General Electric Company

Tyler Nathaniel Nelson

Dean Michael Robinson

Adegboyega Masud Makinde

Pinghai Yang

Brian Scott McCarthy

Rajesh Kartik Bollapragada

Aymeric Moinet

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.

Apparatuses, systems, and methods for providing enhanced recoater event prediction for DMLM additive manufacturing

A compensation field indicating an amount of distortion compensation to be applied across at least a portion of a component is determined, and a nominal computer-aided design (CAD) model of a component is modified based on the compensation field. The amount of distortion compensation corresponds to a multiplication product of: (i) a deviation between the nominal CAD model and a physical representation of the component having been produced based on the nominal CAD model, and (ii) a nonlinear scale factor map that includes a map associating a plurality of locations of the nominal CAD model to corresponding ones of a plurality of scale factors respectively representing an increase or a decrease in the amount of distortion compensation to be applied based on a simulated effect upon the component in response to an iterative simulation process.

Hybrid measurement and simulation based distortion compensation system for additive manufacturing processes

An additive manufacturing system includes a control system communicatively coupled to a consolidation device and configured to control operation of the consolidation device. The control system is configured to generate a model of a component including a plurality of elements and at least one region of interest. The control system is also configured to apply at least one strain load to at least one element of the plurality of elements and generate a build characteristic contribution profile based on the at least one strain load. The control system is further configured to determine a build parameter based at least partly on the build characteristic contribution profile.

Additive manufacturing systems and methods including build characteristic contribution profiles

A method and system, the method including receiving a nominal computer-aided design (CAD) model of a component; producing a physical representation of the component based on the CAD model using an additive manufacturing (AM) process; measuring the produced physical representation of the component to obtain measurement data of the physical representation of the component; determining a deviation between a geometry of the CAD model and the measurement data of the physical representation of the component; calculating a nonlinear scale factor using an iterative simulation process; determining a compensation field based on the determined deviation between the geometry of the CAD model and the measurement data of the physical representation of the component and the calculated nonlinear scale factor; modifying the nominal CAD model by the determined compensation field; and producing a physical representation of the component based on the modified nominal CAD model.

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Schenectady, NY, United States of America

Tyler Nathaniel Nelson