System and method for eliminating surface defects in an additively manufactured component

A method for manufacturing a solid component with an additive manufacturing system, the additive manufacturing system including a first laser device configured to generate and direct a first laser beam and a second laser device configured to generate and direct a second laser beam, the method comprising:

• determining a misalignment vector field for the additive manufacturing system, the misalignment vector field comprising a plurality of misalignment vectors;
• identifying one or more potential stitching positions where the solid component is tangent to one or more misalignment vectors in the misalignment vector field;
• generating a plurality of first hatching paths, a plurality of second hatching paths, and one or more stitching regions, wherein the plurality of first hatching paths and the plurality of second hatching paths overlap at the one or more stitching regions, and wherein the one or more stitching regions are based at least partially on the one or more potential stitching positions;
• selectively directing the first laser beam across a powder bed along the plurality of first hatching paths to consolidate a first portion of the solid component;
• and
• selectively directing the second laser beam across the powder bed along the plurality of second hatching paths to consolidate a second portion of the solid component.