Additive manufacturing systems and methods of pretreating and 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 non-transitory computer readable medium and one or more processors,
• the one or more non-transitory computer readable medium comprising computer-executable instructions, which,
• when executed by the one or more processors,
• cause the additive manufacturing system to perform a method comprising:
• pretreating a workpiece-interface using an energy beam emitted from an energy beam source of the additive manufacturing machine,
• providing a pretreated workpiece-interface,
• wherein pretreating the workpiece-interface comprises remediating an aberrant feature of the workpiece and/or the workpiece-interface at least in part by additive-leveling the workpiece-interface and/or melt-leveling the workpiece-interface;
• and
• additively printing an extension segment on the pretreated workpiece-interface using an energy beam emitted from the energy beam source of the additive manufacturing machine;
• wherein the aberrant feature comprises one or more aberrant regions of the workpiece-interface that differ in elevation and/or that are at least partially askew relative to a congruent region of the workpiece-interface,
• the one or more aberrant regions having been determined from one or more digital representations of the workpiece captured by the vision system;
• and
• wherein the pretreatment comprises additive-leveling at least a portion of the workpiece-interface comprising a first one of the one or more aberrant regions and/or melt-leveling at least a portion of the workpiece-interface comprising a second one of the one or more aberrant regions.

A non-transitory computer readable medium comprising computer-executable instructions, which,

• when executed by one or more processors associated with an additive manufacturing machine, cause the additive manufacturing machine to perform a method comprising:
• pretreating a workpiece-interface using an energy beam from the additive manufacturing machine, providing a pretreated workpiece-interface, wherein pretreat the workpiece-interface comprises remediating an aberrant feature of the workpiece and/or the workpiece-interface at least in part by additive-leveling the workpiece-interface and/or melt-leveling the workpiece-interface;
• and
• additively printing an extension segment on the pretreated workpiece-interface using an energy beam emitted from the energy beam source of from the additive manufacturing machine;
• wherein the aberrant feature comprises one or more aberrant regions of the workpiece-interface that differ in elevation and/or that are at least partially askew relative to a congruent region of the workpiece-interface,
• the one or more aberrant regions having been determined from one or more digital representations of the workpiece-interface captured by a vision system;
• and
• wherein the pretreatment comprises additive-leveling at least a portion of the workpiece-interface comprising a first one of the one or more aberrant regions and/or melt-leveling at least a portion of the workpiece-interface comprising a second one of the one or more aberrant regions.