Method and system for interlayer feedback control and failure detection in an additive manufacturing process

Abstract

An additive manufacturing system configured to: during a first build cycle of an additive manufacturing process for manufacturing a first layer of a build, sampling a first set of sensor data streams via the sensor suite; calculate a first likelihood of failure of the build based on the first set of sensor data streams; in response to calculating the first likelihood of failure within a first likelihood range, flag the build to indicate the first likelihood of failure; and in response to calculating the first likelihood of failure within a second likelihood range greater than the first likelihood range, pause the additive manufacturing process, and notify an operator of the additive manufacturing system of the first likelihood of failure.

I claim: 
     
         1 . An additive manufacturing system comprising:
 a build window;   a projection system:
 arranged beneath a lower surface of the build window; and 
 configured to project electromagnetic radiation toward an upper surface of the build window; 
   a build platform:
 facing the build window; and 
 configured to retract and advance relative to the build window; 
   a sensor suite; and   a controller configured to:
 during a first build cycle of an additive manufacturing process for manufacturing a first layer of a build, sample a first set of sensor data streams via the sensor suite; 
 calculate a first likelihood of failure of the build based on the first set of sensor data streams; 
 in response to calculating the first likelihood of failure within a first likelihood range, flag the build to indicate the first likelihood of failure; and 
 in response to calculating the first likelihood of failure within a second likelihood range greater than the first likelihood range:
 pause the additive manufacturing process; and 
 notify an operator of the additive manufacturing system of the first likelihood of failure. 
 
   
     
     
         2 . The additive manufacturing system of  claim 1 :
 wherein the sensor suite comprises an image sensor arranged below the build window and configured to record images depicting the build window;   wherein the controller is configured to:
 during the first build cycle of the additive manufacturing process:
 record the first set of sensor data streams via the sensor suite, the first set of sensor data streams comprising a first image recorded by the image sensor; 
 
 access a geometry of the first layer of the build; and 
 calculate, via the failure detection model, the first likelihood of failure based on:
 the geometry of the first layer of the build; and 
 the first set of sensor data streams comprising the first image. 
 
   
     
     
         3 . The additive manufacturing system of  claim 2 , wherein the controller is configured to:
 detecting a real geometry of the first layer based on the first image; and   calculate, via the failure detection model the first likelihood of failure of the build based on a comparison between the geometry of the first layer and the real geometry of the first layer and based on the first set of sensor data streams.