METHOD FOR OPTIMIZING PROCESS PARAMETERS OF AN ADDITIVE MANUFACTURING PROCESS

Abstract: a method for optimizing one or more process parameters of an additive manufacturing process. the method includes, a. manufacturing a set of test samples (c. . . c. . . c) on a build platform (p) of an additive manufacturing system, each test sample (c. . . c. . . c) being monitored by at least one electromagnetic sensor for obtaining at least one optimized set of process parameters (p), and storing the at least one optimized set of process parameters (p) for subsequent use during the building process of the said at least one am part, which is representative of a test coupon (c) of a given acceptable quality factor. the at least one optimized set of process parameters (p) is obtained by carrying out the following steps: i. manufacturing at least two test coupons (c. . . c. . . c) with two different sets of guess process parameters (p. . . p. . . p), ii. sensing the two test coupons (c. . . c. . . c) with the at least one electromagnetic sensor, iii. changing for each new coupon at least one process parameter as a function of a) the previous sets of process parameters (p. . . p. . . p) for the respective built test coupons, and b) the quality factor of respective test coupons measured by the electromagnetic sensor to obtain respective new sets of process parameters (p); iv. manufacturing an additional set of test coupons (c) of respective test samples with the respective new set of process parameters (p); v. sensing the additional set of test coupons (c) with the at least one electromagnetic sensor, and vi. repeating steps iii. to v. until a predetermined geometry of each test sample (c. . . c. . . c) is obtained. a process parameters' window yielding an acceptable quality factor for the at least one am part is computed as a function of the sets of process parameters used for building the test coupons of respective test samples, and the quality factor of the test coupons. at least one optimized set of process parameters is selected within the process parameter window.

Inventor(s): Marc LANY, Bernard REVAZ, Gilles SANTI, Adriaan B. SPIERINGS, Marvin A. SPUREK, Jonatan WICHT, Alain BERTHOUD

CPC Classification: B22F10/80 (WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy ); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER)

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