Additive manufacturing systems and methods of generating CAD models for additively printing on workpieces

An additive manufacturing system, comprising:

• a controller operably coupled to a vision system and an additive manufacturing machine, the controller comprising one or more computer readable medium and one or more processors, the one or more computer readable medium comprising computer-executable instructions, which, when executed by the one or more processors, causes the additive manufacturing system to:
• determine, in a library-CAD model, a nominal model-interface comprising a plane traversing the library-CAD model, the library-CAD model comprising a nominal model of an extension segment corresponding to a workpiece or the library-CAD model comprising a nominal model of the workpiece;
• compare the nominal model-interface of the library-CAD model to a digital representation of a workpiece-interface of the workpiece, the digital representation having been obtained using a vision system that has a field of view including the workpiece-interface;
• and
• generate an extension segment-CAD model comprising a model of the extension segment, the extension segment-CAD model differing from the library-CAD model in respect of at least one of a transformation and an extension of the nominal model-interface based at least in part on a comparison of the nominal model-interface to the digital representation of the workpiece-interface, the model of the extension segment comprising a model-interface configured to be additively printed on the workpiece-interface of the workpiece.

A non-transitory computer readable medium comprising computer-executable instructions, which, when executed by one or more processors of an additive manufacturing system, causes the additive manufacturing system to:

• determine, in a library-CAD model, a nominal model-interface comprising a plane traversing the library-CAD model, the library-CAD model comprising a nominal model of an extension segment corresponding to a workpiece or the library-CAD model comprising a nominal model of the workpiece;
• compare the nominal model-interface of the library-CAD model to a digital representation of a workpiece-interface of the workpiece, the digital representation having been obtained using a vision system that has a field of view including the workpiece-interface;
• and
• generate an extension segment-CAD model comprising a model of the extension segment, the extension segment-CAD model differing from the library-CAD model in respect of at least one of a transformation and an extension of the nominal model-interface based at least in part on a comparison of the nominal model-interface to the digital representation of the workpiece-interface, the model of the extension segment comprising a model-interface configured to be additively printed on the workpiece-interface of the workpiece.