US 11,806,784 B2
Rapid material development process for additive manufactured materials
Steven M. Storck, Catonsville, MD (US); Joseph J. Sopcisak, Derwood, MD (US); Christopher M. Peitsch, Perry Hall, MD (US); Salahudin M. Nimer, Fulton, MD (US); and Zachary R. Ulbig, Essex, MD (US)
Assigned to The Johns Hopkins University, Baltimore, MD (US)
Filed by The Johns Hopkins University, Baltimore, MD (US)
Filed on May 14, 2021, as Appl. No. 17/320,443.
Claims priority of provisional application 63/028,131, filed on May 21, 2020.
Prior Publication US 2021/0362242 A1, Nov. 25, 2021
Int. Cl. B22F 10/85 (2021.01); B33Y 50/02 (2015.01); B22F 10/28 (2021.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01); B22F 12/90 (2021.01); G16C 60/00 (2019.01)
CPC B22F 10/85 (2021.01) [B22F 10/28 (2021.01); B22F 12/90 (2021.01); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 50/02 (2014.12)] 11 Claims
OG exemplary drawing
 
1. A system comprising:
at least one computer communicatively coupled to a three-dimensional additive manufacturing printer; and
a mechanical characterization device configured to measure one or more physical outputs associated with additive manufactured reduced volume samples, wherein the reduced volume samples are a fraction of an intended build article;
wherein the at least one computer is configured to provide a computational fluid dynamic simulation of a powder bed fusion additive manufacturing process to simulate melt pool dynamics and provide a simulated optimal parameter set,
wherein the at least one computer is configured to provide a first statistical design of experiments based on the simulated optimal parameter set to generate a multi-factorial parameter space encompassing the simulated optimal parameter set and provide instructions to the three-dimensional additive manufacturing printer to build the reduced volume samples according to the multi-factorial parameter space to determine a first optimal build parameter set, and
wherein the at least one computer is optionally configured to provide at least one additional statistical design of experiments based on the first optimal build parameter set to generate at least one additional multi-factorial parameter space encompassing the first optimal build parameter set and provide instructions to the three-dimensional additive manufacturing printer to build the reduced volume samples according to the at least one additional multi-factorial parameter space to determine at least one additional optimal build parameter set for the first optimal build parameter set.