Empirical Optimization of Additive Manufacturing

In this Phase II STTR project, the proposed collaborative effort between UTC, AFIT, and ULRF represents a crucial step forward for AM. UTC’s unique AM optimization and process control framework, constructed entirely from experimental sensor data collected in-situ, will finally transfer technology from our SLM test bed system to state-of-the-art and commercial-grade systems, including a Concept Laser M2 Cusing and EOS M270 system. UTC’s framework, which leverages a “physics-capturing” empirical black box built on correlations between in-situ data, input process parameters, output AM build characteristics, and machine variations will be used to quantify AM process uncertainty across these systems. This Phase II project will show how seamlessly UTC’s technology can be integrated in to any SLM system to inform real-time output prediction for open loop (closed architecture) systems, and real-time process parameter selection and optimization for closed loop (open architecture) systems.