System and process for evaluating and manufacturing additively manufactured components

An additive manufacturing machine comprising:

• an additive manufacturing chamber;
• and
• a controller operable to control said additive manufacturing chamber, wherein the controller includes a processor and a non-transitory memory, the non-transitory memory including instructions operable to iteratively convert a set of desired output component parameters into a set of manufacturing parameters without constructing a physical component, the manufacturing parameters being adjusted to compensate for at least two second order variations, wherein the instructions are operable to cause the controller to iteratively perform a method including:
• a) determining a nominal parameter of at least one surface of a component, wherein the nominal parameter is a parameter of a nominal component;
• b) determining the at least two second order variations in said nominal parameter;
• c) predicting an actual resultant dimension based at least in part on the nominal parameter and the at least two second order variations, the at least two second order variations includes at least one of powder perturbations, powder particle size variations, power source variations, beam profile, and orientation of a sintered surface relative to prior and subsequent sintered surfaces;
• and
• d) adjusting at least one additive manufacturing process parameter in response to said predicted actual parameter.