair of pixels, the temperature of the two regions, wherein the heat source causes a temperature difference between the two regions such that the first and second pixel detect respective different temperatures over the duration of time; and determining the onset of melting of the material from the evolution of the temperature difference over the duration of time. Further provided is a controller for carrying out the method and an apparatus for the layer by layer formation of a three-dimensional object from particulate material is also provided, comprising the temperature sensor, and in which the onset of melting as determined in situ may be applied as a set point for measurement of the temperature sensor.

Provided is a method for determining the onset of melting of a material and comprising providing a layer of the material; defining a reference area within the layer of material; providing a temperature sensor and a heat source above the reference area, the temperature sensor comprising a plurality of pixels configured to monitor the temperature of the reference area; selecting a first pixel and a second pixel to form a first reference pair of pixels of the temperature sensor to detect the temperature of corresponding first and second regions within the reference area; operating the heat source to heat the reference area over a duration of time, while monitoring, using the reference pair of pixels, the temperature of the two regions, wherein the heat source causes a temperature difference between the two regions such that the first and second pixel detect respective different temperatures over the duration of time; and determining the onset of melting of the material from the evolution of the temperature difference over the duration of time. Further provided is a controller for carrying out the method and an apparatus for the layer by layer formation of a three-dimensional object from particulate material is also provided, comprising the temperature sensor, and in which the onset of melting as determined in situ may be applied as a set point for measurement of the temperature sensor.

A method of characterizing an optical system of a laser processing system includes directing an energy beam through a plurality of portions of a sample by adjusting an orientation of an adjustable beam redirection element of the optical system in accordance with a predetermined movement pattern to form a plurality of test patterns in the sample at each portion. The optical system comprises an imaging system having an expected focal position. In the movement pattern, the energy beam is directed in a plurality of different directions in the sample in the formation of each test pattern. At least two of the plurality of test patterns are formed at different calibration distances from an expected focal position of the optical system. An accuracy of the expected focal position is determined by detecting a level of modification in the sample caused by the energy beam at the plurality of test patterns.

A method of characterizing an optical system of a laser processing system includes directing an energy beam through a plurality of portions of a sample by adjusting an orientation of an adjustable beam redirection element of the optical system in accordance with a predetermined movement pattern to form a plurality of test patterns in the sample at each portion. The optical system comprises an imaging system having an expected focal position. In the movement pattern, the energy beam is directed in a plurality of different directions in the sample in the formation of each test pattern. At least two of the plurality of test patterns are formed at different calibration distances from an expected focal position of the optical system. An accuracy of the expected focal position is determined by detecting a level of modification in the sample caused by the energy beam at the plurality of test patterns.