Embodiments of the present disclosure are drawn to systems and methods for adjusting a three-dimensional (3D) model used in metal additive manufacturing to maintain dimensional accuracy and repeatability of a fabricated 3D part. These embodiments may be used to reduce or remove geometric distortions in the fabricated 3D part. One exemplary method may include: receiving, via one or more processors, a selection made by a user; receiving a 3D model of a desired part; retrieving at least one model constant based on the user's selection; receiving an input of at least one process variable setting from a set of process variable settings; generating transformation factors based on the at least one process variable parameter and the at least one model constant; transforming the 3D model of the desired part based on the transformation factors; and generating processing instructions for fabricating the transformed 3D model of the desired part.

This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensing system that monitors two discrete wavelengths associated with a blackbody radiation curve of the layer of powder; determining temperature variations for an area of the build plane traversed by the scans based upon a ratio of sensor readings taken at the two discrete wavelengths; determining that the temperature variations are outside a threshold range of values; and thereafter, adjusting subsequent scans of the energy source across or proximate the area of the build plane.

A method may include receiving data associated with a part to be built by additive manufacturing using a recoater, predicting a distortion amount comprising a distance that the part is expected to distort in a vertical direction at one or more layers while the part is being built based on a simulation of the part being built, determining a likelihood of a recoater event based on the predicted distortion amount, determining a severity factor associated with the predicted distortion amount at each of the one or more layers of the part based on an orientation of the part at each of the one or more layers, and determining an adjusted likelihood of a recoater event at each of the one or more layers based on the predicted distortion amount and the determined severity factor. Apparatuses and systems are also provided for enhanced recoater event prediction for DMLM additive manufacturing.

Systems, apparatus, computer-readable medium, and associated methods to monitor, analyze, and adjust at least one of 1) additive machine health and configuration or 2) build health and configuration are disclosed. An example apparatus includes an analytics processor, separate from and in a trusted relationship with an additive manufacturing machine building a part, to process, based on a trigger, data from monitoring of the additive manufacturing machine and the build of the part, the analytics processor including a hybrid model fusing additive process physics and data science to process the data to identify an abnormality in at least one of the build or the additive manufacturing machine and to adjust a configuration of the additive manufacturing machine during the build to address the abnormality.

The disclosure provides methods and systems for measuring a base element of a construction cylinder arrangement in machines for the additive manufacture of 3D objects using a high-energy beam, wherein a measurement pattern is produced from laser light that illuminates the base element, and sites of incidence of the laser light are monitored and evaluated with a camera to produce measuring data about the base element, e.g., position information, orientation information, and/or information about the shape of the surface of the base element. The measurement patterns are produced by deflecting measuring laser beams by an optical scanner system towards the base element, and the camera is arranged laterally offset from the deflected laser beams. The new methods and systems enable measuring base elements in a simple and flexible manner, and require only a small amount of space in the processing chamber.

The disclosure provides methods and systems for measuring a base element of a construction cylinder arrangement in machines for the additive manufacture of 3D objects using a high-energy beam, wherein a measurement pattern is produced from laser light that illuminates the base element, and sites of incidence of the laser light are monitored and evaluated with a camera to produce measuring data about the base element, e.g., position information, orientation information, and/or information about the shape of the surface of the base element. The measurement patterns are produced by deflecting measuring laser beams by an optical scanner system towards the base element, and the camera is arranged laterally offset from the deflected laser beams. The new methods and systems enable measuring base elements in a simple and flexible manner, and require only a small amount of space in the processing chamber.

This disclosure describes various methods and apparatus for calibration of temperature sensors in additive manufacturing systems. A method for calibration of temperature sensors can include selecting a first wavelength and a second wavelength spaced apart from the first wavelength; measuring an amount of energy radiated from a black body source at the first wavelength; measuring an amount of energy radiated from the black body source at the second wavelength; generating a relationship between a ratio of the amount of energy radiated at the first wavelength to the amount of energy radiated at the second wavelength; and determining, using the relationship, variations in a temperature of a build plane of an additive manufacturing system based upon a ratio of energy radiated at the first wavelength to energy radiated at the second wavelength.

This disclosure describes various methods and apparatus for calibration of temperature sensors in additive manufacturing systems. A method for calibration of temperature sensors can include selecting a first wavelength and a second wavelength spaced apart from the first wavelength; measuring an amount of energy radiated from a black body source at the first wavelength; measuring an amount of energy radiated from the black body source at the second wavelength; generating a relationship between a ratio of the amount of energy radiated at the first wavelength to the amount of energy radiated at the second wavelength; and determining, using the relationship, variations in a temperature of a build plane of an additive manufacturing system based upon a ratio of energy radiated at the first wavelength to energy radiated at the second wavelength.

This disclosure describes various methods and apparatus for calibration of temperature sensors in additive manufacturing systems. A method for calibration of temperature sensors can include selecting a first wavelength and a second wavelength spaced apart from the first wavelength; measuring an amount of energy radiated from a black body source at the first wavelength; measuring an amount of energy radiated from the black body source at the second wavelength; generating a relationship between a ratio of the amount of energy radiated at the first wavelength to the amount of energy radiated at the second wavelength; and determining, using the relationship, variations in a temperature of a build plane of an additive manufacturing system based upon a ratio of energy radiated at the first wavelength to energy radiated at the second wavelength.

A modular system for performing additive manufacturing of an object includes at least two additive manufacturing devices, each having a housing with two slots on lateral sides to accommodate a manufacturing tray; a printer head and axis system; and a movement mechanism. A control module is operatively coupled to each of the at least two additive manufacturing devices. The control module is configured to control the at least two additive manufacturing devices to arrange the manufacturing tray in a first of the at least two additive manufacturing devices; print a part of the object on the manufacturing tray arranged in the first additive manufacturing device; move the manufacturing tray having the partially manufactured object to a second of the at least two additive manufacturing devices; and print a remaining part of the object on the manufacturing tray to complete the additive manufacturing of the object.