Method and system for integrating real-time monitoring and integrity diagnosis into component manufacturing

Abstract

There is disclosed an improved additive manufacturing method and system for the production of components and structures, which integrates real-time monitoring and integrity diagnosis systems directly into the manufacturing process. The method introduces smart slicing technique by which smart sensor network layers (SNL) are embedded into sliced layers of a 3-D model at critical points during component design. The critical points are identified by structural analyses of the component using Finite Element Analysis (FEA). A Smart Extrusion and Mixing Module (SEMM) produces both primary printing material and conductive material for SNL layers. The SEMM operates in a direct extrusion mode for primary material and in a mixing and extrusion mode for conductive material. An Artificial Intelligence Single Board Computer (AISBC) manages the printing process and communication with SNL layers. Defect detection occurs in real-time during manufacturing, aided by a scanning module powered by an AI algorithm.