Process for identifying and implementing additive manufacturing evacuation gas flow improvements

A method operable to improve evacuation gas flow (EGF) performance of a baseline build chamber for use during an additive manufacturing process, the method comprising:

• receiving, via a host computer device, an input data set comprising:
• an experimental data set associated with a modified build chamber, wherein:
• the modified build chamber is a modified version of the baseline build chamber, and
• the experimental data set is obtained via a particle-velocimetry imaging system in communication with the host computer device;
• a set of improvement metrics operable to characterize flow improvements in the EGF performance of the modified build chamber, wherein:
• the set of improvement metrics are based on a volume of coverage of a laser beam that enters the modified build chamber,
• the set of improvement metrics comprises a debris residence time and a recirculation metric that quantifies vortical flow behavior within the modified build chamber;
• an initial geometry of the modified build chamber;
• and
• defined operating conditions of the modified build chamber;
• generating, via the host computer device, an initial three-dimensional (3D) flow field data set in response to the input data set, the initial 3D flow field data set being indicative of a flow of an inert gas within the modified build chamber;
• performing, via the host computer device, a set of iterations of an optimization loop process, wherein, performing each iteration of the set of iterations comprises:
• extracting, from a data set via the host computer device, a set of evacuation streamline data corresponding to the EGF performance over a build plate of the modified build chamber, the set of evacuation streamline data describing expected flow paths of the inert gas through a scanning path of the laser beam, wherein:
• for a first iteration of the set of iterations, the data set comprises the initial 3D flow field data set, and
• for each subsequent iteration of the set of iterations, the data set comprises an output data set of a previous iteration;
• generating, via the host computer device, an output data set using the set of evacuation streamline data, wherein the output data set comprises a set of flow vectors, an improvement estimate based on the set of improvement metrics, and an updated geometry of the modified build chamber, and wherein the updated geometry is based on a gradient descent calculation to update a set of geometry parameters;
• determining, via the host computer device and based on the output data set, whether a termination condition is satisfied, wherein the termination condition comprises a threshold objective value associated with the output data set;
• initiating, via the host computer device, a next iteration of the set of iterations when the termination condition is not satisfied;
• and
• terminating, via the host computer device, the optimization loop process when the termination condition is satisfied;
• and
• outputting, via the host computer device for transmission to a 3D printer:
• an output data set of a last iteration of the set of iterations, and
• a command to construct the modified build chamber.

A host computer device for improving evacuation gas flow (EGF) performance of a baseline build chamber for use in an additive manufacturing process, the host computer device comprising:

• memory comprising instructions;
• and
• one or more processors configured to execute the instructions and cause the one or more processors to:
• receive an input data set comprising:
• an experimental data set associated with a modified build chamber, wherein:
• the modified build chamber is a modified version of the baseline build chamber, and
• the experimental data set is obtained via a particle-velocimetry imaging system in communication with the host computer device;
• a set of improvement metrics operable to characterize flow improvements in the EGF performance of the modified build chamber, wherein:
• the set of improvement metrics is based on a volume of coverage of a laser beam that enters the modified build chamber,
• the set of improvement metrics comprises a debris residence time and a recirculation metric that quantifies vortical flow behavior within the modified build chamber;
• an initial geometry of the modified build chamber;
• and
• defined operating conditions of the modified build chamber;
• generate an initial three-dimensional (3D) flow field data set in response to the input data set, the initial 3D flow field data set being indicative of a flow of an inert gas within the modified build chamber;
• perform a set of iterations of an optimization loop process, wherein, to perform each iteration of the set of iterations, the one or more processors are configured to execute the instructions and cause the one or more processors to:
• extract, from a data set, a set of evacuation streamline data corresponding to the EGF performance over a build plate of the modified build chamber, the set of evacuation streamline data describing expected flow paths of the inert gas through a scanning path of the laser beam, wherein:
• for a first iteration of the set of iterations, the data set comprises the initial 3D flow field data set, and
• for each subsequent iteration of the set of iterations, the data set comprises an output data set of a previous iteration;
• generate an output data set using the set of evacuation streamline data, wherein the output data set comprises a set of flow vectors, an improvement estimate based on the set of improvement metrics, and an updated geometry of the modified build chamber, and wherein the updated geometry is based on a gradient descent calculation to update a set of geometry parameters;
• determine, based on the output data set, whether a termination condition is satisfied, wherein the termination condition comprises a threshold objective value associated with the output data set;
• initiate a next iteration of the set of iterations when the termination condition is not satisfied;
• and
• terminate the optimization loop process when the termination condition is satisfied;
• and
• output, for transmission to a 3D printer:
• an output data set of a last iteration of the set of iterations, and
• a command to construct the modified build chamber.