Dynamic layer selection in additive manufacturing using sensor feedback

Abstract

The present disclosure relates to methods and systems for improving layer selection in additive manufacturing. In particular, the present disclosure relates to methods and systems for improving layer selection in additive manufacturing using sensor feedback. In some examples, the sensor may be a distance sensor, and design layers may be selected dynamically based on determined part layer heights after layer deposition.

What is claimed is: 
     
         1 . An additive manufacturing apparatus, comprising:
 a process motion system configured to move in a plurality of degrees of freedom;   a deposition element connected to the process motion system;   a distance sensor connected to the process motion system;   a directed energy source;   a powder material feed;   a memory comprising a plurality of design layers representing a part to be additively manufactured; and   a control system, wherein the control system is configured to execute process code and cause the additive manufacturing apparatus to:
 select a current design layer from the plurality of design layers to be deposited; 
 move, via the process motion system, the deposition element and the distance sensor along a deposition path corresponding to the design layer; 
 selectively deposit, via the deposition element, powder material from the powder material feed along the deposition path; 
 selectively provide, via the directed energy source, a directed energy beam to the deposited powder material along the deposition path in order to form a deposited layer; 
 obtain, via the distance sensor, a plurality of measurements of the deposited layer along the deposition path; and 
 determine, based on the plurality of measurements of the deposited layer, a next design layer from the plurality of design layers to be deposited on the deposited layer, wherein the next layer is separated from the current design layer by at least one intervening design layer. 
   
     
     
         2 . The additive manufacturing apparatus of  claim 1 , wherein the control system is further configured to execute process code and cause the additive manufacturing apparatus to: obtain one or more of the plurality of measurements of the deposited layer while selectively depositing, via the deposition element, the powder material along the deposition path. 
     
     
         3 . The additive manufacturing apparatus of  claim 1 , further comprising:
 a build surface motion system configured to move a build surface in a plurality of degrees of freedom,   wherein the control system is further configured to execute process code and cause the additive manufacturing apparatus to: selectively move, via the build surface motion system, a build surface while depositing the powder material.   
     
     
         4 . The additive manufacturing apparatus of  claim 1 , wherein the control system is further configured to execute process code and cause the additive manufacturing apparatus to:
 determine a median height of the deposited layer based on the plurality of measurements of the deposited layer along the deposition path; and   determine, based on the median height of the deposited layer, the next design layer from the plurality of design layers to be deposited.   
     
     
         5 . The additive manufacturing apparatus of  claim 4 , wherein the control system is further configured to execute process code and cause the additive manufacturing apparatus to: move, via the process motion system, the deposition element to a distance above the median height of the deposited layer in order to position a focal point of the directed energy beam for deposition of the next design layer. 
     
     
         6 . The additive manufacturing apparatus of  claim 1 , further comprising:
 a tool configured to remove deposited material,   wherein the control system is further configured to execute process code and cause the additive manufacturing apparatus to: selectively remove material from the deposited layer.   
     
     
         7 . The additive manufacturing apparatus of  claim 1 , wherein the directed energy source is a laser. 
     
     
         8 . The additive manufacturing apparatus of  claim 1 , wherein the distance sensor is offset from the deposition element by a fixed distance. 
     
     
         9 . The additive manufacturing apparatus of  claim 1 , wherein the distance sensor is an optical distance sensor. 
     
     
         10 . The additive manufacturing apparatus of  claim 9 , wherein the optical distance sensor is a laser distance sensor. 
     
     
         11 . A method of performing additive manufacturing, comprising:
 selecting a current design layer from a plurality of design layers stored in a memory and representing a part to be additively manufactured;   moving, via a process motion system, a deposition element and a distance sensor along a deposition path corresponding to the design layer;   selectively depositing, via the deposition element, powder material from a powder material feed along the deposition path;   selectively providing, via a directed energy source, a directed energy beam to the deposited powder material along the deposition path in order to form a deposited layer;   obtaining, via the distance sensor, a plurality of measurements of the deposited layer along the deposition path; and   determining, based on the plurality of measurements of the deposited layer, a next design layer from the plurality of design layers to be deposited on the deposited layer, wherein the next layer is separated from the current design layer by at least one intervening design layer.   
     
     
         12 . The method of  claim 11 , further comprising: obtaining one or more of the plurality of measurements of the deposited layer while selectively depositing, via the deposition element, the powder material along the deposition path. 
     
     
         13 . The method of  claim 11 , further comprising: selectively moving, via a build surface motion system, a build surface while depositing the powder material. 
     
     
         14 . The method of  claim 11 , further comprising:
 determining a median height of the deposited layer based on the plurality of measurements of the deposited layer along the deposition path; and   determining, based on the median height of the deposited layer, the next design layer from the plurality of design layers to be deposited.   
     
     
         15 . The method of  claim 14 , further comprising: moving, via the process motion system, the deposition element to a distance above the median height of the deposited layer in order to position a focal point of the directed energy beam for deposition of the next design layer. 
     
     
         16 . The method of  claim 11 , further comprising: selectively remove material from the deposited layer using a tool attached to the process motion system. 
     
     
         17 . The method of  claim 11 , wherein the directed energy source is a laser. 
     
     
         18 . The method of  claim 11 , wherein the distance sensor is offset from the deposition element by a fixed distance. 
     
     
         19 . The method of  claim 11 , wherein the distance sensor is an optical distance sensor. 
     
     
         20 . The method of  claim 19 , wherein the optical distance sensor is a laser distance sensor.