Systems and methods for receiving sensor data for an operating manufacturing machine and producing an alert during manufacture of a part

A method for receiving sensor data for an operating manufacturing machine and producing an alert during manufacture of a part formed by a plurality of layers, the method comprising:

• receiving, at a first server, the sensor data from at least one sensor for the operating machine;
• determining, using a processor of the first server, values of the sensor data relative to time;
• determining, using the processor of the first server, working tool positions relative to time based on process data which controls operation of the manufacturing machine, the process data comprising vectors defining the working tool positions of at least one of the plurality of layers during a manufacturing process;
• determining one or more sensor data values at the working tool positions of the at least one of the plurality of layers based on a correlation of the values of the sensor data relative to time and the working tool positions of the at least one of the plurality of layers relative to time;
• providing the one or more sensor data values to an analytic model of the manufacturing machine, the analytic model being trained based at least in part on sensor data from another machine manufacturing a same part;
• determining a quality measurement of at least one of the plurality of layers using the analytic model;
• comparing, during the manufacturing process, the quality measurement of at least one of the plurality of layers to a quality threshold for the at least one layer to determine a comparison measure for the at least one layer;
• transmitting an alert if the determined comparison measure of the at least of the plurality of layers is not within a defined range;
• and
• causing a defined action to be applied the manufacturing process in response to the transmitted alert.

A system for receiving sensor data for an operating manufacturing machine and producing an alert during manufacture of a part formed by a plurality of layers, the system comprising:

• a first server having a processor configured to perform:
• receiving, at a first server, the sensor data from a sensor for the operating machine;
• determining, using a processor of the first server, values of the sensor data relative to time;
• determining, using the processor of the first server, working tool positions relative to time based on process data which controls operation of the manufacturing machine, the process data comprising vectors defining the working tool positions of at least one of the plurality of layers during a manufacturing process;
• determining the sensor data values at the working tool positions of the at least one of the plurality of layers based on a correlation of the values of the sensor data relative to time and the working tool positions of the at least one of the plurality of layers relative to time;
• comparing, during the manufacturing process, the sensor data values at the working tool positions of at least one of the plurality of layers to reference data values at the working tool positions for the at least one layer to determine a comparison measure for the at least one layer;
• transmitting an alert if the determined comparison measure of the at least one of the plurality of layers is not within a defined range;
• and
• causing a defined action to be applied to the manufacturing process based on the transmitted alert.