Additive Manufacturing

In collaboration with the Advanced Manufacturing Research Centre (AMRC) and Boeing, Intellegens applied the Alchemite™ deep learning software to design new AM parameter sets for laser powder bed fusion (LPBF) and test them for nickel base alloys across two experimental cycles. Results from the second cycle showed good agreement with the predictions. The model was then used to develop process parameters for the new additive-specific Aheadd® CP1 powder from Constellium in combination with the 400W M2 machine from GE Additive. The project team was able to move from the new powder to final parameters in just two builds, while applying no expert statistical knowledge, dramatically speeding up AM process parameter optimisation.

At an Intellegens webinar, Gabe Guss from Lawrence Livermore National Laboratory showed how Alchemite™ machine learning can be applied to predict and optimise print parameters for additively-manufactured parts. Alchemite™ gave results that compared well with alternative analytical approaches, with the added benefits of ease-of-use and the potential to rapidly model new scenarios with many parameters.

The process to ‘print’ materials is often poorly understood and subject to significant variation based on the exact processing parameters and conditions. In our example, limited data was available on a direct laser deposition method, consisting of only ten sets of processing variables. This dataset was not enough for traditional machine learning techniques to be able to predict the properties of a wider family of processing variables. We optimized the process using historical welding data and the available sparse direct laser deposition dataset, potentially saving years of research.

Intellegens featured in Metal AM Magazine, discussing applications of machine learning to additive manufacturing.  The article explores some of the challenges of applying machine learning in AM projects, how these are being overcome, and the resulting benefits.

The Intellegens additive manufacturing solution was a winner in the Innovation Awards at the 2021 AM Tech Forum event, organised by the American Society of Mechanical Engineers (ASME). Intellegens scooped two of the awards – Best in Class Software, and the Startup Award. You can now view a recording of the award-winning presentation.

Intellegens partners with engineering simulation leader Ansys to integrate Alchemite™ technology into Granta MI, the leading materials data management system for AM applications. For Granta MI user organisations, this provides an additional way to access Alchemite™ capabilities from within their existing workfows.