Uncertainty quantification or predictive defect model for multi-laser powder bed fusion additive manufacturing

A system comprising a computer readable storage device readable by the system, tangibly embodying a program having a set of instructions executable by the system to perform the following steps for predicting defects in powder bed fusion additive manufacturing process for a part, the set of instructions comprising:

• an instruction to execute computational fluid dynamics modeling of a gas flow in an additive manufacturing machine manufacturing chamber;
• an instruction to assign a spatter particle size, velocity and direction relative to a melt pool on a powder bed disposed on a build plate within the manufacturing chamber;
• an instruction to execute computational fluid dynamics post processing for spatter particle tracking;
• an instruction to predict a spatter particle landing pattern;
• an instruction to feed the spatter particle landing pattern prediction into a defect model;
• an instruction to produce a layer thickness map, the layer thickness map configured to demonstrate a location of locally thicker layers on the part;
• and
• an instruction to predict defect location and density to accumulate lack-of-fusion risk as a function of part placement, orientation, and scan strategy.