Anomaly detection in additive manufacturing using meltpool monitoring, and related devices and systems

A method comprising:

• generating a layer of an object according to an instruction generated based on a process model and using a hybrid machine-learning model, the instruction comprising a threshold for additive manufacturing based, at least in part, on a correlation between input area energy density and emitted power;
• taking a reading relative to the generation of the layer;
• comparing the reading to the threshold of the instruction;
• adjusting, based the comparison of the reading to the, and using a hybrid machine-learning model, the instruction, the adjustment, based at least in part, on the correlation between the input area energy density and the emitted power;
• and
• generating a subsequent layer of the object according to the adjusted instruction.

A system for additive manufacture, the system comprising:

• a simulator configured to generate a process model according to a build file, the process model representative of an object to be generated through additive manufacture;
• a hybrid machine-learning model trained using simulated data and measured data, the hybrid machine-learning model configured to generate, based on the process model, an instruction for generating the object, the instruction comprising a threshold for additive manufacturing based, at least in part, on a correlation between input area energy density and emitted power;
• and
• an object generator configured to generate an object through additive manufacture according to the build file and the instruction:
• comprising:
• generating a layer of the object;
• taking a reading relative to the generation of the layer;
• comparing the reading to the threshold of the instruction;
• adjusting, based on the comparison of the reading to the threshold, and using the hybrid machine-learning model, the instruction, the adjustment, based at least in part, on the correlation between the input area energy density and the emitted power;
• and
• generating a subsequent layer of the object according to the adjusted instruction.