Ryan D Carter

US Patent:

20220266531, Aug 25, 2022

Filed:

Feb 21, 2022

Appl. No.:

17/676407

Inventors:

- Baltimore MD, US
Nathan G. Drenkow - Columbia MD, US
Brendan P. Croom - Baltimore MD, US
Ryan H. Carter - Ellicott City MD, US
Robert K. Mueller - Columbia MD, US

International Classification:

B29C 64/393
B29C 64/153
B33Y 10/00
B33Y 50/02
G06T 7/00
G06V 10/70

Abstract:

A method for monitoring and analyzing an additive manufacturing process includes heating a melt zone to fuse an additive media with an active layer to build a part being manufactured based on a part design model, capturing raw melt data of the melt zone, and generating an active layer dataset that is spatially defined. The method may also include analyzing the active layer dataset with respect to a plurality of defect signatures within a defect signature library. The defect signature library may be predefined based on a machine learning processing of historical sensor datasets with corresponding ground truth datasets. The method may also include detecting a defect in the part based on the analysis of the active layer dataset with respect to a plurality of defect signatures, simultaneously with the energy source acting upon the active layer of the part for manufacturing of the part.