System and methods for generating fault indications for an additive manufacturing process based on a probabilistic comparison of the outputs of multiple process models to measured sensor data

A non-transitory computer-readable medium comprising computer-executable instructions, which, when executed by a processor associated with an additive manufacturing machine, cause the processor to perform a method comprising:

• receiving, via a communication interface, sensor data comprising one or more sensor values from one or more sensors of an additive manufacturing machine during an additive manufacturing process to manufacture at least one part;
• computing, for respective ones of a plurality of models, a probability density function defining a probability that a selected set of the sensor data matches an output of a corresponding one of the plurality of models;
• and
• outputting an indication of a defined condition being present during the additive manufacturing process, the defined condition corresponding to a selected one of the plurality of models, wherein the selected one of the plurality of models has at least a specified probability that the selected set of the sensor data matches the output of the selected one of the plurality of models.