There is a stack visualization method using a stack visualization apparatus including a deposition head. The method comprises collecting a moving speed of the deposition head; collecting laser power information of the deposition head by which a laser is irradiated to a stack; selecting a virtual stack corresponding to the moving speed of the deposition head and the laser power information among a plurality of previously stored virtual stacks based on the moving speed of the deposition head and the laser power information; and visualizing the selected virtual stack through a digital twin model.

Disclosed is a method for providing a control command set for an additive manufacturing device. The method includes providing a parameter set consisting of a number of parameters, and a construction rule, which is suitable for describing at least one section of the object by the parameter set geometrically as a number of linear or flat elements in space; generating a computer-based layer model of the section of the object by determining, for each layer, the position and shape of a cross-section of the section of the object within the layer, generating a control command set for an additive manufacturing device by which the production of the section of the object is implemented on the basis of the layer model.

A method of optimizing an additive manufacturing (AM) process includes receiving at least one design parameter of the AM process, receiving information relating to uncertainty in at least one other parameter of the AM process, performing uncertainty quantification in the optimization processor based on the at least one design parameters and uncertainty information to identify a shape error in an object being produced, updating the at least one design parameter of the AM process and utilizing the updated at least one design parameter in the AM process. A system for optimizing an AM process includes a design processor to produce at least one design parameter for an object to be manufactured, and an optimization processor to receive the at least one design parameter and uncertainty information to identify a shape error in the object to be manufactured and update the design parameters based on the shape error, prior or during the manufacturing process.

The present disclosure relates to computer-implemented methods for tuning parameters associated with powder bed fusion processes of additive manufacturing, such as laser sintering. Disclosed herein are methods for determining scanning strategies on the basis of information about the build material, additive manufacturing apparatus, and desired or intended features of the part.

A method of optimizing an additive manufacturing (AM) process includes receiving at least one design parameter of the AM process, receiving information relating to uncertainty in at least one other parameter of the AM process, performing uncertainty quantification in the optimization processor based on the at least one design parameters and uncertainty information to identify a shape error in an object being produced, updating the at least one design parameter of the AM process and utilizing the updated at least one design parameter in the AM process. A system for optimizing an AM process includes a design processor to produce at least one design parameter for an object to be manufactured, and an optimization processor to receive the at least one design parameter and uncertainty information to identify a shape error in the object to be manufactured and update the design parameters based on the shape error, prior or during the manufacturing process.

This invention concerns apparatus for generating instructions for machines of a manufacturing chain used to manufacture a workpiece. The apparatus comprising a processor arranged to receive a model based definition (MBD) of a workpiece including geometric dimensions and tolerances; receive inputs setting an additive build design for building the workpiece based upon the geometric dimensions; generate additive instructions for an additive manufacturing machine of the manufacturing chain based upon the additive build design; determine a prospective intermediate workpiece product expected from an additive build in accordance with the additive build design; determine differences between the prospective intermediate workpiece product and the model based definition of the workpiece; and generate further instructions for at least one further machine of the manufacturing chain based upon the differences.

Disclosed is a method for providing a control command set for an additive manufacturing device. The method includes providing a parameter set consisting of a number of parameters, and a construction rule, which is suitable for describing at least one section of the object by the parameter set geometrically as a number of linear or flat elements in space; generating a computer-based layer model of the section of the object by determining, for each layer, the position and shape of a cross-section of the section of the object within the layer, generating a control command set for an additive manufacturing device by which the production of the section of the object is implemented on the basis of the layer model.

A method (1) for optimizing a production process for a component (20, 32) that is to be manufactured by additive manufacturing by means of simulation (2) of the production process (50) includes: a) ascertaining a position of the component (20, 32) in a production space that has been optimized according to a process optimization criterion (7); b) calculating displacements and/or stresses in the component (20, 32) that can be caused by the production process (50); c) ascertaining supporting structures (31) that counteract the displacements and/or stresses that have been optimized according to the process optimization criterion (7); and d) ascertaining at least a portion of the design of the component (20, 32) that has been optimized according to a component optimization criterion (8).

A system/method for executing a program accessing a plurality of subroutines/libraries; invoking a first subroutine providing the program with axis data having offset values in accordance with a workpiece coordinate system; invoking a second subroutine providing the program with geometric data about a geometric of an additive manufacturing tool and setting a tool offset point of the tool at a distance above a substrate surface; receiving a workpiece identifier from an HMI; invoking a third subroutine providing the program with rapid plasma deposition part programming instructions and rapid plasma deposition features from one of the libraries based on the workpiece identifier; invoking a fourth subroutine verifying the instructions and the rapid plasma deposition features; and invoking a fifth subroutine enabling the program to request an additive manufacturing system to deposit a layer on the substrate surface by the additive manufacturing tool via the additive manufacturing process.

A method for modeling additive manufacturing of a part, includes (i) constructing a model for estimating output of a simulated additive manufacturing process based upon part design, energy equation and at least one additional relationship selected from the group consisting of phase field equation, concentration equation and stress equation; (ii) entering process operating parameters into the model to produce an output; (iii) comparing the output to acceptance criteria to determine whether the output is acceptable or unacceptable; (iv) for acceptable output, adding operating parameters which resulted in the acceptable output to a process map for additive manufacturing the part; and (v) repeating steps (ii) through (iv) for different operating parameters until the process map is complete.