Methods of additively manufacturing a manufactured component and systems that perform the methods

A method of additively manufacturing a manufactured component, the method comprising:

• determining an energy application parameter at an addition location on a previously formed portion of the manufactured component by:
• (i) virtually positioning a virtual geometric shape at the addition location, wherein the virtual geometric shape is characterized by a size parameter that is indicative of a surface area of the virtual geometric shape;
• (ii) during the virtually positioning, quantifying an area of intersection between the previously formed portion of the manufactured component and an outer surface of the virtual geometric shape;
• (iii) repeating the virtually positioning and the quantifying for a plurality of different virtual geometric shapes, wherein each virtual geometric shape of the plurality of different virtual geometric shapes is characterized by a corresponding size parameter that differs from the size parameter of each other virtual geometric shape of the plurality of different virtual geometric shapes, and further wherein all proportions of each virtual geometric shape are identical to all proportions of each other virtual geometric shape;
• (iv) producing an intersection area relationship that quantifies each area of intersection for each virtual geometric shape of the plurality of different virtual geometric shapes as a function of the corresponding size parameter for each virtual geometric shape;
• and
• (v) determining the energy application parameter based, at least in part, on the intersection area relationship;
• supplying a feedstock material to the addition location;
• delivering, from an energy source and to the addition location, an amount of energy sufficient to form a melt pool of the feedstock material at the addition location, wherein the amount of energy is based, at least in part, on the energy application parameter, wherein the delivering the amount of energy includes delivering along an axis of incidence, and further wherein the virtual geometric shape is a shell of rotation about the axis of incidence;
• and
• consolidating the melt pool with the previously formed portion of the manufactured component to form an additional portion of the manufactured component;
• wherein a rate of change of the intersection area relationship with respect to the size parameter is less than a threshold rate of change;
• and
• the method further includes determining that the addition location is proximate a gap within the previously formed portion of the manufactured component.