Assignment of multiple print parameter sets in additive manufacturing

A system comprising:

• a memory storing processor-executable instructions;
• and
• one or more processors to execute the processor-executable instructions to:
• determine a first additive manufacturing (AM) print parameter set, the first AM print parameter set to include a first laser power setting, a first laser speed setting, and a first laser spot size setting;
• retrieve a three-dimensional model of a part, the three-dimensional model to include a set of material properties of the part, the first AM print parameter set corresponding to the set of material properties of the part;
• perform a physical load analysis associated with the three-dimensional model of the part to determine first material properties of a first region of a first layer of a plurality of layers of the part and second material properties of a second region of the first layer of the plurality of layers of the part, the physical load analysis to predict a first load on the first region and a second load on the second region, the first load associated with a first life cycles to failure of the first region and the second load associated with a second life cycles to failure of the second region;
• compare the first life cycles to failure of the first region and the second life cycles to failure of the second region;
• adjust the first AM print parameter set to correspond to the first region and the first life cycles to failure;
• when the second life cycles to failure of the second region is greater than the first life cycles to failure of the first region, generate a second AM print parameter set to correspond to the second region and the second life cycles to failure, the second AM print parameter set to include a second laser power setting, a second laser speed setting, and a second laser spot size setting;
• when the second life cycles to failure of the second region is greater than the first life cycles to failure of the first region by at least an order of magnitude, adjust the second AM print parameter set to a low-fidelity print parameter set from a high-fidelity print parameter set;
• automatically assign at least the first AM print parameter set for the first region of the first layer of the plurality of layers of the part to a first laser of a multi-laser AM device and the second AM print parameter set for the second region of the first layer of the plurality of layers of the part to a second laser of the multi-laser AM device, wherein the automatic assignment generates determined print parameter sets to laser assignments;
• save a record of the determined print parameter sets to laser assignments;
• and
• transmit the record of the determined print parameter sets to laser assignments to an AM controller, the AM controller to control the first laser and the second laser of the multi-laser AM device to generate the part in a single build of the plurality of layers including the first layer based on the three-dimensional model of the part and the assignment of print parameter sets to the first laser and the second laser.

A non-transitory computer-readable medium storing instructions that, when executed by a computer processor, cause the computer processor to perform a method comprising:

• determining a first additive manufacturing (AM) print parameter set, the first AM print parameter set to include a first laser power setting, a first laser speed setting, and a first laser spot size setting;
• retrieving a three-dimensional model of a part, the three-dimensional model to include a set of material properties of the part, the first AM print parameter set corresponding to the set of material properties of the part;
• performing a physical load analysis associated with the three-dimensional model of the part to determine first material properties of a first region of a first layer of a plurality of layers of the part and second material properties of a second region of the first layer of the plurality of layers of the part, the physical load analysis to predict a first load on the first region and a second load on the second region, the first load associated with a first life cycles to failure of the first region and the second load associated with a second life cycles to failure of the second region;
• comparing the first life cycles to failure of the first region and the second life cycles to failure of the second region;
• adjusting the first AM print parameter set to correspond to the first region and the first life cycles to failure;
• when the second life cycles to failure of the second region is greater than the first life cycles to failure of the first region, generating a second AM print parameter set to correspond to the second region and the second life cycles to failure, the second AM print parameter set to include a second laser power setting, a second laser speed setting, and a second laser spot size setting;
• when the second life cycles to failure of the second region is greater than the first life cycles to failure of the first region by at least an order of magnitude, adjusting the second AM print parameter set to a low-fidelity print parameter set from a high-fidelity print parameter set;
• automatically assigning at least the first AM print parameter set for the first region of the first layer of the plurality of layers of the part to a first laser of a multi-laser AM device and the second AM print parameter set for the second region of the first layer of the plurality of layers of the part to a second laser of the multi-laser AM device, wherein the automatic assignment generates determined print parameter sets to laser assignments;
• saving a record of the determined print parameter sets to laser assignments;
• and
• transmitting the record of the determined print parameter sets to laser assignments to an AM controller, the AM controller to control the first laser and the second laser of the multi-laser AM device to generate the part in a single build of the plurality of layers including the first layer based on the three-dimensional model of the part and the assignment of print parameter sets to the first laser and the second laser.