System and method for additively manufacturing an object

An additive manufacturing system comprising:

• a build platform;
• a recoater that deposits powder to form a powder layer on the build platform;
• a mixer that mixes a plurality of powder constituents to produce the powder and dispenses the powder to the recoater;
• a plurality of constituent regulators that dispenses a mass of each one of the plurality of powder constituents to the mixer;
• a plurality of mass sensors that measures the mass of each one of the plurality of powder constituents dispensed to the mixer;
• a mass flow sensor that measures the mass flow of the powder constituents dispensed to the recoater;
• and
• a controller in communication with the plurality of constituent regulators, the plurality of mass sensors, and the mass flow sensor,
• wherein:
• the controller instructs each one of the plurality of constituent regulators to selectively vary the mass of at least one of the plurality of powder constituents being dispensed to the mixer while the powder is being discharged by the recoater such that the powder layer being formed comprises a compositional gradient along at least one of an X-axis and a Y-axis;
• the controller verifies the mass of each one of plurality of powder constituents being dispensed to the mixer based on the mass measured by the mass sensor to produce the powder comprising a compositional ratio;
• and
• the controller verifies the compositional ratio of the powder based on the mass flow rate measured by the mass flow sensor.

A powder-deposition apparatus comprising:

• a plurality of constituent reservoirs that contain a plurality of powder constituents;
• a plurality of constituent regulators, in communication with the plurality of constituent reservoirs, that dispense each one of the plurality of powder constituents;
• a plurality of mass sensors, in communication with the plurality of constituent regulators, that measure a mass of each one of the plurality of powder constituents being dispensed;
• at least one mass flow sensor, in communication with the plurality of constituent regulators, that measures a mass flow of the plurality of powder constituents being dispensed;
• and
• a controller, in communication with the plurality of constituent regulators, the plurality of mass sensors, and the at least one mass flow sensor, that:
• instructs each one of the plurality of constituent regulators to selectively vary the mass of at least one of the plurality of powder constituents to produce powder comprising a compositional ratio selected based on compositional data that is mapped to an X-axis and a Y-axis;
• verifies the mass of each one of plurality of powder constituents being dispensed based on the mass measured by the mass sensor to produce the powder comprising the compositional ratio;
• and
• verifies the compositional ratio of the powder based on the mass flow rate measured by the mass flow sensor such that a powder layer formed from the powder comprises a compositional gradient along at least one of the X-axis and the Y-axis.