US 11,858,207 B2
Defect detection for additive manufacturing systems
Vivek R. Dave, Concord, NH (US); R. Bruce Madigan, Butte, MT (US); Mark J. Cola, Santa Fe, NM (US); and Martin S. Piltch, Los Alamos, NM (US)
Assigned to Sigma Additive Solutions, Inc., Santa Fe, NM (US)
Filed by Sigma Additive Solutions, Inc., Santa Fe, NM (US)
Filed on Feb. 21, 2023, as Appl. No. 18/112,146.
Application 18/112,146 is a continuation of application No. 17/409,711, filed on Aug. 23, 2021, granted, now 11,607,875.
Application 17/409,711 is a continuation of application No. 15/984,104, filed on May 18, 2018, granted, now 11,135,654, issued on Oct. 5, 2021.
Application 15/984,104 is a continuation of application No. 14/832,691, filed on Aug. 21, 2015, granted, now 9,999,924, issued on Jun. 19, 2018.
Claims priority of provisional application 62/040,417, filed on Aug. 22, 2014.
Prior Publication US 2023/0202100 A1, Jun. 29, 2023
Int. Cl. B29C 64/153 (2017.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01); B33Y 50/02 (2015.01); B22F 10/28 (2021.01); B22F 12/44 (2021.01); B22F 12/49 (2021.01); B22F 12/90 (2021.01); B22F 10/31 (2021.01); B22F 10/38 (2021.01); B33Y 40/00 (2020.01); B29C 64/393 (2017.01); B22F 3/24 (2006.01); B22F 10/12 (2021.01); B22F 10/18 (2021.01); B22F 10/25 (2021.01); B22F 10/368 (2021.01)
CPC B29C 64/153 (2017.08) [B22F 10/28 (2021.01); B22F 10/31 (2021.01); B22F 10/38 (2021.01); B22F 12/44 (2021.01); B22F 12/49 (2021.01); B22F 12/90 (2021.01); B29C 64/393 (2017.08); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 40/00 (2014.12); B33Y 50/02 (2014.12); B22F 10/12 (2021.01); B22F 10/18 (2021.01); B22F 10/25 (2021.01); B22F 10/368 (2021.01); B22F 2003/245 (2013.01); Y02P 10/25 (2015.11)] 11 Claims
OG exemplary drawing
 
1. An additive manufacturing system, comprising:
a scan head;
a build plane;
a heat source configured to transmit energy through the scan head and toward the build plane to generate a melt pool;
an optical sensor configured to receive light through the scan head, wherein the light is emitted by the melt pool; and
a processor configured to execute computer code that that causes the additive manufacturing system to carry out an additive manufacturing operation to produce a part, the additive manufacturing operation comprising:
depositing a layer of metal powder on the build plane;
generating the melt pool by melting a portion of the layer of metal powder using the heat source;
generating a dataset from an output of the optical sensor;
comparing the dataset with a known-good range of a baseline dataset to determine whether one or more portions of the part may include a manufacturing defect; and
in response to the comparing, changing a parameter of the heat source.