Systems and methods for selecting and distributing process parameters within a fleet of additive manufacturing machines based on sensor data received during manufacturing processes

A system for iteratively distributing process parameters from a selected machine to other machines in a fleet of additive manufacturing machines, the system comprising:

• at least a first server having a processor configured to perform:
• receiving sensor data from a sensor for a first machine of the fleet of machines;
• determining the sensor data values at working tool positions of each of the plurality of layers of a part being manufactured, based on a correlation of the values of the sensor data relative to time and the working tool positions of each of the plurality of layers relative to time;
• comparing the sensor data values at the working tool positions of the plurality of layers to reference data values at the working tool positions for the plurality of layers to determine a set of comparison measures for the first machine;
• selecting a machine from among the first machine and at least a second machine of the fleet of machines based at least in part on the comparison measures of each of the machines;
• and
• receiving, from the selected machine via a network, process parameters of the selected machine;
• and
• transmitting via a network at least part of the process parameters of the selected machine to other machines of the fleet.

A method for producing, sending and receiving process parameters in a fleet of additive manufacturing machines, the method comprising:

• sending, to a first server, sensor data from a sensor for a first machine of the fleet of machines, the first server being configured to perform:
• determining the sensor data values at the working tool positions of each of the plurality of layers of a part being manufactured, based on a correlation of the values of the sensor data relative to time and working tool positions of each of the plurality of layers relative to time;
• comparing the sensor data values at the working tool positions of the plurality of layers to reference data values at the working tool positions for the plurality of layers to determine a set of comparison measures for the first machine;
• and
• selecting a machine from among the first machine and at least a second machine of the fleet of machines based at least in part on the comparison measures of each of the machines;
• and
• sending via a network, if the first machine is the selected machine, process parameters of the first machine;
• and
• receiving via a network at least part of the process parameters of the selected machine, if the first machine is not the selected machine.