Systems and methods for additively manufacturing parts using multiple processing strategies

Abstract

Systems, methods, and non-transitory computer-readable media are provided that enable additive manufacturing of parts using multiple processing strategies in a single build. In one exemplary aspect, a model representing a part is decomposed into sub-models, each corresponding to a sub-component of the part. Each sub-component may have preselected metrics associated therewith. The model may be decomposed into sub-models based, at least in part, on the preselected metrics. A set of build parameters may be selected or assigned to each sub-model based, at least in part, on the preselected metrics associated with the sub-components. An overlap region may be defined at each interface between adjacent sub-components. The build parameters selected for the adjacent sub-components may be used to blend build parameters for the defined overlap region. The sub-models and blended build parameters may be used to additively manufacture the part.

Description

Technical Field

[0001] This topic generally relates to additive manufacturing. Background Art

[0002] Traditionally, parts have been additively manufactured using a single processing strategy. In other words, for a given part, the same processing strategy is used to build each layer of the part. While parts can be built relatively easily using a single processing strategy, this single processing strategy can be slow and wasteful in terms of material deposition / fusion. Furthermore, specific features of the part may require critical quality metrics that must be achieved. In this case, the build parameters set for the single processing strategy are selected to ensure that the feature meets the quality metric. However, other features of the part may have other metrics or design specifications that may not be achievable using the build parameters selected for the single processing strategy. As a result, the design intent or metrics for other features may not be achieved using a single processing strategy.

[0003] Therefore, systems and methods that address one or more of the challenges described above would be useful. In particular, systems and methods operable to implement multiple processing strategies in a single build of an integral component would be beneficial. Summary of the Invention

[0004] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0005] In one aspect, a method is provided. The method includes decomposing a model representing a part into sub-models each corresponding to a sub-component of the part, each sub-component having a preselected metric associated therewith, and decomposing the model into the sub-models based at least in part on the preselected metric. The method also includes selecting a set of build parameters for each sub-model based at least in part on the preselected metric associated with the sub-component. Furthermore, the method includes additively manufacturing the part in a single build by building the sub-components of the part using the selected sets of build parameters for each of the sub-components.

[0006] In another aspect, a system is provided. The system includes an additive manufacturing machine. The system also includes one or more processors and one or more memory devices. The one or more memory devices store computer-readable instructions that, when executed by the one or more processors, cause the one or more processors to perform operations. When performing the operations, the one or more processors are configured to: decompose a model representing a part into sub-models, each corresponding to a sub-component of the part, each sub-component having a preselected metric associated therewith, decomposing the model into sub-models based at least in part on the preselected metric; select a set of build parameters for each sub-model based at least in part on the preselected metric associated with the sub-component; and cause the additive manufacturing machine to additively manufacture the part in a single build by building the sub-components of the part using the selected multiple sets of build parameters for each of the sub-components.

[0007] In yet another aspect, a non-transitory computer-readable medium is provided. The non-transitory computer-readable medium includes computer-executable instructions that, when executed by one or more processors of a controller, cause the controller to: decompose a model representing a part into sub-models, each corresponding to a sub-component of the part, each sub-component having a preselected metric associated therewith, decomposing the model into sub-models based at least in part on the preselected metric; select a set of build parameters for each sub-model based at least in part on the preselected metric associated with the sub-component; and cause an additive manufacturing machine to additively manufacture the part in a single build using the selected sets of build parameters.

[0008] These and other features, aspects and advantages of the present invention will be better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] A full and enabling disclosure of the invention, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings, in which:

[0010] Figure 1 A schematic diagram of an additive manufacturing machine according to an example embodiment of the present subject matter is provided;

[0011] Figure 2 Provided Figure 1 A close-up diagram of the build platform of the additive manufacturing machine;

[0012] Figure 3 Provided Figure 1 a block diagram of certain components of a controller of an additive manufacturing machine;

[0013] Figure 4A flow chart of a method of additively manufacturing a part according to an example embodiment of the present subject matter is provided;

[0014] Figure 5 Provides a schematic depiction Figure 4 A block diagram of the implementation aspects of the method;

[0015] Figure 6 provides a perspective view of a component that may be additively manufactured according to an example embodiment of the present subject matter;

[0016] Figure 7 Provided Figure 6 a three-dimensional cross-sectional view of a component;

[0017] Figure 8 Provided Figure 6 a perspective view of a first subassembly of a component;

[0018] Figure 9 Provided Figure 6 a perspective view of a second subcomponent of the component;

[0019] Figure 10 Provided Figure 6 The view of the third child component of the component;

[0020] Figure 11 A cross-sectional view of a portion of a component according to an example embodiment of the present subject matter is provided;

[0021] Figure 12 Provided Figure 7 a close-up view of a cross section 12 of the component; and

[0022] Figure 13 A graph is provided that depicts the manner in which two sets of build parameters may be blended to form a set of blended parameters according to an example embodiment of the present subject matter. DETAILED DESCRIPTION

[0023] Reference will now be made in detail to the present embodiment of the present invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided to explain the present invention, not to limit the present invention. In fact, it will be apparent to those skilled in the art that modifications and variations may be made to the present invention without departing from the scope or spirit of the present invention. For example, features shown or described as part of one embodiment may be used in another embodiment to produce yet another embodiment. Therefore, the present invention is intended to encompass such modifications and variations within the scope of any claims and their equivalents.

[0024] The detailed description uses numerical and letter designations to refer to features in the accompanying drawings. The same or similar designations in the drawings and the description are used to refer to the same or similar parts of the invention, and the same numerals represent the same elements throughout the drawings. As used herein, the terms "first," "second," and "third" are used interchangeably to distinguish one component from another and are not intended to indicate the position or relative importance of the various components.

[0025] Aspects of the present disclosure relate to systems, methods, and non-transitory computer-readable media that enable additive manufacturing of parts in a single build using multiple processing strategies. In one example aspect, a model representing a part is broken down or deconstructed into sub-models that each correspond to a sub-component of the part. For example, the model can be a 3D CAD model. The part can be an entire part to be additively manufactured, and the sub-components can be defined as certain parts of the part. Each sub-component can have a pre-selected metric associated with it. For example, the pre-selected metric can be a quality metric that must be met when the part is built via an additive machine. The pre-selected metric can be a strength metric, a durability metric, a weight metric, a surface finish metric, a resolution metric, etc. The model can be broken down into sub-models based at least in part on the pre-selected metric, at least in part on the intended function of the sub-component, and / or at least in part on build speed customization instructions.

[0026] A set of build parameters is selected or assigned to each sub-model based, at least in part, on preselected metrics associated with the sub-part. Example build parameters include energy source power, scan speed, and beam focal spot size settings. Additionally, for hybrid additive machines, the energy source type can be selected. Build parameters can be automatically selected for each sub-model based on geometry and how closely the preselected metrics match predefined metrics stored in the data. An operator can also manually set or change selected build parameters as needed.

[0027] Using build parameters set for each subcomponent, an overlap region can be defined at each interface between adjacent subcomponents. The build parameters selected for adjacent subcomponents can be used in blending parameters so that the subcomponents are properly fused together in the built part despite their different build parameters. The submodels and blended build parameters can be compiled into a merged model. The part can then be additively manufactured based at least in part on the merged model. In particular, by constructing the subcomponents of a part using multiple sets of build parameters selected for each of the subcomponents, the part can be additively manufactured in a single build. Furthermore, by constructing the overlap region between joined subcomponents using multiple sets of blended build parameters, the part can be additively manufactured in a single build. Applying different build parameters to different subcomponents and to the overlap region of the same part helps to optimize and satisfy the design of each subcomponent of a given part.

[0028] In general, the components described herein can be manufactured or formed using an additive manufacturing process (e.g., a 3D printing process). Using such a process can allow the components to be integrally formed as a single, unitary component. In particular, the manufacturing process can allow these components to be integrally formed and include various features that are not possible using existing manufacturing methods. For example, the additive manufacturing methods described herein can produce components with various features, configurations, thicknesses, materials, densities, surface variations, and identifying characteristics that are not possible using existing manufacturing methods.

[0029] As used herein, the term "additive manufacturing" or "additive manufacturing technology or process" generally refers to a manufacturing process in which successive layers of material are provided on top of each other to "build up" a three-dimensional component layer by layer. The successive layers are typically fused together to form a unitary component having multiple integral subcomponents.

[0030] Although additive manufacturing techniques are described herein as being capable of fabricating complex objects by generally building up the object point by point, layer by layer, in a vertical direction, other fabrication methods are possible and within the scope of the present subject matter. For example, while the discussion herein relates to adding material to form successive layers, one skilled in the art will appreciate that the methods and structures disclosed herein can be practiced using any additive manufacturing technique or fabrication technology. For example, embodiments of the present invention can utilize additive layer processing, subtractive layer processing, or hybrid processing.

[0031] Suitable additive manufacturing techniques according to the present disclosure include, but are not limited to, fused deposition modeling (FDM), selective laser sintering (SLS), 3D printing, such as by inkjet and laser jetting, stereolithography (SLA), direct selective laser sintering (DSLS), electron beam sintering (EBS), electron beam melting (EBM), laser engineered net shape (LENS), laser net shape manufacturing (LNSM), direct metal deposition (DMD), digital light processing (DLP), direct selective laser melting (DSLM), selective laser melting (SLM), direct metal laser melting (DMLM) and other known processes.

[0032] In addition to using a direct metal laser sintering (DMLS) or direct metal laser melting (DMLM) process in which an energy source is used to selectively sinter or melt portions of a powder layer, it will be understood that, according to alternative embodiments, the additive manufacturing process can be a "binder jetting" process. In this regard, binder jetting involves continuously depositing layers of additive powder in a manner similar to that described above. However, rather than using an energy source to generate an energy beam to selectively melt or fuse the additive powder, binder jetting involves selectively depositing a liquid binder (e.g., a photocurable polymer or another liquid binder) onto each powder layer. Other suitable additive manufacturing methods and variations are intended to be within the scope of the present subject matter.

[0033] The additive manufacturing processes described herein can be used to form parts using any suitable material. For example, the material can be a plastic, a metal, concrete, a ceramic, a polymer, an epoxy resin, a photopolymer resin, or any other suitable material that can be in a solid, liquid, powder, sheet, wire, or any other suitable form. More specifically, according to exemplary embodiments of the present subject matter, the additively manufactured parts described herein can be formed partially, fully, or in some combination of materials including, but not limited to, pure metals, nickel alloys, chromium alloys, titanium, titanium alloys, magnesium, magnesium alloys, aluminum, aluminum alloys, iron, iron alloys, stainless steel, and nickel or cobalt-based superalloys (e.g., available from Special Metals Corporation under the designation These materials are examples of materials suitable for the additive manufacturing processes described herein and may generally be referred to as “additive materials.”

[0034] In addition, those skilled in the art will understand that a variety of materials and methods for joining these materials may be used and are contemplated to be within the scope of the present disclosure. As used herein, references to "fusing" may refer to any suitable process for producing a bonded layer of any of the aforementioned materials. For example, if the object is made of a polymer, fusing may refer to forming a thermosetting bond between the polymer materials. If the object is an epoxy resin, the bond may be formed by a cross-linking process. If the material is a ceramic, the bond may be formed by a sintering process. If the material is a powdered metal, the bond may be formed by a melting or sintering process. Those skilled in the art will understand that other methods of fusing materials to make parts by additive manufacturing are also possible and may be used to practice the presently disclosed subject matter.

[0035] In addition, the additive manufacturing processes disclosed herein allow a single component to be formed from multiple materials. Thus, the components described herein may be formed from any suitable mixture of the above-mentioned materials. For example, a component may include multiple layers, segments, or parts formed using different materials, processes, and / or on different additive manufacturing machines. In this way, components having different materials and material properties can be constructed to meet the needs of any particular application. In addition, while the components described herein are constructed entirely from additive manufacturing processes, it should be understood that in alternative embodiments, all or a portion of these components may be formed via casting, machining, and / or any other suitable manufacturing process. In fact, any suitable combination of materials and manufacturing methods may be used to form these components.

[0036] An exemplary additive manufacturing process will now be described. An additive manufacturing process uses three-dimensional (3D) information of a component (e.g., a three-dimensional computer model) to fabricate the component. Thus, a three-dimensional design model of the component can be defined prior to manufacturing. In this regard, a model or prototype of the component can be scanned to determine the three-dimensional information of the component. As another example, a model of the component can be constructed using a suitable computer-aided design (CAD) program to define the three-dimensional design model of the component.

[0037] The design model can include 3D digital coordinates of the entire configuration of the component, including the exterior and interior surfaces of the component. For example, the design model can define the body, surfaces, and / or internal passages, such as openings, support structures, and the like. In an exemplary embodiment, the three-dimensional design model is converted into a plurality of slices or segments, for example, along the central (e.g., vertical) axis of the component or any other suitable axis. Each slice can define a thin cross-section of the component for a predetermined height of the slice. Multiple consecutive cross-sectional slices together form the 3D component. The component is then "built" slice by slice or layer by layer until it is complete.

[0038] In this manner, the components described herein can be fabricated using additive processes, or more specifically, each layer can be formed successively by fusing materials, such as by using laser energy or heat to polymerize plastics or by sintering or melting metal powders. For example, certain types of additive manufacturing processes can use energy beams (such as electron beams) or electromagnetic radiation (such as laser beams) to sinter or melt powdered materials. Any suitable laser and laser parameters can be used, including considerations of power, laser beam spot size, and scan speed. The build material can be formed from any suitable powder or material selected for enhanced strength, durability, and service life, particularly at high temperatures.

[0039] Each successive layer can be, for example, between about 10 μm and 200 μm, but the thickness can be selected based on any number of parameters according to alternative embodiments and can be of any suitable dimension. Thus, utilizing the aforementioned additive forming methods, the components described herein can have a cross-section as thin as one thickness (e.g., 10 μm) of the associated powder layer used during the additive forming process.

[0040] Furthermore, with additive processing, the surface finish and characteristics of a component can be varied as desired depending on the application. For example, the surface finish can be adjusted (e.g., made smoother or rougher) by selecting appropriate laser scanning parameters (e.g., laser power, scanning speed, laser spot size, etc.) during additive processing, particularly at the periphery of a cross-sectional layer corresponding to the part surface. For example, a rougher finish can be achieved by increasing the laser scanning speed or reducing the size of the formed melt pool, while a smoother finish can be achieved by decreasing the laser scanning speed or increasing the size of the formed melt pool. The scanning pattern and / or laser power can also be varied to change the surface finish of a selected area.

[0041] After a component is fabricated, various post-processing procedures may be applied to the component. For example, post-processing procedures may include removing excess powder, such as by blowing air or applying a vacuum. Other post-processing procedures may include stress relief. Furthermore, thermal, mechanical, and / or chemical post-processing procedures may be used to finish the part to achieve the desired strength, surface finish, and other component properties or characteristics.

[0042] It is noteworthy that, in exemplary embodiments, several aspects and features of the present subject matter were previously impossible due to manufacturing limitations. However, the present inventors have advantageously leveraged current advances in additive manufacturing technology to improve various components and methods of additively manufacturing these components. While the present disclosure is generally not limited to using additive manufacturing to form these components, additive manufacturing does offer a variety of manufacturing advantages, including ease of manufacture, reduced costs, and greater precision.

[0043] Furthermore, the additive manufacturing methods described above enable the formation of more complex and intricate shapes and contours of the components described herein with a very high level of precision. For example, such components can include thin additively manufactured layers, cross-sectional features, and component contours. Furthermore, the additive manufacturing process enables the fabrication of a single component with different materials, allowing different portions of the component to exhibit different performance characteristics. The continuous, additive nature of the manufacturing process enables the construction of these novel features. As a result, components formed using the methods described herein can exhibit improved performance and reliability.

[0044] Figure 1 A schematic diagram of an additive manufacturing system 100 (or AM system 100 ) is provided according to an example embodiment of the present disclosure. Figure 1The AM system 100 depicted in FIG is a laser powder bed fusion additive manufacturing machine or system, such as a DMLS or DMLM system. The AM system 100 is described herein as being used to build all or a portion of one or more parts. It should be understood that the parts described herein are merely exemplary parts to be built and are primarily used to facilitate a description of the operation of the AM system 100. The present subject matter in this regard is not intended to be limited to the formation of parts as described, but rather the AM system 100 can be used to print any suitable number, type, and configuration of parts or features of parts (e.g., part 300).

[0045] As shown, the AM system 100 generally defines a vertical direction V or Z direction, a lateral direction L or X direction, and a transverse direction T or Y direction ( Figure 1 ), each direction is perpendicular to each other, thus defining an orthogonal coordinate system. As shown, the AM system 100 includes a fixed housing 102 or build area that provides a contamination-free and controlled environment for performing the additive manufacturing process. The housing 102 is used to isolate and protect the components of the AM system 100. In addition, the housing 102 can be provided with a suitable protective gas flow, such as nitrogen, argon, or another suitable gas or gas mixture. In this regard, the housing 102 can define a gas inlet 104 and a gas outlet 106 for receiving the gas flow to generate a static pressurized volume or a dynamic gas flow.

[0046] Enclosure 102 may contain some or all of the components of AM system 100. For this embodiment, AM system 100 includes a workbench 110, a powder supply 112, a scraper or recoater mechanism 114, an overflow container or reservoir 116, and a build platform 118, all located within enclosure 102. Additionally, an energy source 120 generates an energy beam 122, and a beam steering device 124 directs energy beam 122 to facilitate AM processing, as described in greater detail below.

[0047] Workbench 110 is a rigid structure that defines a planar build surface 130. Furthermore, planar build surface 130 defines a build opening 132 through which a build chamber 134 is accessible. More specifically, according to the illustrated embodiment, build chamber 134 is at least partially defined by vertical walls 136 and a build platform 118. Notably, build platform 118 is movable relative to build surface 130 along a build direction 138. More specifically, build direction 138 may correspond to a vertical direction V, such that moving build platform 118 downward increases the height of the part being printed and build chamber 134. Furthermore, build surface 130 defines a supply opening 140 through which additive powder 142 may be supplied from powder supply 112, and a reservoir opening 144 through which excess additive powder 142 may enter overflow reservoir 116. The collected additive powder may optionally be processed to remove loose, agglomerated particles before reuse.

[0048] The powder supply 112 generally includes an additive powder supply container 150, which generally contains a quantity of additive powder 142 sufficient for some or all of the additive manufacturing process for a particular part. Furthermore, the powder supply 112 includes a supply platform 152, which is a plate-like structure that is movable vertically within the powder supply container 150. More specifically, a supply actuator 154 vertically supports the supply platform 152 and selectively moves the supply platform 152 up and down during the additive manufacturing process.

[0049] The AM system 100 also includes a recoater mechanism 114, which is a rigid, laterally elongated structure located near the build surface 130. For example, the recoater mechanism 114 can be a hard scraper, a soft scraper, or a roller. The recoater mechanism 114 is operably coupled to a recoater actuator 160, which is operable to selectively move the recoater mechanism 114 along the build surface 130. In addition, a platform actuator 164 is operably coupled to the build platform 118 and is generally operable to move the build platform 118 in a vertical direction during the build process. Although actuators 154, 160, and 164 are illustrated as hydraulic actuators, it should be understood that, according to alternative embodiments, any other type and configuration of actuator may be used, such as a pneumatic actuator, a hydraulic actuator, a ball screw linear electric actuator, or any other suitable vertical support device. Other configurations are possible and within the scope of the present subject matter.

[0050] As used herein, "energy source" may refer to any device or system of devices configured to direct an energy beam having suitable power and other operating characteristics toward an additive powder layer to sinter, melt, or otherwise fuse a portion of the additive powder layer during a build process. For example, energy source 120 may be a laser or any other suitable radiation-emitting directing device or irradiation device. In this regard, the radiation or laser source may generate photon or laser beam radiation directed by a radiation-emitting directing device or beam steering device.

[0051] The beam steering device 124 includes one or more mirrors, prisms, lenses and / or electromagnets operably coupled to suitable actuators and arranged to direct and focus the energy beam 122. In this regard, for example, the beam steering device 124 can be a galvanometer scanner that moves or scans the focal point of the laser beam 122 emitted by the energy source 120 across the build surface 130 during the laser melting and sintering process. In this regard, the energy beam 122 can be focused to a desired spot size and steered to a desired position in a plane that coincides with the build surface 130. Galvanometer scanners in powder bed fusion technology are typically in a fixed position, but the movable mirrors / lenses contained therein allow various characteristics of the laser beam to be controlled and adjusted. In some embodiments, the beam steering device 124 may also include one or more of the following: an optical lens, a deflector, a mirror, a beam splitter, a telecentric lens, etc.

[0052] It should be understood that other types of energy sources 120 can be used, which can use alternative beam steering devices 124. For example, an electron beam gun or other electron source can be used to generate an electron beam (e.g., an "e-beam"). The e-beam can be guided by any suitable radiation emission guiding device, preferably in a vacuum. When the radiation source is an electron source, the radiation emission guiding device can be, for example, an electronic control unit, which can include, for example, deflection coils, focusing coils, or similar elements. In some embodiments, the energy source 120 can include one or more of a laser, an electron beam, a plasma arc, an electric arc, etc. In some embodiments, the AM system 100 can include multiple energy sources. The multiple energy sources can be different types of energy sources, such as any energy source mentioned herein.

[0053] Prior to the additive manufacturing process, recoater actuator 160 may be lowered to supply powder 142 having a desired composition (e.g., metal, ceramic, and / or organic powder) into supply container 150. Additionally, platform actuator 164 may move build platform 118 to an initial high position, e.g., such that it is substantially flush or coplanar with build surface 130. Build platform 118 is then lowered below build surface 130 in selected layer increments. The layer increments affect the speed of the additive manufacturing process and the resolution of the manufactured part or component. For example, the layer increments may be approximately 10 to 100 microns (0.0004 to 0.004 inches).

[0054] The additive powder is then deposited on build platform 118 before being fused by energy source 120. Specifically, supply actuator 154 can raise supply platform 152 to push powder through supply opening 140, exposing it above build surface 130. Recoater mechanism 114 can then be moved across build surface 130 by recoater actuator 160 to spread raised additive powder 142 horizontally on build platform 118 (e.g., in selected layer increments or thicknesses). As recoater mechanism 114 moves from left to right (e.g., Figure 1 ), any excess additive powder 142 falls through the reservoir opening 144 into the overflow reservoir 116. Subsequently, the recoater mechanism 114 can be moved back to the starting position.

[0055] Therefore, as described in this article and Figure 1 As shown, the recoater mechanism 114, the recoater actuator 160, the supply platform 152, and the supply actuator 154 are generally operable to continuously deposit layers of additive powder 142 or other additive material to facilitate the printing process. Therefore, these components may be collectively referred to herein as a powder dispensing device, system, or assembly. The flattened additive powder 142 may be referred to as a "build layer" 172 (see FIG. Figure 2 ), whose exposed upper surface may be referred to as build surface 130. When build platform 118 is lowered into build chamber 134 during the build process, build chamber 134 and build platform 118 collectively surround and support a volume of additive powder 142 and any part being built. This volume of powder is often referred to as a "powder bed," and this particular class of additive manufacturing processes may be referred to as a "powder bed process."

[0056] During the additive manufacturing process, a directed energy source 120 is used to melt a two-dimensional cross-section or layer of the part 300 being built. More specifically, an energy beam 122 is emitted from the energy source 120 and a beam steering device 124 is used to steer a focal point 174 of the energy beam 122 onto the exposed powder surface in an appropriate pattern (referred to herein as a "tool path"). A small portion of the exposed layer of additive powder 142 surrounding the focal point 174 (referred to herein as a "weld pool" or "melt pool" or "heat-affected zone" 176) is formed. Figure 2 1) is heated by the energy beam 122 to a temperature that allows it to sinter or melt, flow, and solidify. As an example, the molten pool 176 can be approximately 100 microns (0.004 inches) wide. This step can be referred to as fusing the additive powder 142.

[0057] Build platform 118 moves vertically downward by the layer increment, and another layer of additive powder 142 is applied at a similar thickness. Directed energy source 120 again emits energy beam 122, and beam steering device 124 is used to steer focus 174 of energy beam 122 in an appropriate pattern onto the exposed powder surface. The exposed layer of additive powder 142 is heated by energy beam 122 to a temperature that allows it to sinter or melt, flow, and consolidate within the top layer and with the lower, previously solidified layers. This cycle of moving build platform 118, applying additive powder 142, and then directing energy beam 122 to melt additive powder 142 is repeated until the entire part 300 is completed. The additively manufactured part can be a monolithic part.

[0058] Reference again Figure 1 , the AM system 100 includes a controller 180 that can be communicatively coupled to some or all portions of the AM system 100 or an external control system to facilitate system operation. For example, the controller 180 can be communicatively coupled to a user interface panel 182 to allow an operator to communicate with the AM system 100, such as to enter commands, upload a print tool path or CAD model, initiate an operating cycle, or otherwise control the operation of various components of the AM system 100. Generally, the controller 180 can be communicatively coupled to all systems and subsystems within the AM system 100 to allow communication and data transfer between them. In this manner, the controller 180 can generally be configured to operate the AM system 100 and / or perform one or more methods described herein.

[0059] Figure 3 A block diagram of certain components of the controller 180 of the AM system 100 is provided. The controller 180 may include one or more computing devices 180A, which may be used to implement the methods and computer-readable instructions described herein. The computing device 180A may include one or more processors 180B and one or more memory devices 180C. The one or more processors 180B may include any suitable processing device, such as a microprocessor, a microcontroller, an integrated circuit, an application-specific integrated circuit (ASIC), a digital signal processor (DSP), a field-programmable gate array (FPGA), a logic device, one or more central processing units (CPUs), a graphics processing unit (GPU) (e.g., dedicated to efficiently rendering images), a processing unit that performs other specialized calculations, etc. The memory device 180C may include one or more non-transitory computer-readable storage media, such as RAM, ROM, EEPROM, EPROM, flash memory devices, magnetic disks, etc., and / or combinations thereof.

[0060] Memory device 180C may include one or more computer-readable media and may store information accessible by one or more processors 180B, including instructions 180D executable by one or more processors 180B. For example, memory device 180C may store instructions 180D for running one or more software applications, displaying a user interface, receiving user input, processing user input, etc. In some embodiments, instructions 180D may be executed by one or more processors 180B to cause one or more processors 180B to perform operations, such as one or more portions of the methods described herein. Instructions 180D may be software written in any suitable programming language or may be implemented in hardware. Additionally and / or alternatively, instructions 180D may be executed in logically and / or virtually separate threads on processor 180B.

[0061] One or more memory devices 180C may also store data 180E that may be retrieved, manipulated, created, or stored by one or more processors 180B. The data 180E may include, for example, data that facilitates the performance of the methods described herein. The data 180E may be stored in one or more databases or data storage devices. The one or more databases or data storage devices may be connected to the controller 180 via a high-bandwidth LAN or WAN, or may be connected to the controller via one or more networks (not shown). The one or more databases or data storage devices may be split so that they are located in multiple regional settings, or they may all be located in the same location. In some embodiments, the data 180E may be received from another device.

[0062] The computing device 180A may also include a communication module or interface 180F for communicating over a network with the controller 180 or one or more other components of the AM system 100. The communication interface 180F may include any suitable components for interfacing with one or more networks, including, for example, a transmitter, a receiver, a port, a controller, an antenna, or other suitable components.

[0063] Figure 4 A flow chart of a method (200) for additively manufacturing a component according to an example embodiment of the present subject matter is provided. For example, the method (200) may be used to manufacture a component using the above-described and Figure 1 The AM system 100 shown forms a component. In this manner, the AM system 100 and its controller 180 can be configured to implement some or all aspects of the method (200). However, it should be understood that other suitable additive manufacturing systems can be used to implement the method (200). Figure 1 AM system 100 and Figure 3 Various components of the controller 180 are used to provide content for an embodiment of the method (200).

[0064] At (202), the method (200) includes decomposing the model of the component into sub-models each corresponding to a sub-component of the component. In other words, the model is decomposed into sub-models representing the component components. One or more processors 180B of the controller 180 can be configured to decompose the model of the component to be additively manufactured, and more specifically, decompose the model into sub-models each corresponding to a sub-component of the component. The model of the component can be any suitable type of model, such as a 3D CAD model or a point cloud model constructed by scanning the component to determine 3D information associated with the component. The model can include 3D data indicating the coordinates or overall geometry of the component. The model can also include other data, such as, but not limited to, finite element analysis data, product life cycle data, manufacturing data, material data, etc. The component can be a one-piece body or a monolithic component. The sub-component can be a portion or sub-element of a monolithic component.

[0065] For example, Figure 5 A block diagram schematically depicting aspects of an implementation of the method (200) is provided. Figure 5 As shown, model 400 represents, for example, a component 300 to be additively manufactured by AM system 100. For example, model 400 can be a 3D CAD model. As shown, model 400 is decomposed into component parts or sub-models. In particular, for this example embodiment, model 400 is decomposed into a first sub-model 410, a second sub-model 420, and a third sub-model 430. In other embodiments, the model can be decomposed or deconstructed into fewer than three or more than three sub-models. Each model 410, 420, 430 corresponds to a sub-element or sub-component of component 300. Specifically, first sub-model 410 corresponds to first sub-component 310, second sub-model 420 corresponds to second sub-component 320, and third sub-model 430 corresponds to third sub-component 330.

[0066] Each sub-model 410, 420, 430 includes data associated with its associated sub-component. Specifically, first sub-model 410 includes data 416 associated with first sub-component 310, second sub-model 420 includes data 426 associated with second sub-component 320, and third sub-model 430 includes data 436 associated with third sub-component 330. Data 416, 426, 436 may include 3D data associated with the respective sub-component. The 3D data may define or describe the sub-component in space.

[0067] Figures 6 to 10 Various perspective views of the component 300 and its constituent subcomponents 310, 320, 330 are provided. It should be understood that Figures 6 to 10The component 300 shown in and described in the accompanying text is a non-limiting example of a component that can be constructed according to the methods and / or by the systems disclosed herein; other components with different sizes, configurations, shapes, subcomponents, etc. can also be constructed according to the methods and / or by the systems disclosed herein. For reference, the component 300 defines an axial direction A, a radial direction R, and a circumferential direction C. The component 300 also defines a longitudinal centerline LC extending along the axial direction A. For this example embodiment, the component 300 has a unitary body. In other words, the component 300 is a unitary component. The various subcomponents 310, 320, 330 will be described below.

[0068] like Figure 6 、 7 As best shown in FIG8 , the first subassembly 310 of the assembly 300 is a structural element that includes a first annular member 312 and a second annular member 314, the second annular member 314 being spaced apart from the first annular member 312, for example, along the axial direction A. The first annular member 312 includes a plurality of circumferentially spaced receiving members 316, while the second annular member 314 includes a plurality of circumferentially spaced receiving members 318. The first subassembly 310 also includes a central hub 315 connected to the second annular member 314 by a plurality of circumferentially spaced and radially extending connecting members 317.

[0069] like Figure 6 、 7 As best shown in FIG9 , the second subassembly 320 of the assembly 300 is a pneumatic loading element. The second subassembly 320 includes a main body 322 that is generally hollow and cylindrical and extends longitudinally in the axial direction A. The diameter of the main body 322 at the top end is smaller than the diameter of the main body 322 at the bottom end. The second subassembly 320 also includes a plurality of secondary bodies 324 that are generally hollow and cylindrical and extend longitudinally in the axial direction A. The secondary bodies 324 are spaced apart from each other in the circumferential direction C and spaced apart from the main body 322 in the radial direction R.

[0070] like Figure 6 and 7 As shown, the main body 322 extends or protrudes from the central hub 315 of the first subassembly 310 in the axial direction A. The top end of the main body 322 is received by the opening defined by the first annular member 312. The secondary bodies 324 extend between and connect the first annular member 312 and the second annular member 314. In particular, each secondary body 324 extends between one of the receiving members 316 of the first annular member 312 and a corresponding receiving member 318 of the second annular member 314.

[0071] like Figure 6 and Figure 10As shown, third subassembly 330 is a part label or part identifier. As the name implies, a part identifier identifies component 300. The part identifier may include a serial number, the date and location of manufacture of component 300, a model number, and the like. Any suitable identifying information about component 300 may be included in the part identifier. Third subassembly 330 may be positioned at any suitable location on component 300.

[0072] Reference again Figure 5 As described above, the model 400 representing the component 300 is decomposed into sub-models 410, 420, 430 corresponding to their respective or corresponding sub-components 310, 320, 330 of the component 300. Notably, each of the sub-components 310, 320, 330 has a preselected metric associated therewith. For example, for this example embodiment, the first sub-component 310 has a first preselected metric 412 associated therewith, the second sub-component 320 has a second preselected metric 422 associated therewith, and the third sub-component 330 has a third preselected metric 432 associated therewith.

[0073] In some embodiments, the preselected metrics associated with the subcomponent can be quality metrics or measurable key quality metrics. As an example, it can be determined (e.g., via engineering analysis) that the subcomponent requires specific strength and durability for the intended application of the component. As another example, it can be determined that the subcomponent requires a particular surface finish, such as a particular smoothness or roughness. Additionally, as another example, it can be determined that the subcomponent requires particular heat transfer capabilities. As another example, the subcomponent may require a particular resolution, for example, so that the label is legible. As a further example, the subcomponent may have a particular weight requirement. Subcomponents of a component may have other application-specific or key quality metrics associated with them. The examples provided are not intended to be limiting.

[0074] Model 400 can be decomposed into sub-models based at least in part on preselected metrics 412, 422, and 432. Specifically, for this example embodiment, first preselected metric 412 associated with first sub-component 310 is a strength and durability metric. The strength and durability metric associated with first sub-component 310 is the strength and durability requirement that first sub-component 310 must meet when part 300 is constructed using an additive manufacturing machine. Second preselected metric 422 associated with second sub-component 320 is a surface finish metric. The surface finish metric associated with second sub-component 320 is the surface finish requirement that second sub-component 320 must meet when part 300 is constructed using an additive manufacturing machine. Third preselected metric 432 associated with third sub-component 330 is a resolution metric. The resolution metric associated with third sub-component 330 is the resolution requirement that third sub-component 330 must meet when part 300 is constructed using an additive manufacturing machine. In some embodiments, a sub-component can have multiple preselected metrics associated with it. In such an embodiment, the preselected metrics may be sorted in a hierarchical manner (eg, in order of importance or criticality). If the metrics are incompatible with each other, the more important or critical metric will control.

[0075] In addition to decomposing model 400 into sub-models based at least in part on preselected metrics associated with the various sub-components of a component, in some embodiments, model 400 can be decomposed into sub-models based at least in part on the characteristics of the component or the intended functions of the sub-components. For example, after a component is constructed via an additive manufacturing machine, a portion of the component may be intended to be machined or otherwise removed. The portion of the component intended to be removed from the component can be defined as a sub-component. The model can be decomposed so that one of the sub-models represents the designated portion of the component to be removed.

[0076] Furthermore, in some embodiments, the model 400 can be decomposed into sub-models based at least in part on build speed customization. For example, Figure 11 A cross-sectional view of a portion of component 500 is provided. Component 500 has preselected metrics associated therewith. For example, the preselected metrics may be strength and durability metrics. Although component 500 has strength and durability metrics, the model of component 500 may be custom decomposed into sub-models representing corresponding sub-components of component 500 based, at least in part, on build speed.

[0077] In particular, component 500 can be defined as having a first subassembly 510 forming the outer walls of component 500, wherein first subassembly 510 includes a first outer wall 510A and a second outer wall 510B. Component 500 can also be defined as having a second subassembly 520 defined between first and second outer walls 510A, 510B of first subassembly 510. It can be determined that, despite strength and durability metric requirements for component 500, the portion of component 500 between the outer walls can be built at a faster build speed while still meeting the strength and durability metric requirements. In such an example, the intermediate portion disposed between the outer walls can be defined as a separate subassembly, such as subassemblies 510, 520. The model of component 500 can be decomposed into submodels corresponding to subassemblies 510, 520, and 530. Advantageously, this can reduce build time while still meeting or achieving preselected metrics.

[0078] In some embodiments, the model 400 is decomposed into submodels 410, 420, 430 such that each subcomponent 310, 320, 330 corresponding to the submodel 410, 420, 430 is sliced ​​or defined with a layer thickness that is the least common multiple of the layer thicknesses of adjacent subcomponents. For example, assume that the layer thickness of the first subcomponent 310 is set to 30 μm, while the layer thickness of the second subcomponent 320 is set to 50 μm. In such an example, the least common multiple of the layer thicknesses is 10 μm. Therefore, in this case, the first and second subcomponents 310, 320 represented by their submodels 410, 420 will be decomposed or sliced ​​with a layer thickness of 10 μm. This facilitates decomposing the model 400 into the submodels 410, 420, 430 and, in some embodiments, merging the submodels 410, 420, 430 into a merged model, as will be described herein.

[0079] Return to Figure 4 At (204), the method (200) includes selecting a set of build parameters for each sub-model based at least in part on preselected metrics associated with the sub-components. For example, the one or more processors 180B of the controller 180 may be configured to select a set of build parameters for each sub-model based at least in part on preselected metrics associated with the sub-components. Figure 5 As shown, a first set of build parameters 414 may be selected for a first sub-model 410, a second set of build parameters 424 may be selected for a second sub-model 420, and a third set of build parameters 434 may be selected for a third sub-model 430. The build parameters selected for each sub-model may be different from one another. In some cases, some build parameters of one group may be the same as build parameters of another group.

[0080] Example build parameters include, but are not limited to, energy source power, scan speed, and beam focal spot size. These parameters can be set or selected so that, when the component is built, the subcomponent meets or achieves the design intent or preselected metrics associated with the subcomponent of the component. In some embodiments, each set of build parameters includes energy source power, scan speed, and beam focal spot size. In some embodiments, other build parameters are possible.

[0081] For example, in some embodiments, the additive manufacturing machine designated for building a part can be a hybrid additive machine having multiple energy source types. The hybrid additive machine can have at least two energy sources, such as at least two of any of the energy sources mentioned herein. For example, the hybrid additive machine can include at least two of the following: a beam steering device (e.g., the beam steering device 124 of the AM system 100), an electron beam gun or source, a laser, a plasma arc, an electric arc, a projector, and optical devices, etc. Therefore, in some embodiments, selecting multiple sets of build parameters for sub-models can include selecting an energy source type for each sub-model based at least in part on a pre-selected metric associated with the sub-component. In such an embodiment, the sub-components can be built using their respective selected energy source types.

[0082] In some embodiments, one or more processors 180B of controller 180 can automatically select multiple sets of build parameters for a submodel. As an example, one or more processors 180B can determine a set of build parameters for a submodel by matching a preselected metric associated with a subcomponent with a predefined metric from a table that associates predefined metrics with multiple sets of build parameters. In other words, one or more processors 180B can match or best match the preselected metric with a predefined metric in a lookup table, and the set of build parameters associated with the predefined metric that matches or best matches the preselected metric is selected as the set of build parameters. The table can be stored in data storage device 440. Data storage device 440 can be memory device 180C of controller 180, a database, or some other data storage medium. In some embodiments, one or more processors 180B can implement or execute one or more machine learning techniques to match the preselected metric with the predefined metric from the table. In other embodiments, one or more processors 180B may implement or execute one or more machine learning techniques to determine a set of build parameters for one of the subcomponents based at least in part on one or more preselected metrics associated with the subcomponent, the geometry of the subcomponent (determined based on data associated with the submodel).

[0083] The build parameters associated with each predefined metric can be set, for example, based on an engineering analysis. For example, based on the engineering analysis, it can be determined that a certain energy source power and scan speed can produce a component that meets a desired metric at an associated subcomponent of the component. Multiple sets of build parameters can be associated with corresponding types of predefined metrics (e.g., surface finish metrics, resolution metrics, strength and durability metrics, etc.) and stored in a data storage device.

[0084] In some embodiments, one or more of the multiple sets of build parameters selected for the sub-models may be selected based at least in part on the characteristics of the component or the intended functionality of the sub-components. One or more processors 180B may be configured to select a set of build parameters for each sub-model based at least in part on the characteristics of the component or the intended functionality of the sub-components. As an example, a set of build parameters may be selected based on at least one sub-component being designated for removal from the component (after the component is built).

[0085] In some embodiments, one or more of the multiple sets of build parameters can be selected for a sub-model based at least in part on a build speed specification. For example, a set of build parameters can be selected to reduce the build time of a portion of a component. One or more processors 180B can be configured to select a set of build parameters for each sub-model based at least in part on a build speed specification specified for one or more sub-components.

[0086] In other embodiments, one, some, or all of the multiple sets of build parameters may be selected based at least in part on preselected metrics associated with the subcomponents, features of the component, or intended functionality of the subcomponents, and / or based at least in part on build speed customizations specified for one or more subcomponents via manual operator input of values ​​for the multiple sets of build parameters. Figure 5 Manual input 450 is schematically shown in FIG. In some cases, an operator may manually change the value of a build parameter automatically determined by one or more processors 180B, for example, based on engineering observations.

[0087] Reference again Figure 4 At (206), method (200) optionally includes determining a set of hybrid build parameters for each overlapping region of the component. Each overlapping region is defined at an interface between adjacent sub-components of the component. The set of hybrid build parameters for each overlapping region can be determined based at least in part on the set of build parameters associated with the sub-models corresponding to the adjacent sub-components. One or more processors 180B of controller 180 can determine multiple sets of hybrid build parameters. By hybridizing the build parameters at the overlapping regions between the sub-components, proper fusion between the sub-components can be achieved.

[0088] As an example, Figure 12 Provided Figure 7A close-up view of section 12 of component 300 is provided. Figure 12 As shown, the main body 322 of the second subassembly 320 is aligned with the central hub 315 of the first subassembly 310 (see also Figure 7 ) joint. The overlapping region 350 is defined at the interface between the first sub-component 310 and the second sub-component 320, or more specifically, for Figure 12 300 , an overlap region 350 is defined at the interface between the body 322 of the second subcomponent 320 and the central hub 315 of the first subcomponent 310 . The overlap region 350 has a thickness T or height extending along the axial direction A. The overlap region 350 extends between a first end 352 and a second end 354 . It should be understood that the thickness T of the overlap region 350 can also extend in other directions, depending on the orientation of the interface between adjacent subcomponents. In some embodiments, the overlap region 350 is entirely defined within a single layer. In other embodiments, the overlap region 350 is defined such that the overlap region 350 spans multiple layers.

[0089] In some embodiments, one or more processors 180B may define an overlap region 350, as well as a thickness T and a total area of ​​the overlap region defined at an interface between adjacent sub-components of component 300. For example, using data 416, 426 of sub-models 410, 420, one or more processors 180B may determine the geometry and positioning of sub-components 310, 320 relative to each other in space. Furthermore, one or more processors may determine a match score that indicates how closely the selected build parameters of the adjacent sub-components match. For example, to determine the geometry of overlap region 350, one or more processors 180B may compare first set of build parameters 414 with second set of build parameters 424, and based on the comparison, one or more processors 180B may determine a match score. Based on the match score and the geometry of first and second sub-components 310, 320 at the central hub 315 / body 322 interface, one or more processors 180B may determine the area of ​​overlap region 350, including thickness T and the plane in which overlap region 350 extends. Generally, the higher the match score (i.e., the closer the sets of build parameters match), the smaller the thickness T required for overlap region 350. Conversely, the lower the match score (i.e., the further the sets of build parameters are from matching), the larger the thickness T required for overlap region 350.

[0090] As overlap region 350 is defined, one or more processors 180B of controller 180 may determine how to blend construction parameters to construct overlap region 350. As an example, construction parameters for constructing the overlap region may be blended incrementally. Construction parameters for constructing the overlap region may be blended incrementally, layer by layer, or in predetermined layer increments. Parameters for constructing the overlap region may also be blended in other suitable ways.

[0091] Figure 13 A diagram is provided that depicts how two sets of build parameters can be incrementally blended to form a set of blended parameters according to an example embodiment of the present subject matter. In particular, Figure 13 The graph depicts a first set of build parameters 414 associated with the first sub-model as a function of the thickness of the overlap region, and also depicts a second set of build parameters 424 associated with the second sub-model as a function of the thickness of the overlap region. As shown, the first set of build parameters 414 incrementally decreases from the first end 352 to the second end 354 of the thickness of the overlap region 350, and the second set of build parameters 424 incrementally increases from the first end 352 to the second end 354 of the thickness of the overlap region 350. Build parameters 414, 424 are incremented five times across the thickness of the overlap region 350. The increments can be equal or different.

[0092] At a first increment I-1 near the first end 352, the first set of build parameters is reduced from 100% to 80%, and the second set of parameters 424 is increased from 0% to 20% to present an 80 / 20 mix. For example, assume that the value selected for the energy source power of the first set of build parameters 414 is greater than the value selected for the energy source power of the second set of build parameters 424. To mix the parameters at the first increment, the value of the energy source power will be reduced by 20% of the total expected change in the energy source power setting (i.e., the absolute value of the value selected for the energy source power of the first set of build parameters 414 minus the value selected for the energy source power of the second set of build parameters 424). Other build parameters can be mixed in a similar manner. It should be understood that over the thickness T of the overlap region 350, some values ​​can increase and some values ​​can decrease.

[0093] At the second increment I-2, the first set of build parameters decreases from 80% to 60%, while the second set of parameters 424 increases from 20% to 40%, creating a 60 / 40 mix. Thus, continuing with the above example, the value of the energy source power will decrease by another 20% of the total expected variation in the energy source power setting. At the third increment I-3, the first set of build parameters decreases from 60% to 40%, while the second set of parameters 424 increases from 40% to 60%, creating a 40 / 60 mix. Thus, referring back to the above example, the value of the energy source power will decrease by another 20% of the total expected variation in the energy source power setting. Furthermore, at the fourth increment I-4, the first set of build parameters decreases from 40% to 20%, while the second set of parameters 424 increases from 60% to 80%, creating a 20 / 80 mix. The value of the energy source power will decrease by another 20% of the total expected variation in the energy source power setting. Finally, at the fifth increment I-5, the first set of build parameters decreases from 20% to 0%, while the second set of parameters 424 increases from 80% to 100%. The value of the energy source power will be reduced by an additional 20% of the total expected variation in the energy source power setting; therefore, the value of the energy source power will be set to the selected value of the second set of build parameters 424. Part 300 can be additively manufactured in a single build using the determined set of mixed build parameters. As will be appreciated, some or all of the build parameters to be applied to build overlap region 350 can be mixed as described above or can be determined in another suitable manner.

[0094] Furthermore, it should be understood that an overlap region can be defined at each interface between adjacent sub-components, and hybrid build parameters can be determined so that they can be used to build the overlap region. Thus, as noted, method (200) can include determining a set of hybrid build parameters for each overlap region of a component. Each overlap region is defined at an interface between adjacent sub-components of the component. The set of hybrid build parameters for each overlap region can be determined based, at least in part, on the set of build parameters associated with the sub-models corresponding to the adjacent sub-components. In this manner, a component (e.g., component 300) can be additively manufactured in a single build using multiple sets of determined hybrid build parameters.

[0095] Reference again Figure 4 , at (208), the method (200) includes compiling the sub-models into a merged model. For example, referring to Figure 5, the sub-models 410, 420, 430 and their associated sets of build parameters 414, 424, 434 and data 416, 426, 436, as well as the hybrid build parameters 460 determined for each defined overlapping region, can be merged by one or more processors into a merged model 470. The data 416, 426, 436 can be used to rearrange the sub-components 310, 320, 330 represented by their respective sub-models 410, 420, 430 back into the complete part 300 or a merged 3D model representing the part. In some embodiments, the merged model 470 serves as a build instruction that, when executed by one or more processors 180B of the controller 180, causes an additive manufacturing machine (e.g., Figure 1 The AM system 100 of FIG. 4 builds the component 300 according to the build instructions. In other embodiments, the one or more processors 180B may generate the build instructions based at least in part on the merged model 470.

[0096] In some alternative embodiments, sub-models 410, 420, 430 may be merged into a preliminary merged model (not shown), overlapping regions may be defined as described above, and then the preliminary merged model and the determined blended sets of build parameters associated with the overlapping regions may be compiled into a merged model 470. In other embodiments, sub-models 410, 420, 430 need not be merged into a merged model. Instead, during additive manufacturing of the part, one or more processors may receive all information / data directly from sub-models 410, 420, 430 and the determined blended build parameters 460 to build part 300.

[0097] Reference again Figure 4 At (210), method (200) includes additively manufacturing the component in a single build by building subcomponents of the component using the selected multiple sets of build parameters for each of the subcomponents. In this manner, a component (such as the unitary body or monolithic component 300 provided herein) can be additively manufactured in a single build using multiple processing strategies. Furthermore, in some embodiments, the component can be additively manufactured in a single build by building overlapping regions defined at interfaces between the subcomponents using the determined multiple sets of hybrid build parameters.

[0098] The part may be additively manufactured in a single build by one or more processors 180B executing build instructions generated at least in part from the merged model 470 or based at least in part on the merged model 470. Alternatively, the part may be additively manufactured in a single build by one or more processors 180B executing build instructions generated directly from the sub-models 410, 420, 430 and the determined sets of hybrid build parameters 460.

[0099] Furthermore, in view of the teachings herein, it will be understood that a single layer of a component may be constructed using multiple processing strategies. In fact, many layers of a component may each be constructed using multiple processing strategies. In other words, for a given axial or vertical height of a component being constructed, multiple sets of build parameters may be used to construct that axial or vertical portion of the component. For reference, Figure 7 An example of Figure 7 , first annular member 312 of first subcomponent 310 is built using a first set of build parameters 414 associated therewith, and body 322 of second subcomponent 320 is built using a second set of build parameters 424 associated therewith. Thus, in some embodiments, when building a layer of a component using one or more energy sources of an additive manufacturing machine, at least one layer is built using at least two sets of selected build parameters. In some embodiments, a single layer of a component may be built using more than two sets of selected build parameters.

[0100] Advantageously, according to the methods and systems described herein, multiple processing strategies can be used to additively manufacture a part in a single build. In particular, applying different build parameters to different subcomponents of the same part allows for optimizing and satisfying the design intent of each subcomponent. For example, the methods and systems described herein can enable additively manufactured parts to meet multiple key quality metrics and enable a hybrid part approach. Furthermore, the methods and systems described herein can facilitate maximizing throughput, optimizing design performance capabilities, and reducing waste / cost associated with traditional additive manufacturing build strategies.

[0101] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

[0102] Further aspects of the invention are provided by the subject matter of the following clauses:

[0103] 1. A method comprising: decomposing a model representing a part into sub-models each corresponding to a sub-component of the part, each sub-component having a preselected metric associated therewith, decomposing the model into the sub-models based at least in part on the preselected metric; selecting a set of build parameters for each of the sub-models based at least in part on the preselected metric associated with the sub-component; and additively manufacturing the part in a single build by building the sub-components of the part using the respective selected sets of build parameters for the sub-components.

[0104] 2. A method according to any preceding clause, wherein additively manufacturing the part using the selected multiple sets of build parameters includes building a plurality of layers using one or more energy sources of an additive manufacturing machine, and wherein, for at least one of the multiple layers, at least two selected sets of build parameters are used to build the at least one layer.

[0105] 3. A method according to any preceding clause, wherein the multiple sets of construction parameters each include energy source power, scanning speed and beam focal spot size.

[0106] 4. The method of any preceding clause, further comprising: selecting an energy source type for each of the sub-models based at least in part on the preselected metrics associated with the sub-components, and wherein the sub-components are constructed using the respective selected energy source types.

[0107] 5. A method according to any preceding clause, wherein the sub-model includes a first sub-model and a second sub-model, the first sub-model corresponding to a first sub-component of the sub-component and the second sub-model corresponding to a second sub-component of the sub-component, and wherein the method further comprises: defining an overlapping region at an interface between the first sub-component and the second sub-component of the sub-component; and determining a set of hybrid build parameters for the overlapping region based at least in part on a first set of build parameters associated with the first sub-model and a second set of build parameters associated with the second sub-model, and wherein the component is additively manufactured in the single build using the determined set of hybrid build parameters.

[0108] 6. A method according to any preceding clause, wherein defining the overlap region comprises: determining a match score indicating how closely the first set of build parameters match the second set of build parameters, and determining an area of ​​the overlap region based at least in part on the match score.

[0109] 7. The method of any preceding clause, further comprising: determining a set of hybrid build parameters for each overlapping region of the part, each overlapping region being defined at an interface between adjacent sub-parts of the part, the set of hybrid build parameters for each overlapping region being determined at least in part based on the set of build parameters associated with the sub-models corresponding to the adjacent sub-parts, and wherein the part is additively manufactured in the single build using the determined multiple sets of hybrid build parameters.

[0110] 8. A method according to any preceding clause, wherein the model is decomposed into the sub-models so that each sub-component corresponding to the sub-model is sliced ​​with a layer thickness that is the least common multiple of the layer thicknesses of adjacent sub-components.

[0111] 9. The method of any preceding clause, wherein the model is decomposed into the sub-models based at least in part on at least one of the sub-components being designated for removal subsequent to additive manufacturing of the component in the single build.

[0112] 10. The method of any preceding clause, wherein the model is decomposed into the sub-models based at least in part on a build speed customization associated with at least one of the sub-components.

[0113] 11. A system comprising: an additive manufacturing machine; one or more processors; and one or more memory devices storing computer-readable instructions that, when executed by the one or more processors, cause the one or more processors to perform operations, wherein when performing the operations, the one or more processors are configured to: decompose a model representing a component into sub-models each corresponding to a sub-component of the component, each sub-component having a preselected metric associated therewith, decomposing the model into the sub-models based at least in part on the preselected metric; select a set of build parameters for each of the sub-models based at least in part on the preselected metric associated with the sub-component; and cause the additive manufacturing machine to additively manufacture the component in a single build by building the sub-components of the component using the selected multiple sets of build parameters for each of the sub-components.

[0114] 12. A system according to any preceding clause, wherein the sub-model includes a first sub-model and a second sub-model, the first sub-model corresponding to a first sub-component of the sub-component and the second sub-model corresponding to a second sub-component of the sub-component, and wherein the one or more processors are further constructed to: define an overlapping area at an interface between the first sub-component and the second sub-component of the sub-component; and determine a set of hybrid build parameters for the overlapping area based at least in part on a first set of build parameters associated with the first sub-model and a second set of build parameters associated with the second sub-model, and wherein the component is additively manufactured in the single build using the determined set of hybrid build parameters.

[0115] 13. A system according to any preceding clause, wherein, when causing the additive manufacturing machine to additively manufacture the subcomponents of the component in the single build by using multiple selected sets of build parameters for each of the subcomponents, the one or more processors are configured to: cause the additive manufacturing machine to additively manufacture the component by using one or more energy sources of the additive manufacturing machine to build multiple layers, and wherein, for at least one of the multiple layers, at least two sets of selected build parameters are used to build at least one layer.

[0116] 14. The system of any preceding clause, wherein the plurality of sets of build parameters each include energy source power, scan speed, and beam focal spot size.

[0117] 15. A system according to any preceding clause, wherein the one or more processors are constructed to: select an energy source type for each of the sub-models based at least in part on the preselected metrics associated with the sub-components, and wherein the sub-components are constructed using the respective selected energy source types.

[0118] 16. A non-transitory computer-readable medium comprising computer-executable instructions that, when executed by one or more processors of a controller, cause the controller to: decompose a model representing a part into sub-models each corresponding to a sub-part of the part, each sub-part having a preselected metric associated therewith, decomposing the model into the sub-models based at least in part on the preselected metric; select a set of build parameters for each sub-model based at least in part on the preselected metric associated with the sub-part; and cause an additive manufacturing machine to additively manufacture the part in a single build using the selected multiple sets of build parameters.

[0119] 17. A non-transitory computer-readable medium according to any preceding clause, wherein the sub-model includes a first sub-model and a second sub-model, the first sub-model corresponding to a first sub-component of the sub-component, and the second sub-model corresponding to a second sub-component of the sub-component, and wherein, when the computer-executable instructions are executed, the controller: defines an overlapping area at an interface between the first sub-component and the second sub-component of the sub-component; and determines a set of hybrid build parameters for the overlapping area based at least in part on a first set of build parameters associated with the first sub-model and a second set of build parameters associated with the second sub-model, and wherein the part is additively manufactured in the single build using the determined set of hybrid build parameters.

[0120] 18. The non-transitory computer-readable medium of any preceding clause, wherein the computer-executable instructions, when executed, cause the controller to: decompose the model into the sub-models based at least in part on at least one of the sub-parts designated for removal following additive manufacturing of the part in the single build.

[0121] 19. The non-transitory computer-readable medium of any preceding clause, wherein at least one of the plurality of sets of build parameters comprises energy source power, scan speed, and beam focal spot size.

[0122] 20. The non-transitory computer-readable medium of any preceding clause, wherein the computer-executable instructions, when executed, cause the controller to: select an energy source type for each of the sub-models based at least in part on the preselected metrics associated with the sub-components, and wherein when the controller causes the additive manufacturing machine to additively manufacture the component in the single build using the selected multiple sets of build parameters, the sub-components are built using the respective selected energy source types.

Claims

1. A method, characterized in that include: decomposing a model representing a component into sub-models each corresponding to a sub-component of the component, each sub-component having a preselected metric associated therewith, the decomposition of the model into the sub-models based at least in part on the preselected metric; selecting a set of build parameters for each of the sub-models based at least in part on the preselected metrics associated with the sub-components, wherein the set of build parameters includes a first set of build parameters for a first sub-model and a second set of build parameters for a second sub-model; defining an overlap region at an interface between a first subassembly and a second subassembly of the subassembly; determining a set of hybrid build parameters for the overlap region based at least in part on the first set of build parameters associated with the first sub-model and the second set of build parameters associated with the second sub-model, wherein the hybrid build parameters are incrementally hybridized in predetermined layer increments, wherein determining the set of hybrid build parameters includes determining a geometry of the overlap region, wherein determining the geometry of the overlap region includes comparing the first set of build parameters to the second set of build parameters to determine a match score, and determining a thickness and a plane in which the overlap region extends based on the match score and the geometries of the first and second sub-components; as well as The part is additively manufactured in a single build by building the subcomponents of the part using respective selected sets of build parameters for the subcomponents.

2. The method according to claim 1, characterized in that in, Additively manufacturing the part using the selected multiple sets of build parameters includes building a plurality of layers using one or more energy sources of an additive manufacturing machine, and wherein, for at least one of the multiple layers, at least two selected sets of build parameters are used to build the at least one of the multiple layers.

3. The method according to claim 1, characterized in that Further including: determining a set of hybrid build parameters based at least in part on the set of build parameters associated with the sub-model corresponding to the adjacent sub-component, and wherein the component is additively manufactured in the single build using the determined sets of hybrid build parameters.

4. The method according to claim 1, wherein in, The model is decomposed into at least one of the following: the submodel such that each subcomponent corresponding to the submodel is sliced ​​with a layer thickness that is a least common multiple of layer thicknesses of adjacent subcomponents; The sub-model is based at least in part on at least one of the sub-components designated for removal after additive manufacturing of the component in the single build or The sub-model is customized based at least in part on a build speed associated with at least one of the sub-components.

5. A system, characterized in that: include: additive manufacturing machines; one or more processors; as well as one or more memory devices storing computer-readable instructions that, when executed by the one or more processors, cause the one or more processors to perform operations that, when executing the operations, cause the one or more processors to: decomposing a model representing a component into sub-models each corresponding to a sub-component of the component, each sub-component having a preselected quality metric associated therewith, decomposing the model into the sub-models based at least in part on the preselected quality metric, wherein the sub-models include a first sub-model and a second sub-model, the first sub-model corresponding to a first sub-component of the sub-component and the second sub-model corresponding to a second sub-component of the sub-component; selecting a set of build parameters for each of the sub-models based at least in part on the preselected metrics associated with the sub-components, wherein the set of build parameters includes a first set of build parameters for a first sub-model and a second set of build parameters for a second sub-model; defining an overlap region at an interface between the first subassembly and the second subassembly of the subassembly; determining a set of hybrid build parameters for the overlap region based at least in part on the first set of build parameters associated with the first sub-model and the second set of build parameters associated with the second sub-model, wherein the hybrid build parameters are incrementally hybridized in predetermined layer increments, wherein determining the set of hybrid build parameters includes determining a geometry of the overlap region, wherein determining the geometry of the overlap region includes comparing the first set of build parameters to the second set of build parameters to determine a match score, and determining a thickness and a plane in which the overlap region extends based on the match score and the geometries of the first and second sub-components; as well as The additive manufacturing machine is caused to additively manufacture the part in a single build by building the subcomponents of the part using the selected sets of build parameters for each of the subcomponents.

6. The system according to claim 5, characterized in that in, In causing the additive manufacturing machine to additively manufacture the component in the single build by building the subcomponents of the component using respective selected sets of build parameters for the subcomponents, the one or more processors are configured to: The additive manufacturing machine is caused to additively manufacture the part by building a plurality of layers using one or more energy sources of the additive manufacturing machine, and wherein, for at least one of the plurality of layers, at least two sets of selected build parameters are used to build at least one layer of the plurality of layers.

7. A non-transitory computer-readable medium, characterized in that The non-transitory computer-readable medium includes computer-executable instructions that, when executed by one or more processors of a controller, cause the controller to: decomposing a model representing a component into sub-models each corresponding to a sub-component of the component, each sub-component having a preselected metric associated therewith, decomposing the model into the sub-models based at least in part on the preselected metric, wherein the sub-models include a first sub-model and a second sub-model, the first sub-model corresponding to a first sub-component of the sub-component and the second sub-model corresponding to a second sub-component of the sub-component; selecting a set of build parameters for each of the sub-models based at least in part on the preselected metrics associated with the sub-components, wherein the set of build parameters includes a first set of build parameters for a first sub-model and a second set of build parameters for a second sub-model; defining an overlap region at an interface between the first subassembly and the second subassembly of the subassembly; determining a set of hybrid build parameters for the overlap region based at least in part on the first set of build parameters associated with the first sub-model and the second set of build parameters associated with the second sub-model, wherein the hybrid build parameters are incrementally hybridized in predetermined layer increments, wherein determining the set of hybrid build parameters includes determining a geometry of the overlap region, wherein determining the geometry of the overlap region includes comparing the first set of build parameters to the second set of build parameters to determine a match score, and determining a thickness and a plane in which the overlap region extends based on the match score and the geometries of the first and second sub-components; as well as An additive manufacturing machine is caused to additively manufacture the part in a single build using the selected sets of build parameters.

8. The non-transitory computer-readable medium of claim 7, wherein: in, At least one of the plurality of sets of build parameters comprises energy source power, scan speed, and beam focal spot size, and wherein when the computer executable instructions are executed, cause the controller to: selecting an energy source type for each of said sub-models based at least in part on said preselected metrics associated with said sub-components, and Wherein, when the controller causes the additive manufacturing machine to additively manufacture the component in the single build using the selected sets of build parameters, the subcomponents are built using the respective selected energy source types.

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