Systems and methods for using wire printing process data to predict material properties and part quality

A system for printing a three-dimensional (3D) object, comprising:

• a controller configured to extract data corresponding to successive layers of a 3D object and to control, in accordance with said data, a mechanical movement system capable of motion in one or more of five or six axes and a wire feeder that positions a wire,
• at least one computer memory configured to maintain in memory a set of printing parameters, one or more predicted states, and at least one measured parameter;
• one or more computer processors operatively coupled to said at least one computer memory, wherein said one or more computer processors are individually or collectively configured to:
• obtain a) said set of printing parameters and b) a predicted state of said 3D object that is based on at least one printing parameter of said set of printing parameters, wherein said predicted state of said 3D object is a state of said 3D object during printing;
• with said mechanical movement system and said wire feeder, bring said wire adjacent to a support and direct current to melt said wire and thereby print said wire adjacent to said support, in accordance with said set of printing parameters;
• perform a function at multiple times over course of said printing, said function comprising:
• processing a measured parameter of said 3D object against at least one printing parameter of said set to determine at least one quality measure of said 3D object, wherein said at least one quality measure comprises at least one of:
• dimensional accuracy, surface finish, strength, warp, and dimensional instability;
• predicting an intermediate printing state of said 3D object, of a set of predicted intermediate printing states compiled over the multiple times performing the function, based at least in part on a still image, video, or other sensed measurement of said 3D object, as partially formed, and
• electronically outputting said at least one quality measure in real-time;
• and
• from said set of predicted intermediate printing states, determine a final 3D object, wherein said final 3D object is said 3D object after printing.