This invention teaches a multi-sensor quality inference system for additive manufacturing. This invention still further teaches a quality system that is capable of discerning and addressing three quality issues: i) process anomalies, or extreme unpredictable events uncorrelated to process inputs; ii) process variations, or difference between desired process parameters and actual operating conditions; and iii) material structure and properties, or the quality of the resultant material created by the Additive Manufacturing process. This invention further teaches experimental observations of the Additive Manufacturing process made only in a Lagrangian frame of reference. This invention even further teaches the use of the gathered sensor data to evaluate and control additive manufacturing operations in real time.

This invention teaches a multi-sensor quality inference system for additive manufacturing. This invention still further teaches a quality system that is capable of discerning and addressing three quality issues: i) process anomalies, or extreme unpredictable events uncorrelated to process inputs; ii) process variations, or difference between desired process parameters and actual operating conditions; and iii) material structure and properties, or the quality of the resultant material created by the Additive Manufacturing process. This invention further teaches experimental observations of the Additive Manufacturing process made only in a Lagrangian frame of reference. This invention even further teaches the use of the gathered sensor data to evaluate and control additive manufacturing operations in real time.

A powder bed machine including a distribution device, which is configured to be charged with process material. The powder bed machine has a residual powder tank within the manufacturing process, wherein the residual powder tank holds a surplus of the process material. The powder bed machine is positioned on feet and weighing cells are located in the feet.

A powder bed machine including a distribution device, which is configured to be charged with process material. The powder bed machine has a residual powder tank within the manufacturing process, wherein the residual powder tank holds a surplus of the process material. The powder bed machine is positioned on feet and weighing cells are located in the feet.

A method for calibrating a system that includes a build chamber to accommodate powder to be melted and an object to be produced and a height-adjustable build plate support in the build chamber to support a build plate. The system also includes a controllable optical unit comprising (1) a laser source, (2) a plurality of lenses, and (3) a mirror arrangement having a plurality of adjustably arranged mirrors. The controllable optical unit is configured to selectively direct a laser beam to a point in the build chamber at which to melt the powder. The method includes placing a scanning field plate on the build plate support, creating a plurality of optical reference points on the scanning field plate, generating a measuring grid on the scanning field plate by adjusting the mirrors using a calibration data set, and determining a relative positioning between the optical reference points and the measuring grid.

A method for calibrating a system that includes a build chamber to accommodate powder to be melted and an object to be produced and a height-adjustable build plate support in the build chamber to support a build plate. The system also includes a controllable optical unit comprising (1) a laser source, (2) a plurality of lenses, and (3) a mirror arrangement having a plurality of adjustably arranged mirrors. The controllable optical unit is configured to selectively direct a laser beam to a point in the build chamber at which to melt the powder. The method includes placing a scanning field plate on the build plate support, creating a plurality of optical reference points on the scanning field plate, generating a measuring grid on the scanning field plate by adjusting the mirrors using a calibration data set, and determining a relative positioning between the optical reference points and the measuring grid.

A processing system includes: a processing apparatus for processing an object; a rotation apparatus for rotating a holding part holding the object; a movement apparatus for moving at least one of the processing apparatus and the holding part; a measurement apparatus for measuring at least a part of the object held by the holding part; and a control apparatus for controlling the movement apparatus and the rotation apparatus based on a measured result by the measurement apparatus to rotate the holding part and to move at least one of the processing apparatus and the holding part

The present disclosure relates to a manufacturing system for additive manufacturing of a workpiece and an additive manufacturing method. The manufacturing system for additive manufacturing of a workpiece includes a building panel, a lifting device for the building panel, a blade device, an optical device, and a control unit. The blade device comprises at least one coater element for applying or removing a powder material to the building panel. The optical device comprises an optical element for reception of image data from the building panel and/or from the powder layer. The lifting device is configured to raise and/or lower the building panel. The control unit is configured to control the lifting device based on the image data.

A method of manufacturing 3D objects with an apparatus having first and second heat sources and a thermal sensor. The method includes carrying out a build process after a thermal calibration process for a thermal control component(s). The calibration and build processes include a layer cycle including (i) providing a layer of particulate material defining a build bed surface; (ia) heating the surface; (ii) depositing absorption modifier over a layer-specific region and/or a surrounding area; (iii) heating the layer-specific region with the first heat source; and (iv) measuring a temperature of the surface after at least one of (i) to (iii). The layer cycle includes heating the surface of each layer with the second heat source and repeating until the calibration/build processes are complete. The outcome of each calibration routine being based on the measured temperature and being applied to the thermal control component for the subsequent layer cycle.

A method for determining a set point for a thermal sensor. The method includes (a) distributing a layer of particulate material to provide a build bed surface; (b) depositing an amount of absorption modifier over a test region or a surrounding area; (c) heating the test region; (d) measuring a temperature value within the test region with the sensor; (e) distributing a new layer of material over the preceding layer; repeating (b) to (e) until the material of the test region starts to melt, wherein repeated step (b) deposits additional absorption modifier over the test region to absorb more energy from the heat source than the preceding layer; determining a set point for the thermal sensor from a characteristic in the evolution of the measured temperature value within the test region; and applying the set point to subsequent measurements of the thermal sensor.