Systems and methods for monitoring powder spreading in additive manufacturing systems

1. An additive manufacturing system configured to manufacture a component, said additive manufacturing system comprising:

a build platform, the component disposed on said build platform;

a recoater comprising a recoater blade configured to spread a powdered build material across said build platform and the component forming a powder bed;

a monitoring camera positioned to image said recoater blade, said monitoring camera configured to acquire a plurality of images of said recoater blade; and

a controller configured to receive said plurality of images from said monitoring camera, wherein said controller is further configured to identify a region of interest in each image of the plurality of images and identify an accumulation of the powdered build material in the region of interest, and wherein said controller is configured to detect defects in the powder bed based on the accumulation of the powdered build material in the region of interest in said plurality of images received from said monitoring camera.

2. The additive manufacturing system in accordance with claim 1 , wherein the region of interest extends from an outer edge of said recoater blade to an inner edge of said recoater blade and from a region of interest height to a bottom edge of recoater blade.

3. The additive manufacturing system in accordance with claim 1 , wherein said controller is further configured to detect the powdered build material between said recoater blade and said monitoring camera in said plurality of images received from said monitoring camera.

4. The additive manufacturing system in accordance with claim 1 , further comprising a containment wall circumscribing the component.

5. The additive manufacturing system in accordance with claim 4 , wherein said monitoring camera is further configured to image said containment wall.

6. A controller for use in an additive manufacturing system including a build platform, a recoater, a monitoring camera, and a controller, the recoater including a recoater blade, the monitoring camera positioned to image the recoater blade, the monitoring camera further configured to acquire a plurality of images of the recoater blade, said controller including a processing device and a memory device coupled to said processing device, said controller configured to:

receive the plurality of images from the monitoring camera;

identify a region of interest in each image of the plurality of images;

identify an accumulation of the powdered build material in the region of interest; and

analyze the plurality of images of the recoater to detect at least one defect in a powder bed based on the accumulation of the powdered build material in the region of interest in the plurality of images received from the monitoring camera.

7. The controller in accordance with claim 6 , wherein the region of interest extends from an outer edge of the recoater blade to an inner edge of the recoater blade and from a region of interest height to a bottom edge of recoater blade.

8. The controller in accordance with claim 6 , wherein said controller is further configured to produce a plurality of binary images based on the plurality of images.

9. The controller in accordance with claim 8 , wherein the region of interest is isolated in each binary image of the plurality of binary images.

10. The controller in accordance with claim 8 , wherein said controller is further configured to identify the accumulation of the powdered material between the recoater blade and the monitoring camera in the plurality of binary images.

11. The controller in accordance with claim 8 , wherein said controller is further configured to generate an output graph based on the plurality of binary images.

12. A method of manufacturing a component with an additive manufacturing system, the additive manufacturing system including a build platform, a recoater, a monitoring camera, and a controller, the recoater including a recoater blade, the monitoring camera positioned to image the recoater blade, the monitoring camera configured to acquire a plurality of images of the recoater blade, the component is disposed on the build platform, said method comprising:

spreading a powdered build material on the build platform and the component using the recoater to form a powder bed;

acquiring the plurality of images of the recoater using the monitoring camera;

identify a region of interest in each image of the plurality of images;

identify an accumulation of the powdered build material in the region of interest; and

analyzing the plurality of images of the recoater using the controller to detect at least one defect in the powder bed based on the accumulation of the powdered build material in the region of interest in the plurality of images received from the monitoring camera.

13. The method of claim 12 , further comprising rotating the build platform relative to the recoater.

14. The method of claim 12 , further comprising dispensing the powdered build material on the build platform and the component.

15. The method of claim 12 , further comprising determining an amount of powered build material to dispense based on the plurality of images of the recoater.

16. The method of claim 12 , further comprising detecting the powdered build material between the recoater blade and the monitoring camera in the plurality of images received from the monitoring camera.