Patent Publication Number: US-2018035080-A1

Title: Verification and adjustment systems and methods for additive manufacturing

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. Ser. No. 14/910,926 filed Feb. 8, 2016 which is a 371 application of PCT/US2016/012992 filed Jan. 12, 2016, which claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Patent Application No. 62/102,839, filed on Jan. 13, 2015 and U.S. Provisional Patent Application Nos. 62/153,729 and 62/153,752, both filed on Apr. 28, 2015, which are incorporated herein by reference in their entirety. 
    
    
     FIELD OF THE DISCLOSURE 
     The present verification and adjustment systems and/or methods (collectively known hereinafter as “systems and/or methods”) comprise, provide and/or utilize at least one additive manufacturing machine or device (hereinafter “AM device”) and a plurality of computer-implemented instructions or computer software (hereinafter “software”) to effectively calibrate the AM device such that at least one three-dimensional object or component (hereinafter “component”) may be built, synthesized, produced and/or fabricated consistently and/or accurately from at least one three-dimensional (hereinafter “3D”) computer model. The present systems and/or methods may comprise, provide and/or utilize a plurality of imaging sensors or devices along with the software to verify tolerances and/or automatically identify and/or correct any geometric anomalies of the built component that may not adhere to the given tolerances set forth by the at least one 3D computer model (hereinafter “3D computer model”). The plurality of imaging sensors or devices may be integrated into, and/or located at, near or adjacent to, the AM device and/or may comprise at least one first imaging device and at least one second imaging device. The at least one first imaging device may be located, or positioned at a first orientation with respect to a build platform of the AM device, and the at least one second imaging device may be located, or positioned, at a second orientation with respect to the build platform of the AM device. The present systems and/or methods may utilize the software and image data collected by the at least one first imaging device and/or the at least one second imaging device to effectively verify, calibrate and/or adjust the AM device. As a result, the AM device may be a self-correcting AM device that first compares the actual built or first component to and/or against the 3D computer model to identify any geometric anomalies of the actual built component and subsequently adjusts and/or calibrates the AM device to build at least one subsequent or at least one second component which does not have, exhibit or contain the geometric anomalies. Moreover, the present systems and/or methods may analyze the collected image data of the actual built or first component to identify any geometric anomalies of the actual built or first component and subsequently adjust and/or calibrate the AM device based on the analysis of the collected image data to avoid any identified geometric anomalies from being present in one or more subsequent built or one or more second components built by the AM device. 
     BACKGROUND OF THE DISCLOSURE 
     Current AM devices do not incorporate any type of feedback loop that allows for the verification of build geometry of a component or the adjustment thereof for subsequently built components. The present systems and/or methods effectively allow for the adjustment and/or calibration of the AM device disclosed hereinafter so that one or more components may be built consistently, in various applicable materials, with the appropriate geometric parameters already built in, without the need of manual adjustments of the initial computer aided design (hereinafter “CAD”) file by a highly skilled operator. 
     SUMMARY OF THE DISCLOSURE 
     In embodiments, the present systems and/or method may utilize at least one primary feedback loop and/or at least one secondary feedback loop to avoid any identified geometric anomalies from being present in the remainder of components being built or one or more subsequent second built components based on image data collected by at least one first imaging device and at least one second imaging device and/or analyzed by software executed and/or computer-implemented steps performed by the present systems and/or methods. 
     In embodiments, a verification and adjustment system for correcting at least one build error present in a component built by additive manufacturing is provided. The system may comprise an additive manufacturing device having a top end and a bottom end connected by perimeter sides, wherein the additive manufacturing device has an interior space defined between the top end, the bottom end and the perimeter sides of the additive manufacturing device, wherein the interior space is configured to house a build platform for building the component thereon. Further, the system may comprise a first imaging device for collecting first digital images of, or data associated with, the component, wherein the first imaging device is located adjacent to a portion of the interior space of the additive manufacturing device, positioned at a first orientation with respect to the build platform and directed at the build platform. Moreover, the system may comprise a second imaging device for collecting second digital images of, or data associated with, the component, wherein the second imaging device is located adjacent to one perimeter side of the additive manufacturing device and at an elevation between the bottom end and the top end of the additive manufacturing device, positioned at a second orientation with respect to the build platform, and directed at the build platform. 
     In an embodiment, the first digital images may be collected by the first imaging device and may comprise digital 2D images, and the second digital images may be collected by the second imaging device and may comprise digital 3D images. 
     In an embodiment, the second imaging device may be located outside, or inside, the interior space of the additive manufacturing device. 
     In an embodiment, the second imaging device may be stationary, or movable, with respect to the build platform of the additive manufacturing device. 
     In an embodiment, the second imaging device may be located adjacent to a portion of the interior space of the additive manufacturing device. 
     In an embodiment, the first imaging device may be located at a position with respect to a top surface of the build platform that forms a first angle, wherein the first angle may be greater than about forty-five degrees and no more than ninety degrees. 
     In an embodiment, the first orientation of the first imaging device may be perpendicular with respect to the build platform. 
     In an embodiment, the second imaging device may be located at a position with respect to a top surface of the build platform that forms a second angle, wherein the second angle may be about ±10°. 
     In an embodiment, the second orientation of the second imaging device may be parallel or nonparallel with respect to the build platform. 
     In an embodiment, at least one imaging device, selected from the first imaging device and the second imaging device, may be mounted on at least one print head of the additive manufacturing device. 
     In embodiments, a verification and adjustment method for correcting at least one build error present in a component built by additive manufacturing is provided. The method may comprise extracting digital 3D geometric data of the component from collected digital data, wherein the collected digital data is based on the component built on a build platform of an additive manufacturing device, wherein the collected digital data comprises digital 2D images collected from a first imaging device associated with the additive manufacturing device and digital 3D images collected from a second imaging device associated with the additive manufacturing device. Further, the method may comprise detecting at least one build error present in the component built on the build platform by comparing the extracted digital 3D geometric data with a first digital 3D model of the component, wherein a first digital 3D printable file of the component comprises the first digital 3D model of the component. Still further the method may comprise generating a second digital 3D model of the component based on the detected at least one build error present in the component, wherein the second digital 3D model accounts for, or corrects, the detected at least one build error present in the component. Moreover, the method may comprise providing a second digital 3D printable file that accounts for, or corrects, the detected at least one build error by changing the line-by-line code of the first digital 3D printable file to incorporate the generated second digital 3D model of the component. 
     In an embodiment, the method may comprise building one or more corrected components based on the second digital 3D printable file. 
     In an embodiment, the first imaging device may be located above the build platform and the second imaging device may be located at a side of the additive manufacturing device. In an embodiment, the second imaging device may be stationary, or movable, with respect to the build platform of the additive manufacturing device, and may be parallel, or nonparallel, with respect to the build platform of the additive manufacturing device. 
     In an embodiment, the collected digital 2D data may comprise digital 2D images of a plurality of build layers of the component built on the build platform and the collected digital 3D data may comprise digital 3D images of the plurality of build layers of the component built on the build platform. 
     In an embodiment, the plurality of build layers may comprise each build layer added by the additive manufacturing device to build the component on the build platform. 
     In an embodiment, the first imaging device and the second imaging devices may both be directed at a build layer immediately added to the component by the additive manufacturing device. 
     In an embodiment, at least one imaging device, selected from the first imaging device and the second imaging device, may be mounted on at least one print head of the additive manufacturing device. 
     In an embodiment, the method may comprise changing firmware associated with the additive manufacturing device based on the extracted digital 3D geometric data. 
     In an embodiment, the method may comprise introducing corrections into subsequent building of the component, when the component is only a partially built component, wherein the corrections are based on, or determined from, the extracted digital 3D geometric data. 
     In an embodiment, the method may comprise acquiring the collected digital data from (i) at least two different angle with respect to the build platform and (ii) inside or outside an interior space of the additive manufacturing device, wherein the interior space is configured to house the component and the build platform during the additive manufacturing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       So that the above recited features and advantages of the present systems and/or methods can be understood in detail, a more particular description of the present systems and/or methods, briefly summarized above, may be had by reference to the embodiments thereof that are illustrated in the appended drawings. It is to be noted, however, that the appended drawing illustrates only typical embodiments of the present systems and/or methods and are therefore not to be considered limiting of its scope, for the present systems and/or methods may admit to other equally effective embodiments. 
         FIG. 1  illustrates a block diagram of a verification and adjustment system (hereinafter “system”) for effectively adjusting and/or calibrating an AM device and/or building at least one component in an embodiment. 
         FIG. 2  illustrates a perspective view of an AM device for building a component in an embodiment. 
         FIG. 3  illustrates a top plan view of the AM device shown in  FIG. 2  in an embodiment. 
         FIG. 4  illustrates a front plan view of the AM device shown in  FIG. 2  in an embodiment. 
         FIG. 5  illustrates a cross-section view of the AM device shown in  FIG. 2  in an embodiment. 
         FIG. 6  illustrates a partial cross-section view of the AM device shown in  FIG. 2  in an embodiment. 
         FIG. 7  illustrates a first perspective view of an AM device for building a component in another embodiment. 
         FIG. 8  illustrates a top plan view of the AM device shown in  FIG. 7  in an embodiment. 
         FIG. 9  illustrates a front cross-sectional view of the AM device shown in  FIG. 7  in an embodiment. 
         FIG. 10  illustrates a side cross-sectional view of the AM device shown in  FIG. 7  in an embodiment. 
         FIG. 11  illustrates a partial perspective view of the AM device shown in  FIG. 7  in an embodiment. 
         FIG. 12  illustrates a first perspective view of an AM device for building a component in yet another embodiment. 
         FIG. 13  illustrates a front plan view of the AM device shown in  FIG. 12  in an embodiment. 
         FIG. 14  illustrates a rear plan view of the AM device shown in  FIG. 12  in an embodiment. 
         FIG. 15  illustrates a side cross-sectional view of the AM device shown in  FIG. 12  in an embodiment. 
         FIG. 16  illustrates a partial side cross-section view of the AM device shown in  FIG. 12  and/or a galvanometer housing in an embodiment. 
         FIG. 17  illustrates a first side plan view of the AM device shown in  FIG. 12  in an embodiment. 
         FIG. 18  illustrates a second side plan view of the AM device shown in  FIG. 12  in an embodiment. 
         FIG. 19  illustrates a top plan view of the AM device shown in  FIG. 12  in an embodiment. 
         FIG. 20  illustrates a first perspective view of an AM device for building a component having a lowered build platform in yet another embodiment. 
         FIG. 21  illustrates a side plan view of the AM device shown in  FIG. 20  having the lowered build platform in an embodiment. 
         FIG. 22  illustrates a side cross-sectional view of the AM device shown in  FIG. 20  having the lowered build platform in an embodiment. 
         FIG. 23  illustrates a second perspective view of the AM device shown in  FIG. 20  having a raised build platform in an embodiment. 
         FIG. 24  illustrates a side plan view of the AM device shown in  FIG. 20  having the raised build platform in an embodiment. 
         FIG. 25  illustrates a cross-sectional view of the AM device shown in  FIG. 20  having the raised build platform in an embodiment. 
         FIG. 26  illustrates a front plan view of the AM device shown in  FIG. 20  having the lowered build platform in an embodiment. 
         FIG. 27  illustrates a front cross-sectional view of the AM device shown in  FIG. 20  having the lowered build platform in an embodiment. 
         FIG. 28  illustrates a top plan view of the AM device shown in  FIG. 20  in an embodiment. 
         FIG. 29  illustrates a front plan view of the AM device shown in  FIG. 20  having the raised build platform in an embodiment. 
         FIG. 30  illustrates a first perspective view of an AM device for building a component having a lowered build platform in still yet another embodiment. 
         FIG. 31  illustrates a side plan view of the AM device shown in  FIG. 30  having the lowered build platform in an embodiment. 
         FIG. 32  illustrates a side cross-sectional view of the AM device shown in  FIG. 30  having the lowered build platform in an embodiment. 
         FIG. 33  illustrates a partial cross-sectional view of the AM device shown in  FIG. 30  and/or a galvanometer housing in an embodiment. 
         FIG. 34  illustrates a perspective view of the AM device shown in  FIG. 30  having the raised build platform in an embodiment. 
         FIG. 35  illustrates a side plan view of the AM device shown in  FIG. 30  having the raised build platform in an embodiment. 
         FIG. 36  illustrates a side cross-sectional view of the AM device shown in  FIG. 30  having the raised build platform in an embodiment. 
         FIG. 37  illustrates a front plan view of the AM device shown in  FIG. 30  having the lowered build platform in an embodiment. 
         FIG. 38  illustrates a front cross-sectional view of the AM device shown in  FIG. 30  having the lowered build platform in an embodiment. 
         FIG. 39  illustrates a front plan view of the AM device shown in  FIG. 20  having the raised build platform in an embodiment. 
         FIG. 40  illustrates a flowchart of a verification and adjustment method (hereinafter “method”) for effectively calibrating an AM device and/or building at least one component in an embodiment. 
         FIG. 41  illustrates a flowchart of another method for effectively calibrating an AM device and/or building at least one component in another embodiment. 
         FIG. 42  illustrates a flowchart of another method for effectively calibrating an AM device and/or building at least one component in yet another embodiment. 
         FIG. 43  illustrates a flowchart of a sub-method of one or more of the methods shown in  FIGS. 40-42  in an embodiment. 
         FIG. 44  illustrates a flowchart of a sub-method of one or more of the methods shown in  FIGS. 40-42  in an embodiment. 
         FIG. 45  illustrates a flowchart of a sub-method of the sub-method shown in  FIG. 44  in an embodiment. 
         FIG. 46  illustrates a flowchart of a sub-method of the sub-method shown in  FIG. 44  in an embodiment. 
         FIG. 47  illustrates a flowchart of a sub-method of one or more of the methods shown in  FIGS. 40-42  in an embodiment. 
         FIG. 48  illustrates a flowchart of a sub-method of one or more of the methods shown in  FIGS. 40-42  in an embodiment. 
         FIG. 49  illustrates a flowchart of sub-steps of the sub-method shown in  FIG. 48  in an embodiment. 
         FIG. 50  illustrates a flowchart of sub-steps of the sub-method shown in  FIG. 48  in an embodiment. 
         FIG. 51  illustrates a flowchart of sub-steps of the sub-method shown in  FIG. 48  in an embodiment. 
         FIG. 52  illustrates a flowchart of a sub-method of one or more of the methods shown in  FIGS. 40-42  in an embodiment. 
         FIG. 53  illustrates a flowchart of a sub-method of one or more of the methods shown in  FIGS. 40-42  in an embodiment. 
         FIG. 54  illustrates a flowchart of a sub-method of one or more of the methods shown in  FIGS. 40-42  in an embodiment. 
         FIG. 55  illustrates a flowchart of a sub-method of one or more of the methods shown in  FIGS. 40-42  in an embodiment. 
         FIG. 56  illustrates a flowchart of a sub-method of one or more of the methods shown in  FIGS. 23-25  in an embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     Referring now to the drawings wherein like numerals refer to like parts,  FIG. 1  shows a verification and adjustment system  10  (hereinafter “system  10 ”) that may comprise, provide and/or utilize one or more of the following components: at least one AM device  12  (hereinafter “AM device  12 ”), at least one first imaging device  14  (hereinafter “first imaging device  14 ”), at least one second imaging device  16  (hereinafter “second imaging device  16 ”), at least one computer terminal  18  (hereinafter “terminal  18 ”), one or more digital monitors or displays  20  (hereinafter “displays  20 ”), a calibration block (not shown in the drawings), movable lighting (not shown in the drawings), a program splash screen and/or user interface displayable via the displays  20  and/or the above-mentioned verification, adjustment and/or calibration software. One or more of the above-mentioned components may be utilized by the system  10  to effectively calibrate the AM device  12  such that at least one component  2  (hereinafter “component  2 ”) may be built, synthesized, produced and/or fabricated consistently and/or accurately from at least one 3D computer model (not shown in the drawings). The present system  10  and/or methods  100 ,  200 ,  300 , shown in  FIGS. 40-42 , respectively, may comprise, provide and/or utilize the first imaging device  14  and/or the second imaging device  16  (collectively known hereinafter as “imaging devices  14 ,  16 ”), along with collected image data, the software and the terminal  18 , to verify tolerances and/or automatically indicate and/or correct any geometric anomalies of the component  2  that may not adhere to the given tolerances set forth by the at least one 3D computer model. As a result, the present systems  10  and/or methods  100 ,  200 ,  300  may accurately calibrate the AM device  12  based on collected image data of a first component  2  such that subsequently built components (not shown in the drawings) may not contain and/or exhibit any geometric anomalies that were or are exhibited by an earlier built component, such as, for example, the component  2 . 
     The imaging devices  14 ,  16  may be integrated into, or located adjacent with respect to, the AM device  12  such that the first imaging device  14  may be located, or positioned, at a first orientation with respect to a build platform  22  (hereinafter “platform  22 ”) of the AM device  12 , and the second imaging device  16  may be located, or positioned, at a second orientation with respect to the platform  22  of the AM device  12 . The present system  10  and/or methods  100 ,  200 ,  300  may utilize the software and/or image data collected by the imaging devices  14 ,  16  to effectively calibrate the AM device  12  such that any subsequently built components may not contain and/or exhibit any geometric anomalies that were or are exhibited by an earlier built component, such as, the component  2 . 
     The software, which may be stored within a memory storage unit (not shown in the drawings) of, or associated with, the terminal  18 , may comprise one or more computer-implemented steps, techniques, algorithms, tools and/or instructions adapted or configured to verify the tolerances, to automatically indicate and/or to automatically correct any geometric anomalies exhibited by an earlier built component that may not adhere to the given tolerances set forth by the at least one 3D computer model and/or CAD file of the component  2 . As a result, the software, the terminal  18  and/or at least one of the methods  100 ,  200 ,  300  may accurately calibrate the AM device  12  such that one or more subsequently built components may adhere to the said given tolerances set forth by the at least one 3D computer model or CAD file of the component  2 . The software may be executed by one or more microprocessors associated with the system  10  and/or the terminal  18  to perform, execute and/or implement at least one or more of the methods  100 ,  200 ,  300  shown in  FIGS. 40-42 , respectively, at least one or more of the sub-method and/or sub-steps of one or more sub-methods shown in  FIGS. 43-56 . 
     The system  10 , the AM device  12  and/or the methods  100 ,  200 ,  300  may utilize at least one additive manufacturing process (hereinafter “AM process”) as a primary means and/or technique by which to produce, build, print and/or fabricate the component  2  and/or one or more subsequently built components based on at least one 3D printable model for the component  2  and/or at least one 3D printable file format comprising the component  2 . In embodiments, the AM process may be an extrusion AM process, a light-polymerized AM process, a powder bed AM process, a laminated AM process, a wire AM process, a laser powder forming AM process, an inkjet 3D printing process, semi-conductor epitaxial-thin film deposition process, circuit printing process, fused filament fabrication (hereinafter “FFF”) AM process and/or any combination(s) thereof. The extrusion AM process may comprise fused deposition modeling (hereinafter “FDM”), FFF, plastic jet printing and/or robocasting or direct ink writing; the light polymerized AM process may comprise stereolithography (hereinafter “SLA”) and/or digital light processing; the laminated AM process may comprise laminated object manufacturing; and the wire AM process may comprise electron beam free form fabrication and/or laser metal deposition-wire AM process. In embodiments, the powder bed AM process may comprise powder bed and inkjet head 3D printing, electron-beam melting (hereinafter “EBM”), selective laser melting, selective heat sintering, selective laser sintering and/or direct metal laser sintering (hereinafter “DMLS”); and the laser powder forming may comprise laser engineered net shaping (hereinafter “LENS”), direct metal deposition and laser consolidation. 
     In embodiments, the materials utilized during the AM process may be, but are not limited to, metal alloy(s), photopolymer, thermoplastics, eutectic metals, edible materials, rubbers, modeling and/or metal clay, ceramic materials, powdered polymers, thermoplastic powder, ceramic powders, paper, metal foil, plastic film. The AM process may build the component  2  and/or one or more subsequent components based on one or more 3D computer models set forth in one or more printable file formats selected from, but not limited to, STL file format, WRL file format, VRML file format, 3MF file format, AMF file format, ZPR file format, FORM file format and Gcode file format. The AM process may be utilized to build the component  2  for one or more of the following type applications: manufacturing applications; industrial applications; sociocultural applications; and/or any combination(s) thereof. In embodiments, the manufacturing applications may be associated with, related to or directed to distributed manufacturing, mass customization, rapid manufacturing, rapid prototyping, research, food, medical application, custom fit medical casts and/or any combination(s) thereof. In an embodiment, the industrial application may be associated with, related to or directed to apparel, vehicles, construction, firearms, space, computer, robots and/or medical, such as, for example, medical devices, bio-printing and/or pills. In an embodiment, the sociocultural applications may be associated with, related to or directed to art, communication, domestic or household uses, education, research and development, environmental uses and/or any combinations thereof. It should be understood that the present disclosure is not limited to a specific embodiment of the materials, the 3D printable file formats and/or the application types. 
     In embodiments, the terminal  18  may be computer workstation with a plurality of central processing units and/or virtual cores, at least one graphics card and a sufficient amount of RAM to execute the present methods  100 ,  200 ,  300  and to calibrate the AM device  12  based on analysis of image data collected by the first imaging device  14  and/or the second imaging device  16 . The displays  20  may comprise at least two computer monitors to provide improved and/or easier multitasking for an operator (not shown in the drawings) of the system  10  and/or methods  100 ,  200 ,  300 . In an embodiment, one of the displays  20  may render and/or display the fabricated component to being built, or that was built, by the AM device  12  during the AM process and/or another of the displays  20  may render and/or display a re-fabricated component which may contain one or more corrections therein which may account for any geometric anomalies which were, or are, exhibited by the fabricated component. In an embodiment, the program splash screen and/or user interface may provide or create an improved and easier utilization of the system  10  and/or the methods  100 ,  200 ,  300  by providing at least one desktop based shortcut to digital folders and/or computer programs housing one or more functions and/or operations associated with the present system  10  and/or one or more of the methods  100 ,  200 ,  300 . The calibration block may be geometrically shaped block having a multiple sections exhibiting at least two colors which may be utilized by the operator of the system  10  to calibrate at least one imaging device selected from the imaging devices  14 ,  16 . The movable lighting may be positioned and/or located near, adjacent to, below and/or above the component  2 , the platform  22 , the AM device  12  and/or the imaging devices  14 ,  16  such that improved image data may be gather and/or collected by the imaging devices  14 ,  16  to account for different surrounding conditions and/or when the buildable filament or material may exhibit at least one single color and/or multiple colors. 
     In embodiments, the software utilized and/or executed by the system  10  and/or the methods  100 ,  200 ,  300  may provide automated image or picture capture after one or more layers is built or added during the AM process executed by the AM device  12  which may allow, facilitate and/or provide for consistent, continuous and/or uninterrupted image capturing of the component  2  by at least one of the imaging devices  14 ,  16  without any additional input from the operator during the execution of the AM process. Further, the software and/or AM device  12  may provide automated vertical movement of the platform  22  to a scan height during the AM process via at least one of the imaging devices  14 ,  16 . In an embodiment, digital two dimensional (hereinafter “2D”) images, digital 3D images, digital 2D image data and/or digital 3D image data may be collected, recorded and/or captured by at least one the imaging devices  14 ,  16  after each and every single build layer is built or added during the AM process and/or the platform  22  may be moved vertically downward by a distance equal to, or substantially equal to, a height of each build layer during the AM process executed by the AM device  12 . In embodiments, the software may automatically open one or more 3D and/or 2D imaging programs when terminal  18  is activated, may provide one or more folders which may house all, or at least some, of the operational programs, 3D and/or 2D imaging programs and/or data collection software. Moreover, the program splash screen and/or user interface may automatically open a printer control program or the operator may activate a launch button or link which may immediately open and/or activate the printer control program and/or the one or more 3D and/or 2D imaging programs. 
     In embodiments, the terminal  18  of the system  10  may be a completely, or partially, isolated computer terminal having a sole, or at least one, function of operating the AM device  12  and/or at least a 64-bit operating system may have been installed on the terminal  18 . Additionally, the operating system may have been configured and, if necessary, reconfigured until the AM device  12  functions appropriately and/or accurately to build the component  2  and/or any subsequently built components. As a result, specific methods for installing the operating system on similar systems were developed based on user problems, configuration issues, reconfiguration issues and/or other necessary requirements. Moreover, the terminal  18  may be mobile with respect to the AM device such that the terminal  18  may be movable with respect to another AM device and/or additional AM development locations. 
     As shown in  FIG. 1 , the system  10  may comprise the displays  20  which may be configured and/or adapted to display digital information provided by or from the terminal  18  regarding operations of the AM device  12  and/or the AM process being performed, executed by and/or implemented by the AM device  12  to layerwise build the component  2  via a plurality of build layers. Further, the displays  20  may be electrically connected to, and/or in digital communication with the terminal  18  for displaying or rendering said digital information. In an embodiment, the displays  20  may be, or may comprise, touch activated digital screens that allow, facilitate or provide for the operator to control and/or utilize the terminal  18  via the displays  20  and/or operate the AM device  12  or perform the AM process. It should be understood that the present disclosure is not limited to a specific embodiment of the displays  20 . 
     In embodiments, the terminal  18  is electrically connected to, and/or in digital communication with, the AM device  12  and/or the imaging devices  14 ,  16 . Further, the AM device  12  and/or the imaging devices  14 ,  16  may receive one or more digital communications and/or instructions from the terminal  18 , and the terminal  18  may receive digital information from the AM device  12  and/or imaging data from the imaging devices  14 ,  16 . As a result, AM device  12  may be controlled by the terminal  18  such that the AM process building the component  2  may be controlled by and/or operated via the terminal  18 . Moreover, the imaging devices  14 ,  16  may be controlled by and/or operated by the terminal  18  and/or the AM process may be calibrated and/or corrected by the image data and/or information received by the terminal  18  from the imaging devices  14 ,  16 . 
     As shown in  FIGS. 2, 4, 7, 9, 12, 14, 15, 19, 21, 26, 31, 32 and 34 , the AM device  12  may comprise a top end  24  and a bottom end  26  which may be located opposite with respect to the top end  24  of the AM device  12 . The AM device  12  may comprise a plurality of perimeter sides  28  (hereinafter “perimeter sides  28 ”) extending from the top end  24  to the bottom end  26  and/or connecting the top end  24  and bottom end  26  (collectively known hereinafter as “ends  24 ,  26 ”), as shown in  FIGS. 3, 8, 19, 28 and 34 . The ends  24 ,  26  and/or the perimeter sides  28  may define an interior space  30  (hereinafter “interior  30 ”) of the AM device  12  wherein the operations and/or actions of the AM process may build and/or fabricate the component  2  and/or one or more subsequently built components within the interior  30  of the AM device  12  as shown in  FIGS. 2, 5, 9, 15, 27 and 38 . In embodiments, the component  2  and/or the platform  22  may be entirely, or at least partially, enclosed or surrounded by the ends  24 ,  26  and/or the perimeter sides  28  of the AM device  12 . Further, the component  2  being built during the AM process and/or the platform  22  may be entirely, or at least partially, located within the interior  30  of the AM device  12 . Still further, the interior  30  of the AM device  12  may be located or positioned at, near or adjacent to the bottom end  26  of AM device  12  and/or the interior  30  may be located or positioned between the ends  24 ,  26  of the AM device  12 . Yet still further, the interior  30  of the AM device  12  may be defined as, or refer to, the area or location within or inside the AM device  12  wherein the component  2  is built or fabricated by the AM device  12  during the AM process. Any area or location within or inside the AM device  12  where the building or fabricating of the component  2  does not occur is known as or referred to outer or non-interior space (not shown in the drawings) of the AM device  12 . Moreover, one side of the perimeter sides  28  may be considered to be, and/or subsequently referred to as, a front side of the AM device  12 . 
     In an embodiment, the AM device  12  may utilize FDM as a means by with to produce, fabricate and/or build one or more of the components  2  with a plurality of build layers as shown in  FIGS. 2-6 . The AM device  12  shown in  FIGS. 2-6  may comprise one or more of the following FDM components: the first imaging device  14 ; the second imaging device  16 ; the component  2  being built by the AM device  12 ; a first imaging device holder  32  (hereinafter “first device holder  32 ”); the platform  22 ; a circuit board controller  34  (hereinafter “controller  34 ”); a second imaging device connector extension  36  (hereinafter “second device connector  36 ”); an extruder head  38 ; a X/Y-axis rod for extruder mobility  40  (hereinafter “extruder mobility  40 ”); a Z-axis rod for platform mobility  42  (hereinafter “platform mobility  42 ”); a Z-stage/platform carrier  44  (hereinafter “platform carrier  44 ”); a device frame  46  (hereinafter “frame  46 ”); a Y-axis motor  48 , an extruder motor  50 ; an extruder filament  52  (hereinafter “filament  52 ”); a X-axis motor  54 ; and/or an extruder carrier  56 . 
     In embodiments, the first imaging device  14  may be a high resolution optical instrument, such as, a high resolution optical camera which may be located at, near and/or adjacent with respect to the top end  24  of the AM device  12 . As a result, the first imaging device  14  may be located and/or positioned at a first orientation with respect to the build platform  22  within the interior  30  of the AM device  12 . In other embodiments, the first imaging device  14  may be mounted to one or more portions and/or parts of the AM device  12 . For example, when the AM device  12  comprises one or more print heads, the first imaging device  14  may be mounted on the one or more print heads. Further, types of imaging capturing performed and/or executed by the first imaging device  14  may include, but is not limited to, analog imaging, digital imaging, print imaging, thermal imaging, infrared imaging, radiation imaging, acoustic based imaging and/or any combination(s) thereof. Moreover, the first imaging device  14  is capable of utilizing types of resolution which may include, but are not limited to, vary pixel resolution, spatial resolution, spectral resolution, temporal resolution (in reference to possible videography capabilities), radio resolution and/or any combination(s) thereof. 
     In an embodiment, the longitudinal axis of the first imaging device  14  may be located and/or positioned at the first orientation with respect to a top surface of the platform  22  configured and/or adapted for building the component  2  thereon. For example, the first orientation may be perpendicular or substantially perpendicular and the top surface of the build platform  22  may be a planar or substantially planar surface. In an embodiment, the longitudinal axis of the first imaging device  14  may be located and/or positioned at a first angle with respect to the top surface of the platform  22 , wherein the first angle is greater than about forty-five degree, about sixty degrees or about eighty degrees and/or the first angle is no more than about ninety degrees, about ninety-five degrees or about one-hundred degrees. Further, the first imaging device  14 , or at least a portion of the first imaging device  14 , may be positioned or located directly above the component  2 . As a result, first end of the first imaging device  14  may extend into, or be positioned within, the AM device  12  such that the first image device  14  may collect, gather and/or record image data associated with the interior  30  of the AM device  12 , the component  2  and/or the topmost build layer of the component  2  being built by the AM device  12 . In an embodiment, the first end of the first imaging device may comprise a digital camera lens and/or the like. The first imaging device  14  may comprise adequate and/or sufficient resolution which may allow for appropriate and/or accurate measurements of the component  2  and/or subsequent components being generated or built via the AM process within the interior  30  of the AM device  12 . The first imaging device  14  may collect, obtain, gather, record and/or take at least one digital image or digital image data of one or more layers of the component  2  being built during the AM process within the interior  30  of the AM device  12 . In an embodiment, at least one digital image or digital image data may be collected, gathered and/or recorded by the first imaging device  14  for each and every layer of the component being built by the AM device  12 . Further, the at least one digital image or digital image data collected, gathered and/or recorded by the first image device may be at least one digital 2D image, at least one digital 3D image, digital 2D image data and/or digital 3D image data. In embodiments, one or more portions of the first imaging device  14  may be located or positioned within the interior  30  of the AM device  12  or at or in the outer or non-interior space within or inside the AM device  12 . In other embodiments, one or more portions of the first imaging device  14  may be located or positioned at, near or adjacent to the bottom end  26  of the AM device. 
     In embodiments, the system  10  may comprise a plurality (not shown in the drawings) of first imaging devices  14  which may be located, at, near or adjacent to the top end  24  of the AM device  12 . Each of the plurality of first imaging devices  14  may be orientated at one or more different angles, the same angle or one or more substantially similar angles with respect to the top surface of the platform  22  or the component  2  being built by the AM device  12 . The plurality of first imaging devices  14  may collect, obtain, gather, record and/or take a plurality of digital images or digital image data of one or more layers of the component  2  being built or added during the AM process occurring within the interior  30  of the AM device  12 . In an embodiment, the plurality of digital images or digital image data may be collected, gathered and/or recorded by the plurality of first imaging devices  14  for each and every build layer of the component being built or added by the AM device  12 . Further, the plurality of digital image or digital image data may comprise one or more digital 2D images, one or more digital 3D images, digital 2D image data and/or digital 3D image data. 
     In embodiments, the second imaging device  16  may be at least one 3D imaging device, such as, at least one 3D scanning device, and/or at least one computerized tomography scanning device, which may be mounted, located and/or positioned in the second orientation with respect to the platform  22 . In some embodiments, the second imaging device  16  may be mounted, located and/or positioned in a third orientation, which is different than the second orientation, with respect to the platform  22  and/or one or more portions/parts of the AM device  12 . With respect to the perimeter sides  30  of the AM device  12 , the second imaging device  16  may be located and/or positioned at the front side of the AM device such that the second imaging device  16  is directed to, or pointed at, the interior  30  of the AM device  12  where the component  2  may be built or fabricated by the AM device  12  during the AM process. Further, one or more portions of the second imaging device  16  may be located or positioned at, near or adjacent to the bottom end  26  of the AM device  12  as shown in  FIGS. 2, 4, 5, 7 and 10 . In other embodiments, one or more portions of the second imaging device  16  may be located or positioned outside the interior  30  of the AM device  12  and/or at a height that is between the ends  24 ,  26  of the AM device  12  as shown in  FIGS. 12-14 and 17 . In yet other embodiments, one or more portions of the second imaging device  16  may be located or positioned at the height between the ends  24 ,  26  of the AM device and/or at or in the outer or non-interior space within the AM device  12  as shown in  FIGS. 20, 21, 23-25, 30-32 and 35 . In yet still other embodiments, the second imaging device  16  may be located and/or positioned within the interior  30  of the AM device  12  and/or may be stationary or movable with respect to the platform  22  and/or one or more portions/parts of the AM device  12 . 
     In embodiments, the second imaging device  16  may be an active 3D scanning device that emits a kind of radiation or light and detect its reflection or radiation passing through object in order to probe the component  2  being built by the AM device  12  via the plurality of build layers of material. In other embodiments, the second imaging device  16  may utilize laser triangulation, time of flight laser scanning, phase shift laser scanning, photogrammetry based 3D model rendering technology and/or photo-tomography based 3D model rendering technology to produce one or more digital 3D images and/or digital 3D image data of the component  2  at one or more pre-determined stages of the AM process being utilized by the AM device  12  to build the component  2 . In yet other embodiments, the second imaging device  16  may gather, record and/or take X-ray images of the component  2  at different angles, which may be utilized with computer-processed combinations to produce cross-sectional and/or tomographic images or virtual slices of specific areas of the component  2  at the pre-determined stages of the AM process. As a result, an inside of the component  2  may be seen or observed without cutting or removing the component  2  from the platform  22  and/or the AM device  12 . In yet still other embodiments, the second imaging device  16  is capable of utilizing photogrammetry 3D scanning or 3D mapping of environments which may be based on sonar, radar, acoustics, and robotic mapping via simultaneous localization and mapping (hereinafter “SLAM”). In an embodiment, when the AM device  12  comprises one or more print heads, the second imaging device  16  may be a 3D scanning device mountable on the one or more print heads for one or more surface roughness and analyses processes. 
     In embodiments, the pre-determined stages may occur after one or more build layers of material have been added to and/or built onto the component  2  by the AM process executed by the AM device  12 . As a result, the second imaging device  16  may collect, gather and/or record one or more digital 3D images, digital 3D image data and/or one or more X-ray images of one or more build layers of the component  2  being built or added during the AM process occurring within the interior  30  of the AM device  12 . In an embodiment, the pre-determined stages may occur after each and every build layer of material has been added to and/or built onto the component  2  by the AM process performed by the AM device  12 . As a result, the second imaging device  16  may collect, gather and/or record one or more digital 3D images, digital 3D image data and/or one or more X-ray images of each and every build layer of the component  2  being built or added by the AM device  12 . 
     In embodiments, the system  10  may comprise a plurality (not shown in the drawings) of second imaging devices  16  which may be positioned or located at one or more of the perimeter sides  28  of the AM device  12 . For example, the system  10  may comprise more than one second imaging devices  16  located at, near or adjacent to at more than one of the perimeter sides  28  of the AM device  12 . As a result, the plurality of second imaging devices  16  may collect, gather and/or record one or more digital 3D images and/or digital 3D imaging data of one or more build layers of material being built onto or added to the component  2  in the interior  30  during the AM process executed by the AM device  12 . Thus, the digital 3D images and/or digital 3D imaging data collected, gathered and/or recorded by the plurality of second imaging devices  16  may comprise digital 3D images, digital 3D imaging data and/or X-ray images related to and/or associate with two or more different side views of the component  2  being built by the AM device  12 . In an embodiment, the plurality of second imaging devices  16  may be located outside of the AM device  12 , outside the interior  30  of the AM device  12  and/or at or in the outer or non-interior space inside the AM device  12 . 
     In an embodiment, the second imaging device  16  may be located and/or positioned outside the interior  30  of the AM device, perimeter sides  28  and/or the frame  46 , may be stationary with respect to the platform  22  and/or the component(s)  2  being built thereon, may be located and/or positioned in the outer or non-interior space inside the AM device  12  and/or may be located and/or positioned in the second orientation with respect to the top surface of the platform  22 . In embodiments, the second imaging device  16  may be connected, attached and/or fastened to the platform  22  and/or the component  2  being built thereon. The second orientation may be parallel or substantially parallel with respect to the top surface of the platform  22  and/or the top surface of the platform  22  may be a planar, or a substantially planar, surface. In an embodiment, the second imaging device  16  may be located and/or positioned at a second angle with respect to the top surface of the platform  22 , whereby the second angle may be about ±10°, about ±5°, about ±1° or less than about ±1°. 
     The second imaging device  16  collects, obtains and/or gathers one or more digital 3D images, digital 3D imaging data and/or X-ray images of the component  2  as the component  2  is being generated or built on the platform  22  of AM device  12  during the AM process. The second imaging device  16  may be positioned such that the digital 3D images, digital 3D imaging data and/or the X-ray images collected, obtained and/or gathered by the second imaging device  16  may be one or more digital 3D images, digital 3D imaging data and/or X-ray images associated the last build layer of material that was immediately built, added, produced and/or fabricated during the AM process executed by the AM device  12 . In embodiments, the second imaging device  16 , which is stationary with respect to the platform  22 , may move vertically and/or downwardly with the movement of the platform  22  during the AM process performed by the AM device  12 ; therefore, the digital 3D images, digital 3D image data and/or X-ray images collected, recorded and/or gathered by the second imaging device  16  may be directly related to and/or indicative of the most recently added, and/or present, build layer of material being produced, fabricated, added and/or built by the AM device  12 . 
     As shown in  FIGS. 3-6 , the first imaging device holder  32  may be located or positioned at, near or adjacent to the top end  26  of the AM device  12  and/or may have an opening or window formed therein which may be sized and/or configured to receive and/or hold the first imaging device  14  and/or at least a portion of the first imaging device  14 . As a result, at least the first portion of the first imaging device  14  may be positioned within and/or may extend into the AM device  12  such that the at least first portion of the first imaging device  14  may be directed to, or pointed at, the interior  30  of the AM device  12 . In an embodiment, the top end  26  may be comprised of the first imaging device holder  32  or at least a portion of the first imaging device holder  32 . The first imaging device holder  32  may be a structure that may hold the first imaging device  14 , or at least a portion thereof, in an appropriate position for acquiring, collecting, gathering and/or recording the one or more digital images and/or digital imaging data of the component  2  or subsequent components being built within the interior  30  of the AM device  12  during the AM process. In embodiments, one or more portions of the first imaging device holder  32  may extend downwardly away from the top end  24  of the AM device  12  towards the bottom end  26  of the AM device  12 . In an embodiment, one or more of the perimeter sides  28 , and/or portions thereof, of the AM device  12  may be formed by and/or may comprise one or more portions of the first imaging device holder  32  as shown in  FIGS. 3, 5 and 6 . 
     In embodiments, the platform  22  may be rotatable which may allow for an easier, improved and/or more effective collecting, recording and/or imaging of the one or more digital images and/or digital imaging data of the component  2  and/or the build layer being built by the AM device  12  by at least one of the imaging devices  14 ,  16 . Alternatively, the second imaging device  16  may rotate around the component  2  during the AM process to collect, record and/or gather the one or more digital 3D images, digital 3D imaging data and/or X-ray images of the component  2  and/or the build layer being built by the AM device  12 . In embodiments, the platform  22  and/or the top side or bed of the platform  22  may be heated to increase and/or improve the ability of the AM device  12  to build component  2  and/or subsequent components via the AM process. In some embodiments, the AM device  12  may comprise one or more heated build volumes in conjunction with one or more heated build platforms. 
     In embodiments, the controller  34  may be an interface between the terminal  18  and heating elements (not shown in the drawings), the Y-axis motor  48 , the extruder motor  50  and/or the X-axis motor  54 . The second imaging device connector  36  may extend outwardly away from the interior  30  of the AM device  12  and/or from the front side of the AM device  12  and/or may act as the physical connector between a bottom of the platform  22  and the second imaging device  16 . As a result, the second imaging device  12  may be stationary and/or non-movable with respect to the platform  22  and/or directly connected and/or attached to the platform  22  via the second imaging device connector  36 . The extruder head  38  may feed and/or extrude the material onto the platform  22  and/or the component  2  via a heated nozzle (not shown in the drawings) of the extruder head  38  to build and/or add one or more build layers of material onto the component  2  or subsequent components during the AM processes. In embodiments, the extruder head  38  may comprise a plurality of heated nozzles (not shown in the drawings) such that a plurality of same or different materials may be extruded onto the platform  22  and/or the component  2 . In some embodiments, the AM device  12  may comprise a plurality of extruder heads (not shown in the drawings) and/or each extruder head  38  of the plurality of extruder heads may comprise a plurality of heated nozzles (not shown in the drawings). The extruder mobility  40  may act as a gantry for the X-axis and Y-axis of a build volume of the AM device  12 , the platform mobility  42  may act as a gantry for the Z-axis of the build volume of the AM device  12 , and/or the platform carrier  44  may house and/or contain the platform  22  which may sit, or be positioned, on top of the platform carrier  44 . 
     As shown in  FIGS. 5, 7 and 10 , the frame  46  may house one or more of the components of the AM device  12  and/or may be located or positioned at, near and/or adjacent to the bottom end  26  of the AM device  12 . In an embodiment, the bottom end  26  may comprise the frame  46  or at least a portion of the frame  46 . In embodiments, one or more portions of the frame  46  may extend upwardly and away from the bottom end  26 . In an embodiment, one or more of the perimeter sides  28 , or at least portions of one or more of the perimeter sides  28  may be formed by and/or may comprise at least one or more portions of the frame  46 . Moreover, the interior  30  of the AM device  12  may be defined within, or formed inside, the frame  46  and the first imaging device holder  32 . Furthermore, the Y-axis motor  48  may control and/or facilitate the movement of an extruder carrier  56  along the Y-axis, the extruder motor  50  may feed extruder filament  52  through the heated extruder nozzle of the extruder head  58 , the extruder filament  52  may comprise the material to be extruded by the extruder head  58  onto the platform  22  and/or the previously built component  2  which is already present on the platform  22 , the X-axis motor  54  may control and/or facilitate movement of the extruder carrier  56  along the X-axis, and/or the extruder carrier  56  may house and/or surround the extruder motor  50  and/or the heated extruder nozzle of the extruder head  38 . In an embodiment, the extruder motor  58  may feed a plurality of extruder filaments (not shown in the drawings) through a plurality of heated extruder nozzles (not shown in the drawings) of the extruder head  58 . In some embodiments, extruder motor  58  may feed the plurality of extruder filaments through heated extruder nozzles of a plurality of extruder heads (not shown in the drawings) and/or through a plurality of heated extruder nozzles of each extruder head of the plurality of extruder heads (not shown in the drawings). 
     In an embodiment, the AM device  12  may utilize LENS as a means by with to produce, fabricate and/or build one or more of the components  2  as shown in  FIGS. 7-11 . The AM device  12  shown in  FIGS. 7-11  may comprise one or more of the following LENS components: the first imaging device  14 ; the second imaging device  16 ; the component  2  being built by the AM device  12 ; the first device holder  32 ; the platform  22 ; the second device connector  36 ; a metal additive laser head (hereinafter “laser head  58 ”); a X/Y-axis rod for platform mobility  60  (hereinafter “platform mobility  60 ”); Z-axis rods for laser head mobility  62  (hereinafter “head mobility  62 ”); a X/Y-stage/platform carrier  64  (hereinafter “platform carrier  64 ”); the frame  46 ; a X-axis motor  66 ; a Y-axis motor  68 , a Z-axis motor  70 ; metal additive injection nozzles  72  (hereinafter “injection nozzles  72 ”); a Z-stage laser mount/bracket  74  (hereinafter “laser mount  74 ”); and/or an excess additive removal fan  76  (hereinafter “removal fan  76 ”). 
     As shown in  FIGS. 7 and 9-11 , the laser head  58  may be connected, attached and/or fastened to at least one of the top end  24 , one perimeter side  28  and/or the first imaging device holder  32  and/or may emit a high intensity beam while injecting metal additive into the focal point of the beam. As a result, the metal additive may be cured to form and/or to add one or more layers of material to the platform  22  and/or the previously built component  2 . The platform mobility  60  may act as the gantry for the X-axis and Y-axis of the build volume of the AM device  12 ; the head mobility  62  may act as the gantry for the Z-axis of the build volume of the AM device  12 ; the platform carrier  64  may house and/or contain the platform  22  which may sit on top of the platform carrier  64 ; and the frame  46  may house or contain one or more of the LENS components of the AM device  12  shown in  FIGS. 7-11 . In embodiments, the X-axis motor  66  may control the movement of the laser head  58  along the X-axis; the Y-axis motor  68  may control the movement of the laser head  58  along the Y-axis; and the Z-axis motor  70  may control the movement of the laser head  58  along the Z-axis. Moreover, the injection nozzles  72  may spray or dispense metal additive evenly, or at least substantially or partially evenly, into the focal of the laser beam provided from the laser head  58  such that the metal additive may be cured, sintered welded and/or laser welded; the laser bracket  74  may hold or maintain the laser head  58  in one or more positions, wherein the laser head  58  may be mountable through at least one hole or opening at a top of the laser bracket  74 ; and the removal fan  76  may remove any, or at least some, excess metal additive which may be left over from, or remain after, the AM process performed by the AM device  10 . As a result of the excess metal additive removal, the imaging devices  14 ,  16  may collect, gather, record and/or produce clear high resolution digital images and/or X-rays images for the software to utilize and/or analyze to determine if the component  2  being built by the AM device  12  contains and/or exhibits any geometric anomalies that may not adhere to the given and/or predetermined tolerances set forth by, for example, the CAD file. 
     In an embodiment, the AM device  12  may utilize SLA as a means by with to produce, fabricate and/or build one or more of the components  2  as shown in  FIGS. 12-19 . The AM device  12  shown in  FIGS. 12-19  may comprise one or more of the following SLA components: the first imaging device  14 ; the second imaging device  16 ; the component  2  being built by the AM device  12 ; the platform  22 ; the second device connector  36 ; the frame  46 ; a Z-axis rod and motor for platform mobility  78  (hereinafter “platform mobility  78 ”)′ a resin bin  80 ; a Z-stage/platform carrier  82  (hereinafter “platform carrier  82 ”); one or more drying fans  84 ; a X-axis rod and motor for platform mobility  86  (hereinafter “x-axis platform mobility  86 ”); an ultrasonic basin  88 ; a galvanometer  90 ; a Y-axis galvanometer  92 ; a X-axis galvanometer  94 ; a galvanometer and optical instrument frame  96  (hereinafter instrument frame  96 ″); a mirror  97 ; a circuit board and/or computer controller  98  (hereinafter “controller  98 ”); and/or a laser  99 . In an embodiment, the ultrasonic basin  88  may be, for example, an automated isopropyl ultrasonic basin. 
     The platform mobility  78  may act as a gantry for the Z-Axis for raising and lowering the platform  22 ; the resin bin  80  may be a bin where with resin or build material may be poured and/or where the platform  22  may be lowered into during the AM process performed by the AM device  12 ; the platform carrier  82  may be a component that houses the platform  22 , wherein the platform  22  may be connected to the platform carrier  82 ; and/or the one or more drying fans  84  may act as dryers for the component  2  when the component  2  may exit the ultrasonic basin  88  by blowing off any excess solvent or liquid from the component  2 . Further, the X-axis platform mobility  86  may control the movement of the platform carrier  82  along the X-Axis; the ultrasonic basin  88  may be a basin to wash the component  2  in during the AM process to rid any excess resin or built material so as to not interfere with the imaging by the imaging devices  14 ,  16 , and, then again, when the AM process is completed to clean the component  2  prior to removal from the platform  22 ; the galvanometer  90  may comprise one or more limited-rotation direct current motors that may drive one or more mirrors for laser-beam steering, which is achievable with at least one internal position detector that may enable a closed loop servo control of the motor by providing a position signal proportional to the rotation of the motor; the Y-axis galvanometer  92  may steer the laser-beam in the y-axis; and/or the X-axis galvanometer  94  may steer the laser-beam in the x-axis. Moreover, the instrument frame  96  may be a structure that may hold the galvanometers  92 ,  94 , the laser  99  and/or the first imaging device  14  in the appropriate position for acquiring, capturing and/or recording the one or more digital images and/or digital imaging data; the mirror  97  may be positioned at a third angle to reflect the laser-beam up towards the platform  22 , and may also allow the first imaging device  14  to capture a top view digital image(s) of the component  2 ; the controller  98  may be a circuit board controller that may be the interface between the terminal  18  and the AM device  12  and/or the imaging devices  14 ,  16 ; and the laser  99  may comprise a laser diode that may be utilized to set, or to solidify, the resin or build material during the AM process performed by the AM device  12 . In an embodiment, the third angle may be greater than about forty-five degrees, less than about forty-five degrees or about forty-five degrees. 
     In an embodiment, the AM device  12  may utilize EBM as a means by which to produce, fabricate and/or build one or more of the components  2  as shown in  FIGS. 20-29 . The AM device  12  shown in  FIGS. 20-29  may comprise one or more of the following EBM components: the first imaging device  14 ; the second imaging device  16 ; the component  2  being built by the AM device  12 ; the platform  22 ; the frame  46 ; a powder overflow bin  210 ; a CT scanner X-axis travel stage  216 ; an optics bracket for recoater blade  218 ; a feed powder bin  220 ; a powder removal vacuum system  222 ; an electron beam source  224 ; a recoater X-axis travel path  226 ; a powder removal vacuum pivot assembly  228 ; a CT scanner pivot assembly  230 ; a device frame  232 ; a recoater blade  236 ; a build powder bin  238 ; an overflow powder platform  240 ; a build powder platform  234 ; a feed powder platform  242 ; build platform hydraulics  244 ; a Y-axis motor and carriage  246 ; and/or Y-axis travel rails  248 . 
     The powder overflow bin  210  may be configured and/or adapted such that any excess powder that is leftover or remaining after the recoater blade  236  has placed powder in the feed powder bin  220  may be pushed into the powder overflow bin  210  and recycled for later use via a manual and/or automatic sieve; the CT scanner X-axis travel stage  216  may able to move different distances from the component  2  on the platform  22  and thus may utilize said travel stage to do so; the optics bracket for recoater blade  218  may affix the first imaging device  14  to the recoater blade  236 ; and the feed powder bin  220  may feed material to the recoater blade  236  such that the fed material may be pushed over to the build powder bin  238 . Additionally, the powder removal vacuum system  222  may remove any excess powder from the build powder bin  238  prior to moving the platform  22  up to where the platform  22  and/or built component  2  may be imaged and/or scanned by the second imaging device  16 ; an electron beam source  224  may provide thermal energy necessary and/or required to melt the powder material into the component  2  being built by the AM process performed by the AM device  12 ; a recoater X-axis travel path  226  may depict and/or provide the path the recoater blade  236  may utilize to bring powder material from one bin to another bin; and/or the powder removal vacuum pivot assembly  228  may allow for the powder removal vacuum system  222  to move such that the platform  22  may be raised and/or lowered. 
     Further, the CT scanner pivot assembly  230  may allow for the collection of data and/or X-ray images via the second imaging device  16  at one or more different angles; the device frame  232  may sit on top of the frame  46  and/or may house the second imaging device  16 ; the recoater blade  236  may push or more build material from one bin to another bin; the build powder bin  238  may hold or store build material that may be subsequently melted to the platform  22  and/or the built component  2 ; and/or the overflow powder platform  240  may lower and/or raise as powder fills the powder overflow bin  210  via the recoater blade  236 . Still further, the build powder platform  234  may lower and/or raise as powder fills the build powder bin  238 ; the feed powder platform  242  may lower and/or raise as the recoater blade  236  may push powder into the build powder bin  238 ; the build platform hydraulics  244  may lower and/or raise the build powder platform  234  with respect to the second imaging device  16 ; the Y-axis motor and carriage may carry and/or move the electron beam source  224  and/or may sit or rest on the Y-axis travel rails  248 ; and/or the Y-axis travel rails may depict, provide and/or control the travel path for the electron beam source  224  during the AM process executed and/or performed by the AM device  12 . 
     In an embodiment, the AM device  12  may utilize DMLS as a means by which to produce, fabricate and/or build one or more of the components  2  as shown in  FIGS. 30-39 . The AM device  12  shown in  FIGS. 30-39  may comprise one or more of the following DMLS components: the first imaging device  14 ; the second imaging device  16 ; the component  2  being built by the AM device  12 ; the platform  22 ; the frame  46 ; a powder overflow bin  252 ; a build powder bin  256 ; a laser source  258 ; a galvanometer housing  260 ; a recoater blade  262 ; a device frame  264 ; an optics bracket for recoater blade  266 ; a feed powder bin  268 ; a powder removal vacuum system  270 ; a powder removal vacuum pivot assembly  274 ; a recoater blade X-axis  276 ; a feed powder platform  278 ; a build powder platform  254 ; an overflow powder platform  280 ; pivot for CT scanner  282 ; a CT scanner X-axis travel stage  284 ; a X-axis galvanometer  286 ; a Y-axis galvanometer  288 ; a galvanometer housing frame  290 ; and/or a substrate platform lift  292   
     The powder overflow bin  252  may be configured and/or adapted such that any excess powder material that is leftover and/or remains after the recoater blade  262  has placed powder in the feed powder bin  268  may be pushed into said bin  252  and/or recycled for later use via a manual and/or automatic sieve; the build powder bin  256  may hold and/or store build material that may be melted to the platform  22  and/or the built component  2 ; the laser source  258  may provide laser power and/or correct wavelength require to melt the powdered material during the AM process; the galvanometer housing  260  may house the X-axis galvanometers  286  and/or the Y-axis galvanometers  288 ; and the recoater blade  262  may push and/or move the build material from one bin to another bin. Additionally, the device frame  264  may sit on top of the frame  22  and/or may house the second imaging device  16 ; the optics bracket for recoater blade  266  may affix the first imaging device  14  to the recoater blade  262 ; the feed powder bin  268  may feed build material to the recoater blade  262  such that the build material may be pushed or move over to the build powder bin  254 ; and/or the powder removal vacuum system  270  may remove any excess build powder from the build powder bin  254  prior to moving the platform  22  up to where it may be imaged by the second imaging device  16 . 
     Further, the powder removal vacuum pivot assembly  274  may allow for the powder removal vacuum system  270  to move with respect the platform  22  when the platform  22  may be raised and lowered; the recoater blade X-axis  276  may control the direction of travel for the recoater blade  262 ; the feed powder platform  278  may lower and/or raise as the recoater blade  262  and/or may push build powder into the build powder bin  252 ; and the build powder platform  254  may lower and/or raise as build powder fills the build powder bin  252 . Still further, the overflow powder platform  280  may lower and/or raise as build powder fills the powder overflow bin  252  via the recoater blade  262 ; the pivot for CT scanner  282  may allow for the collection of data via the second imaging device at different angles; and/or the CT scanner X-axis travel stage  284  may be able to move different distances from the component  2  on the platform  22  and/or may utilize said travel stage and/or rails to facilitate said movement. Moreover, the X-axis galvanometer  286  may direct the laser-beam in the x-axis; the Y-axis galvanometer  288  may direct the laser-beam in the y-axis; the galvanometer housing frame  290  may include holes and fixtures required to mount the galvanometers  286 ,  288  in the correct and/or accurate position or location; and/or the substrate platform lift  292  may lower and/or raise the build powder platform  254  up to the second imaging device  16  for imaging and/or collection of one or more digital 3D images, digital 3D data and/or one or more X-rays. 
     In embodiments, the imaging devices  14 ,  16  may be integrated into and/or associated with the AM device  12  to act as the primary feedback loop, wherein the second imaging device  16  may sit in parallel with the platform  22  or the top surface of the platform  22  to produce, generate and/or collect the one or more digital 3D images, digital 3D imaging data and/or one or more X-ray images of the component  2  at pre-determined stages of the AM process. The first imaging device  14 , that may collect, gather and/or record the one or more digital 2D images and/or digital 2D imaging data, may simultaneously or subsequently collect the one or more digital images and/or digital imaging data perpendicular to the platform  22 . 
     In an embodiment, the system  10  comprises the terminal  18  in digital communication with the AM device  12  and the imaging devices  14 ,  16 , wherein the first imaging device  14  collects digital 2D images or data of the component  2  during the AM process performed or executed by the AM device  12  that is based on a virtual or digital model or image of the component  2 . The second imaging device  16  collects digital 3D images or data and/or X-ray images of the component  2  during the AM process performed or executed by the AM device  12  that is based on the virtual or digital model or image of the component  2 . The collected digital 2D and 3D images or data and/or X-ray images may be analyzed by the terminal  18  and/or software executed by the terminal  18  to create a revised virtual or digital model or image so that the AM device  12  may account for, and/or may correct, any build inconsistencies, build discrepancies and/or tolerancing errors (hereinafter collectively known as “build errors”) detected, determined and/or recognized during the analysis of the collected digital 2D and 3D images or data and/or X-ray images. As a result, the AM device  12  may build subsequent components that exclude previously discovered build errors based on the revised virtual or digital model or image created by the terminal  18  and/or the software executed by the terminal  18 . The one or more subsequently built components may be based on a corrected 3D printable file whereby the revised virtual or digital model or image has been incorporated into the line by line code of the corrected 3D printable. 
     The collected 2D and 3D digital images or data and/or X-ray images (hereinafter “collected data”) collected by the imaging devices  14 ,  16  at various elevations with respect to the component  2  may be relayed or transmitted to the terminal  18 , which feeds and/or controls the AM device  12 . In an embodiment, the terminal  18  feeds line by line code to the AM device  12  which is utilized by the AM device  12  to build the component  2  and/or the one or more subsequent components. The collected data may comprises one or more digital 2D images, one or more digital 3D images, digital 2D imaging data, digital 3D imaging data and/or one or more X-ray images collected by the imaging devices  14 ,  16  at various elevations with respect to the component  2  during the AM process performed or executed by the AM device  12 . Geometric data may be pulled and/or extracted from the collected data and/or analyzed by the terminal  18  and/or the software executed by the terminal  18 . Said geometric data, after extraction, may be cross-referenced and/or compared with the virtual or digital model or image of the component  2  as set forth in the CAD file and/or 3D printable file associated with the component  2 . 
     Any build errors between the extracted geometric data and the virtual or digital model or image of the component  2  may be detected, determined and/or recognized by a secondary loop which comprises the software executable by the terminal  18 . In an embodiment, the software may be the same software, similar software or different software that may feed the line by line code to the AM device  12 . Based on the detected, determined and/or recognized build errors, the software may create geometric offsets throughout the virtual or digital model or image and/or may create a revised or corrected virtual or digital model or image of the component  2 . As a result, the tool build path of the AM device  12  may account for any detected, determined and/or recognized build errors when the AM device builds one or more subsequent components. 
     The revised or corrected virtual or digital model or image may account for and/or correct any detected build errors that may have led to previously detected build errors caused by the AM device  12 . The software may change the line by line code of CAD file and/or 3D printable file associated with the component  2  to incorporate the revised or corrected virtual or digital model or image for the component  2 . The software may prompt a user of the AM device  12  to clear the platform  22  of the component  2  with the build errors or may allow the AM device  12  to continue building the component  2  to completion. 
     In embodiments, the software and/or the terminal  18  may deliver a revised or corrected virtual or digital model or image which may allow for the production and/or fabrication of a revised or corrected CAD and/or 3D printable file containing the correct geometric parameters that account for the detected build errors without the need of a highly trained CAD operator and AM device operator. The present system  10  and/or the methods  100 ,  200 ,  300  may provide the revised or corrected CAD and/or 3d printable file to the AM device  12  for building one or more subsequent components that exclude any and all detected build errors. As a result, the present system  10  and/or methods  100 ,  200 ,  300  may allow for the consistent fabrication of the component  2  and/or subsequent components with geometric parameters that match the original CAD or 3D printable file or the revised or corrected CAD or 3D printable file. 
     In embodiments, the collected digital 2D images and/or data, the collected digital 3D images and/or data, the collected X-ray images, the CAD file of the component  2 , the 3D printable file of the component  2 , the revised or corrected CAD file, the revised or corrected 3D printable file, any results from comparing and/or analyzing the collected images and/or data and the CAD file and/or the 3D printable file, from determining and/or detecting the one or more build errors, and/or from any of the present methods may be stored in any memory storage unit associated with the terminal and/or may be stored in any digital computer format as known to one of ordinary skill in the art. 
     The present systems and methods for detecting or determining one or more build errors and/or subsequently correcting or accounting for those build errors may utilize, perform and/or execute, but are not limited to, at least one of the methods  100 ,  200 ,  300  and/or one or more of the sub-methods  400 ,  500 ,  600 ,  700 ,  800 ,  900 ,  1000 ,  1100 ,  1200 ,  1300 ,  1400 ,  1500 ,  1600 ,  1700  illustrated by the flowcharts set forth in  FIGS. 40-56 . The methods and/or sub-methods set forth in  FIGS. 40-56  are non-limiting examples that may effectively calibrate the AM device  12  and built at least one subsequent component that accounts for, and/or corrects, at least one build error detected in a previously built component, such as, component  2 . 
       FIG. 23  illustrates a flowchart of the method  100  for effectively calibrating the AM device  12 . First, an idea for the component  2  may be determined, identified and/or proposed as shown at step  102 , and the terminal  18  and/or the software executed by the terminal  18  may be utilized to create, generated and/or provide the CAD file that represents, or is indicative of, the 3D shape, size and/or configuration of the component  2  based on the determined, identified and/or proposed idea for the component  2  from step  102 , as shown at step  104 . The terminal  18  and/or the software may convert the CAD file of the component  2  into the 3D printable file having a 3D printable file format, such as, for example, a 3D printable file in the .STL file format (hereinafter “.STL file”) as shown at step  106 . The terminal  18  and/or the software executed by the terminal  18  may repair the .STL file as shown at step  108 . 
     Next, the method  100  may insert the .STL file into the software which may comprise printer control software as shown at step  110  which may be completed, performed and/or achieved according the sub-method  400  illustrated by  FIG. 43 . Thus, step  110  may comprise or include, but is not limited to, the sub-method  400  shown in  FIG. 43 . In the sub-method  400 , the software may check for proper and/or working digital connections, as shown at step  402 , between the terminal  18  and the first imaging device  14 , the AM device  12  and/or the second imaging device  16  as shown at steps  404 ,  406 ,  408 , respectively. If proper and/or working digital connections are established and/or identified by the software, the sub-method  400  may run, execute and/or perform at least one device program and/or at least one executable file, such as, for example, at least one .exe file as shown at step  410 . As a result, host software, such as, for example, repetier-host software may be open and/or executed by method  100  and/or other required software(s) and/or a screenshot program, such as, for example, greenshot may be turned on, initiated and/or activated as shown at step  412 . 
     Next, the terminal  18  and/or the software may connected to the AM device  12  as shown at step  414 , the adding device, such as, for example, the extruder of the AM device  12  may be heated as shown at step  416  and the bed or top surface of the platform  22  may be heated as shown at step  418 . The sub-method  400  may set one or more profiles of a digital software tool, such as, for example, Slic3r (which converts a digital 3D model into printing instructions for your 3D printer) with respect to material and resolution for building the component  4  as shown at step  420 . Next, the 3D printable file or the .STL file may be inserted as shown at step  422  and/or may be centered as shown at step  424 , and/or the functionality of the adding device, such as, for example, the extruder of the AM device  12  may be verified and/or confirm as shown at step  426 . Further, the sub-method  400  may start the initial build of the component  2  as shown at step  428 , may verify digital image or data and/or picture capture features of the imaging device  14 ,  16  are functional as shown at step  430 , and/or may await build completion of the component  2  as shown at step  432 . Moreover, the sub-method  400  may activate the second imaging device  16  as shown at step  434  and/or may clean the substrate of the component  2  as shown at step  436 . 
     The terminal  18  may utilize the software and/or the printer control software to create a machine code file and/or a numerical control programming language file, such as, for example, a g-code file as shown at step  112  of method  100 . Next, the method  100  may start, begin or unitize the AM process to be performed by the AM device  12  which may, in an embodiment, be a 3D printing process as shown at step  114 . After the AM process has started and the AM device  12  is building the component  2 , the method  100  may begin, start and/or unitize data collection of the digital images or digital imaging data from the imaging device  14 ,  16  as shown at step  116 . The first imaging device  14  may collect digital 2D images and/or data as shown at step  118  in according with one or more of sub-method  500  as illustrated in  FIG. 44 . After the digital 2D images and/or data are collected, the method  100  may analyze the collected digital 2D images and/or data as shown at step  120  in accordance with sub-method  800  as illustrated in  FIG. 47 . Thus, step  118  may comprise and/or include, but is not limited to, sub-method  500  and step  120  may comprise and/or include, but is not limited to, sub-method  800 . 
     In embodiments, the sub-method  500  may collect the digital 2D images and/or data by collecting experimental digital 2D images and/or data as shown at step  502  in accordance sub-method  600  illustrated in  FIG. 45  and/or by collecting theoretical digital 2D images and/or data at step  504  in accordance with sub-method  700  illustrated in  FIG. 46 . Thus, step  502  may comprise and/or include, but is not limited to sub-method  600  and step  504  may comprise and/or include, but is not limited to sub-method  700 . 
     For collecting the experimental digital 2D images and/or data, the sub-method  600  may, in embodiments, slice the 3D printable file or the .STL file with a regular slicer as shown at step  602 . For each and every build layer, the slicer profile may include, for example, movement of an extruder carrier, such as, platform carrier  44  to a home position and/or activation of the first imaging device  12  as shown at step  604 . The software may initiate a system pause for a set or predetermined amount of time to allow for the extruder carrier and/or adding device to move from a first position to a second position that is not between the first imaging device  14  and the component  2  and/or may trigger one metadata file by another computer file, such as, for example, a batch file as shown at step  606 . As a result, the extruder carrier and/or adding device may not interfere with and/or conceal images and/or imaging data collected and/or gathered by the first imaging device  12 . The metadata file may open an executable file which may in turn activate an executable file associated with the first imaging device  14  and/or may run one or more commands associated with the first imaging device  14  as shown at step  608 . As a result, the first imaging device  14  may capture one or more digital 2D images and/or data and/or send or transmit the captured one or more digital 2D images and/or data to a default digital folder associated with the terminal  18  and/or to an internal memory device associated with the first imaging device  14  as shown at step  610 . Next, the AM device  12  may move or return the extruder carrier to the first position and/or the AM device  12  may begin or start to add the next build layer to the component  2  as shown at steps  612  and  614 , respectively. 
     For collecting the theoretical digital 2D images and/or data, the sub-method  700  may, in embodiments, slice the 3D printable profile with a virtual slicer profile, such as, for example, slice the .STL file with virtual slice profile as shown at step  702 . For each and every build layer, the slicer profile may include movement of a virtual extruder carrier to a first or home position and/or may include activation of device  12  as shown at step  704 . At step  706 , an operator of the system  10  and/or the method  100 , may open host software, such as, for example, a repetier-host program of the software and/or the operator may go to digital control tab and/or select an operational mode as shown at step  708 . Thus, the sub-method  700  may open a tool path depiction at step  706 , and a dry run may be verified to be enabled as shown at step  708 . 
     Next, the operator may open a digital editor tab, select to view a single build layer with a parallel projection from a top view and/or adjust the display zoom and/or display resolution as shown at step  710 . Thus, the sub-method  700  and/or the software may utilize parallel projection to simulate correct virtual imager view and/or verify correctiveness of zoom and/or resolution at step  710 . At step  712 , the operator may verify and/or confirm that the screenshot program is activated and running, confirm that software and/or the first imaging device  14  is capturing full screen and that captured digital 2D images and/or data is being properly stored at a known or desired digital storage location associated with the terminal  18  and/or the first imaging device  14 . Thus, image storage location may be verified at step  712 . The operator may return to the repetier-host program, continue job run and return to digital editor tab select arrows associated with the layer selection area as shown at step  714 . Thus, virtual fabrication process and/or image capture process may be initiated at step  714 . For each build layer, the software may activate a batch file as shown at step  716 , and the activated batch file may pause the system  10  and/or AM device  12  for a set or predetermined amount of time and/or may activate a VBScript file which may move to the next build layer as shown at step  718 . Thus, the software and/or sub-method  700  may activate the virtual imager for each built layer at step  716  and/or image activation may be pause the system  10  for a set amount of time before moving to the next build layer at step  718 . At step  720 , the batch file may activate the VBScript file which may take or collect a screenshot picture which may be subsequently stored at the known or desired digital storage location. Thus, the captured images may be stored in the specific location at step  720 . 
     The sub-method  800  of step  120  may be utilized to analyze the collected digital 2D images and/or data which comprises the experimental digital 2D images and/or data collected according to sub-method  600  and the theoretical digital 2D images and/or data collected according to sub-method  700 . The collected experimental digital 2D images and/or data, according to sub-method  600 , may be opened as shown at step  802 , may be imported as shown at step  804 , may be converted to 8-bit grayscale and numerically name sorted as shown at step  806 , may be cropped as shown at step  808 , may be processed and/or made binary as shown at step  810  and/or may be analyzed as shown at step  812 . Further, sub-method  800  may open image manipulator software at step  802 , import an image sequence (i.e., collected digital 2D images and/or data) at step  804 , verify a number of images matches layer count and/or convert the images to 8-bit grayscale at step  806 , crop images, if necessary to reduce computational operations at step  808 , convert images to binary with a black background at step  810  and/or utilize the image manipulator software to determine an amount of material (dM) per amount of area (dA). Next, the collected experimental digital 2D images and/or data may be processed and/or the processing results may be stored in the desired storage location and/or the memory storage unit associated with the terminal  18  as shown in step  814 . In an embodiment, the processing results for the collected experimental digital 2D images and/or data may be imported into a mutual text document that by be savable by the terminal  18  as shown at step  816 . 
     The collected theoretical digital 2D images and/or data may be opened as shown at step  817 , may be imported as shown at step  818 , may be converted to 8-bit grayscale and numerically name sorted as shown at step  820 , may be cropped as shown at step  822 , may be processed and/or made binary as shown at step  824  and/or may be analyzed as shown at step  826 . Further, the sub-method  800  may open image manipulator software at step  817 , import an image sequence (i.e., collected theoretical digital 2D images and/or data) from a specified location at step  818 , verify a number of images matches layer count and/or convert images to 8-bit greyscale at step  820 , crop images, if necessary, to reduce computational operations at step  822 , convert images to binary with a black background at step  824  and/or utilize the image manipulator software to determine the amount of material (dM) per amount of area (dA) at step  826 . Next, the collected theoretical digital 2D images and/or data may be processed and/or the processing results may be stored in the desired storage location and/or the memory storage unit associated with the terminal  18  as shown in step  828 . In an embodiment, the processing results for the collected theoretical digital 2D images and/or data may be imported into a mutual text document that by be savable by the terminal  18  as shown at step  830 . 
     At step  832 , the differences between the processing results of the collected experimental and theoretical digital 2D images and/or data may be calculated by the software and/or sub-method  800 , wherein the differences are calculated in areas per matched pair. Plus/minus offsets may be determined by the software based on the calculated differences between the processing results of the collected experimental and theoretical digital 2D images and/or data as shown at step  834 . Based on the determined plus/minus offsets, the software and/or sub-method  800  may create, produce and/or generate a general 2D offset for the component  2  as shown at step  836 , and/or a 2D solution, based on the general 2D offset, which may be applied by the software and/or sub-method  800  as shown at step  838 . 
     As shown in  FIG. 48 , sub-method  900  of step  122  for collecting digital 3D images and/or data may collect: experimental digital 3D images and/or data via the second imaging device  16  as shown at step  902  in accordance with sub-method  1000  shown in  FIG. 49 ; experimental digital 3D images and/or data via experimental images as shown at step  904  in accordance with sub-method  1100  shown in  FIG. 50 ; and/or experimental digital 3D images and/or data via theoretical images as shown at step  906  in accordance with sub-method  1200  shown in  FIG. 51   
     The sub-method  1000 , shown in  FIG. 49 , may activate the second imaging device  16  for each and every build layer and/or at build completion of the component  2  as shown at step  1002  and/or may add a batch file after build completion as shown at step  1004 . Next, the batch file may activate another computer file which in turn activates an executable file and/or opens software associated with the second imaging device  16  as shown at step  1006 . The operator may activate and/or calibrate the second imaging device  16  manually as shown at step  1008 . Next, the operator may wait for the complete collection of the 3D image or data collected by the second imaging device  16 , may use clean and/or crop tools of the software associated with the second imaging device  16  to remove any unwanted or undesirable noise from the 3D image or data collected by the second imaging device  16 , and/or may save the collected 3D image or data in a desired location and/or within the digital storage unit associated with the terminal  18  as a 3D printable file format, such as, for example, a STL file format as shown at step  1010 . Moreover, sub-method  1000  may activate the second imaging device  16  at every built layer and/or at build completion of the component  2  at step  1002 , activate the second imaging device  16  after build completion at step  1004 , opening software associated with the second imaging device  16  at step  1006 , calibrate the second imaging device  16  and/or start imaging and/or image or data collection by the second imaging device  16  at step  1008  and/or wait of completion of imaging, utilize clean and/or crop tools within the opened software to remove any unwanted noise from the collected images or data and/or save the collected images or data as a 3D printable file in a 3D printable file format, such as, for example, a .STL file at step  1010 . 
     In sub-method  1100  shown in  FIG. 50 , an experimental image may be open as shown at step  1102 , may be imported as shown at step  1104 , may be converted to 8-bit grayscale and/or numerically name sorted as shown at step  1106 , may be cropped as shown at step  1108  and/or may be processed and/or made binary as shown at step  1110 . A 3D viewer plugin may be selected or activated as shown at step  1112 , unwanted or undesirable noise may be removed by adjusting a threshold as shown at step  1114 , a surface display may be selected as shown at step  1116  and/or a file containing the experimental image in binary form may be exported and/or saved to a desired location and/or the digital storage unit associated with the terminal  18  as shown at step  1118 . The previously saved file may be imported into additive manufacturing software which have been opened as shown at step  1120 , the z-axis may be proportionally scaled as shown at step  1122  and/or a new 3D printable file based on the proportionally scaled z-axis may be exported and/or save to a desired location and/or the digital storage unit associated with the terminal  18  as shown at step  1124 . Additionally, the sub-method  1100  may open image manipulator software at step  1102 , import the image sequence from a specified location at step  1104 , verify a number of images matches layer count and/or convert the images to 8-bit grayscale at step  1106 , crop the images, if necessary, to reduce computational operations at step  1108 , convert the images to binary with a black background at step  1110  and/or convert the image sequence into a 3D image at step  1112 . Moreover, the sub-method  1100  may remove noise by may remove noise by adjusting the threshold accordingly or as necessary at step  1114 , display the 3D image as a surface at step  1116 , export the surface as a binary 3D printable file, such as, a .STL file at step  1118 , open .STL file manipulator software and/or import a saved file or the binary .STL file at step  1120 , scale the z-axis of the file proportionally and/or correctly at step  1122  and/or save the new or scaled .STL file to a, or the, desired location at step  1124 . 
     In sub-method  1200  shown in  FIG. 51 , an experimental image may be open as shown at step  1202 , may be imported as shown at step  1204 , may be converted to 8-bit grayscale and/or numerically name sorted as shown at step  1206 , may be cropped as shown at step  1208  and/or may be processed and/or made binary as shown at step  1210 . A 3D viewer plugin may be selected as shown at step  1212 , unwanted or undesirable noise may be removed by adjusting a threshold as shown at step  1214 , a surface display may be selected as shown at step  1216  and/or a file containing the experimental image in binary form may be exported and/or saved to a desired location and/or the digital storage unit associated with the terminal  18  as shown at step  1218 . The previously saved file may be imported into additive manufacturing software which have been opened as shown at step  1220 , the z-axis may be proportionally scaled as shown at step  1222  and/or a new 3D printable file based on the proportionally scaled z-axis may be exported and/or save to a desired location and/or the digital storage unit associated with the terminal  18  as shown at step  1224 . Additionally, the sub-method  1200  may open image manipulator software at step  1202 , import an image sequence from a specified location at step  1204 , verify a number of images matches layer count and/or convert the images to 8-bit grayscale at step  1206 , crop the images, if necessary, to reduce computational operations at step  1208  and/or convert the images to binary with a black background at step  1210 . Further, the sub-method  1200  may convert the image sequence into a 3D image at step  1212 , remove noise by adjusting the threshold accordingly and/or necessary at step  1214 , display the 3D image as a surface at step  1216  and/or export the surface a binary 3D printable file, such as, a .STL file at step  1218 . Moreover, the sub-method  1200  may open .STL file manipulator software and/or import the previously saved file or the .STL file at step  1220 , scale the z-axis of the file proportionally and/or correctly at step  1222  and/or save the new scaled .STL file to a, or the, desired location at step  1224 . 
     Step  124  of method  100  shown in  FIG. 40  may analyze the collected digital 3D images and/or data from step  122  in accordance with sub-method  1300  shown in  FIG. 52 . The sub-method  1300  may comprise, but is not limited to, a first plurality of sub-steps  1310 , a second plurality of sub-steps  1320 , a third plurality of sub-steps  1330  and/or a fourth plurality of sub-steps  1340 . 
     The software, step  124  of method  100  and/or sub-method  1300  may execute and/or perform the first plurality of sub-steps  1310  which may output the saved .STL file from step  1010  of  FIG. 49 , input the outputted .STL file into the .STL manipulator software or program and/or determine and/or calculate surface area and/or volume based on the outputted .STL file and/or the saved .STL file from step  1010  of  FIG. 49 . Additionally, software, step  124  of method  100  and/or sub-method  1300  may execute and/or perform the second plurality of sub-steps  1320  which may output the saved .STL file from step  1124  of  FIG. 50 , input the outputted.STL file into the .STL manipulator software or program and/or determine surface area and/or volume based on the outputted .STL file and/or the saved .STL file from step  1124  of  FIG. 50 . Further, the software, step  124  of method  100  and/or sub-method  1300  may execute and/or perform the third plurality of sub-steps  1330  which may output the saved .STL file from step  1224  of  FIG. 51 , input the outputted .STL file into the .STL manipulator software or program and/or determine surface area and/or volume based on the outputted .STL file and/or the saved .STL file from step  1224  of  FIG. 51 . Moreover, the software, step  124  of method  100  and/or sub-method  1300  may execute and/or perform the fourth plurality of sub-steps  1340  which may output a CAD-based .STL file based on, associated with and/or indicative of the original CAD model of, or associated with the component  2 , input the outputted CAD-based .STL file into the .STL manipulator software or program and/or determine surface area and/or volume based on the outputted CAD-based .STL file and/or the original CAD model. 
     The software, the step  12  of method  100  and/or the sub-method  1300  may compare the surface area and/or volume determinations from sub-steps  1310 ,  1320 ,  1330 ,  1340  and/or determine and/or calculate one or more 3D offsets between the outputted .STL files of sub-steps  1310 ,  1320 ,  1330 ,  1340  at step  1342  of  FIG. 52 . Finally, the software, step  124  of method  100  and/or sub-method  1300  may apply at least one 3D solution based on the determined and/or calculated one or more 3D offsets between the outputted .STL files as shown at step  1344  of sub-method  1300 . 
     After the collected 2D images and/or data have been analyzed at step  120  and the collected 3D images and/or data have been analyzed at step  124 , the software and/or the method  100  may executed, perform and/or facilitate an in process analysis of the analyzed 2D images and/or data and the analyzed 3D images and/or data during the AM process being executed by the AM device  12  as shown at step  126  in  FIG. 40 . Next, the software and/or the method  100  may determine and/or detect if any inconsistencies and/or build errors are present and/or exist based on the executed in process analysis as shown at step  128 . Further, the software and/or the method  100  may execute and/or perform an analysis decision at step  130  based on whether any inconsistences and/or build errors were determined and/or detected at step  128 . 
     If the executed and/or performed analysis decision at step  130  determines or detects one or more major or substantial mechanical inconsistencies or build errors, the software and/or the method  100  may stop or terminal any subsequent building of the component  2  by the AM device  12  as shown at step  132 . Next, the software and/or the method  100  may alert an operator of the AM device  12  and/or system  10  that one or more major or substantial mechanical inconsistences or build errors were determined or detected and/or may provide the operator with at least one solution via the displays  20  as shown at step  134 . The step  134  of alerting the operator with at least one solution may comprise and/or include, but is not limited to the sub-method  1400  shown in  FIG. 53 . 
     The sub-method  1400  may determine that the system  10  and/or the AM device  12  may be experiences at least one error that is not resolvable without assistance by, or aid from, the operator of the system  10  and/or the AM device  12  as shown at step  1402 . The sub-method  1400  may determine that the system  10  and/or the AM device is experience a motor failure at step  1404 , has a clogged extruder at step  1408 , is out of build material at step  1410 , has lost power at step  1412 , is experience a heating element failure at step  1414  and/or is experiencing another type of error or failure at step  1416 . Once the software and/or sub-method  1400  has determined that at least one of the errors set forth in steps  1404 ,  1408 ,  1410 ,  1412 ,  1414 ,  1416  is present and/or being experienced by the system  10  and/or the AM device  12 , the software and/or sub-method  1400  may provide a step-by-step solution or operation to the at least one error to be executed by the operator as shown at step  1406 . Next, the operator may execute the step-by-step solution or operation as shown at step  1418 . The executed step-by-step solution or operation may correct the at least one build error as shown at step  1420  or may not correct the build error as shown at step  1422 . If the executed step-by-step solution or operation does not correct the at least one error, the sub-method  1400  may return to step  1406  and/or provide the operator with one or more subsequent, additional and/or alternative step-by-step solutions or operations to correct the at least one error being experienced by the system  10  and/or the AM device  12 . If none of executed step-by-step solutions or operations provided at step  1406  corrects the at least one error, the software and/or the sub-method  1400  may instruct the operator to contact customer support via one or more communications as shown at step  1424 . 
     If the at least one error was corrected via sub-method  1400  at step  134  of  FIG. 40 , the software and/or method  100  may restart the AM process and continue building the component  2  as shown at step  136  of  FIG. 40 . 
     The executed and/or performed analysis decision at step  130  may determine that no inconsistencies or build errors exist as shown at step  138  of  FIG. 40 . Next, the software and/or method  100  may complete the build of the component  2  by finishing or applying the last build layer to the component  2  as shown at step  140 . Moreover, the software and/or method  100  may proceed with the collection of the 2D images and/or data by the first imaging device  14  and/or the 3D images and/or data by the second imaging device  16  as shown at step  142 . 
     The executed and/or performed analysis decision at step  130  may determine and/or detect that at least one recoverable and/or continuable inconsistency or build error exist as shown at step  144  of  FIG. 40 . Next, the software and/or method  100  may complete the build of the component  2  by finishing or applying the last build layer to the component  2  as shown at step  146 . Alternatively, the software and/or method  100  may determine one or more solutions to correct the determined and/or detected at least one recoverable and/or continuable inconsistency or build error as shown at step  148 . The determined one or more solutions for correcting at least one recoverable and/or continuable inconsistency or build error(s) may comprise and/or include, but are not limited to, adjusting the .STL associated with, or indicative of, the component  2  as shown at step  150 , adjusting printer firmware as shown at step  154  and/or adjusting the CAD file associated with, or indicative of, the component  2  as shown at step  156 . After correcting the at least one recoverable and/or continuable inconsistency or build error, the software and/or method  100  may implement one or more adjustments and/or corrections as shown at step  152 . 
     The step  154  of adjusting the printer firmware may comprise and/or include, but is not limited to, the sub-method  1500  as shown in  FIG. 54 . The software and/or sub-method  1500  may open microcontroller software as shown at step  1502  and/or may subsequently scale the component  2  and/or subsequently built components via firmware associated with the AM device  12  as shown at step  1514 . In embodiment, the software and/or sub-method  1500  may subsequently re-arrange the print bed of the AM device  12  and/or the .STL file of the component  2  as shown at step  1508  and/or subsequently adjust one or more temperature sensors of the AM device  12  as shown at step  1512 . After step  1508  and/or step  1512 , the software and/or sub-method  1500  may proceed to step  1510  whereby the software and/or sub-method  1500  may clear an electrically erasable programmable read-only memory (hereinafter “EEPROM”) associated with, and/or contain within, the system  10  and/or the AM device  12 . In an embodiment, the software and/or sub-method  1500  may clear the EEPROM as shown at step  1504  and/or may subsequently reload one or more correct defaults associated with the system  10  and/or the AM device  12  as shown at step  1506 . In another embodiment, the software and/or sub-method  1500  may adjust one or more printer speeds associated with the AM device  12  as shown at step  1516  and/or may subsequently increase one or more printer speeds of the AM device  12  at step  1518  or may subsequently decrease one or more printer speeds of the AM device  12  as step  1520 . After step  1518  or step  1510 , the software and/or sub-method  1500  may clear the EEPROM associated with the system  10  and/or the AM device  12  as shown at step  1510 . After the step  1510  of clearing the EEPROM, the software and/or sub-method  1500  may save and/or upload new firmware at step  1522  and may subsequently close the microcontroller software  1524  as step  1524 . 
     The step  150  of adjust the .STL file shown in  FIG. 40  may comprise and/or include, but is not limited to, the sub-method  1600  as shown in  FIG. 55 . The sub-method  1600  may comprise and/or include, but is not limited to, repairing the .STL file at step  1602 , scaling the .STL file at step  1604  and/or altering geometry associated with the .STL file at step  1606 . After the step  1606  of altering the geometry, the software and/or sub-method  1600  may cut the .STL file at step  1608  and/or extrude the .STL file at step  1610 . 
     The step  156  of adjusting the CAD file shown in  FIG. 40  may comprise and/or include, but is not limited to, the sub-method  1700  as shown in  FIG. 56  which may adjust .STL file triangulation associated with the component  2  at step  1702  or adjust geometry of the original CAD file of the component  2  at step  1712 . After step  1702  of adjust the .STL file triangulation, the software and/or sub-method  1700  may adjust at least one deviation tolerance of the .STL file at step  1704  or adjust at least one angle tolerance of the .STL file at step  1706  and/or may subsequently export the new .STL file containing the adjusted deviation or angle tolerance as shown at step  1708 . After the step  1712  of adjusting the geometry of the CAD file, the software and/or sub-method  1700  may save the new CAD file containing the adjusted geometry at step  1714 , adjust the .STL file triangulation at step  1716  and/or adjust at least one deviation tolerance of the .STL file at step  1718  or adjust at least one angle tolerance at step  1720 . After step  1708 , step  1718  or step  1720 , the software and/or sub-method  1700  may save the new .STL file comprising the at least one adjusted deviation or angle tolerance as shown at step  1710 . 
     The step  142  of proceeding with the data collection and/or the step  152  of implementing one or more adjustments and/or corrections may proceed to step  158  as shown in  FIG. 40 . At the step  158 , dependent upon the adjustment step executed by method  100 , the software and/or method  100  may, but is not limited to, changing to a CAD file at step  160 , changing to a .STL file at step  162  or changing to printer firmware at step  164 . For example, if method  100  executed the step  154  of adjusting the printer firmware, then the software and/or method  100  may proceed to the step  164  of changing to the printer firmware. After step  164 , the software and/or method  100  may proceed to step  114  as shown in  FIG. 40 . Alternatively, if method  100  executed the step  150  of adjusting the .STL file, then the software and/or method  100  may proceed to the step  162  of changing to the .STL file. After step  162 , the software and/or method  100  may proceed to the step  110 . In yet another alternative, if method  100  executed the step  156  of adjusting the CAD, then the software and/or method  100  may proceed to the step  160  of changing to the CAD file. After step  160 , the software and/or method  100  may proceed to step  104 . 
     In embodiments, the software may utilize method  200  shown in  FIG. 41  instead of method  100 . Method  200  may comprise a plurality of the steps and sub-methods utilized during, or by, method  100 . For example, method  200  may comprise or include, but is not limited to, steps  102 ,  104 ,  106 ,  108 ,  110 ,  112 ,  114 ,  118 ,  12 ,  122 ,  124 ,  128 ,  132 ,  134 ,  136 ,  138 ,  148 ,  150 ,  152 ,  154 ,  156 ,  158 ,  160 ,  162 ,  164 . In embodiment, method  200  may exclude steps  126 ,  130 ,  140 ,  142 ,  144 ,  146  of method  100 . Moreover, method  200  may finish building the component  2  at step  202  before the software and/or method  200  analyzes the collected 2D and 3D images and/or data at step  204 . One difference from method  100  is that method  200  completely builds the component  2  before proceeding to analyze any images or data collected by the imaging device  14 ,  16  at step  204 . As a result, the step  128  of determining any consistencies and/or build errors present or exhibited by the component  2  is executed or performed by the software and/or method  200  until after the built component is completed by the AM process executed by the AM device  12 . The subsequent steps after step  128  of method  200  proceed in the same, or substantially the same, order as the steps subsequent to step  128  of method  100 . 
     In embodiments, the software may utilize method  300  shown in  FIG. 42  instead of method  100 ,  200 . Method  200  may comprise a plurality of the steps and sub-methods utilized during, or by methods  100 ,  200 . For example, method  300  may comprise or include, but is not limited to, steps  102 ,  104 ,  106 ,  108 ,  110 ,  112 ,  114 ,  118 ,  120 ,  124 ,  128 ,  132 ,  132 ,  136 ,  138 ,  148 ,  150 ,  152 ,  154 ,  156 ,  158 ,  160 ,  162 ,  164 . Method  300  may exclude the step  126  of executing an in process analysis of the collected 2D and 3D images or data. Instead, method  300  may analysis the collected 2D and 3D images or data at step  302  and may subsequently finish building the component  2  at step  304  before the step  148  of determining one or more solutions for correcting the determined and/or detected at least one inconsistency and/or build errors. In method  300 , step  148  is executed after the build of component  2  is completed; therefore, the adjusting steps  150 ,  154  and  156  and/or changing steps  160 ,  162 ,  164  may be executed and/or performed by the software and/or method  300  subsequent to completing the build of component  2  during the AM process executed by the AM device  12 . 
     Example 
     A working example was conducted whereby the following set of rules or principles governed the conduct within the experiment. First, the resulting test component was not allowed to be removed from platform  22  until a geometric analysis of the test component was concluded. Additionally, hand measurements of the test component were allowed after completion of the build of the test component to verify calculations were correct. Further, an operator of system  10  was only allowed: to start the build of the test component; to perform scanner operations after build completion of the test component; and to perform a geometric analysis of the test component. Still further, the operator was allowed to manually adjust for build errors or corrections as to derive a procedural path for future automated software. Yet still further, only two data sets from the same component were presented wherein Data Set 1 was collected before any build adjustment(s) and Data Set 2 was collected after the build adjustments were applied to produce a second scaled component (hereinafter “scaled component”). Moreover, any build or operational decisions made by the operator were logged while been shown alongside the data collection and adjustments. 
     In the experiment, the test component was a one inch cube (i.e., 1 inch×1 inch×1 inch) because a one inch cube may be a simple object but also has the ability to exhibit fabrication inconsistencies, errors and/or malfunctions. Further, the test component was made solid for ease of calculations throughout the experiment. The CAD file of the test component was created and measurements were performed whereby each of the three dimensions of the CAD model of the test component were 1.00±0.02 inches for the x-axis, y-axis, and z-axis. Next, the .STL file of the CAD model was created and repaired whereby the each of the three dimensions were measured virtually to be 1.00 inch for the x, y, and z-axis. Further, the layers of the theoretical build of the sliced repaired .STL of the CAD model were created. These layers were then virtually stacked creating a 3D view of what the slicer settings generated. However, the 3D image appeared squashed because no thickness for each layer was transferred through the 2D images. In order to solve this, we employed a scaling method, assuming the theoretical lengths of the squares (since the example component is a cube) were 1 inch in length for both the x and y-axis, it was then possible to determine a ratio of pixels per inch for the 2D layers exported by the slicer settings. This ratio was determined to be 636 pixels/inch and was determined using an image analysis software. When manipulating the squashed 3D view of these 2D layers during the stacking process, we called the previously determined ratio the Z-axis scale factor. This factor was then utilized for calculating the theoretical 3D height of the generated stacked 3D model with the image software. The measurements of the theoretical 2D data which had been converted to a 3D model were 1 inch for the x and y-axis and for the third dimension was 1.00 inch. This same process was utilized during the analysis of what was actually being fabricated by the AM device. 
     The experimental build consisted of the same .gcode file that was created by the previous sliced .STL which was used as the theoretical build. The AM device captured the necessary 2D and 3D data required to perform the following analysis. The original experimental 2D in 3D was generated by preparing the 3D model with the image software. 
     The Z-axis scale factor for the experimental data was calculated from the 2D data collected from the experimental build and was based on the following: 
     Note: 
     Z pix  was the height of the stacked experimental images in pixels, this was due to the fact that the slice heights to not carry with the collected 2D data. 
     Scale was the ration of pixels per unit length that could be found by measuring an object in an experimental 2D image with a known length such as a feature on the build volume. Using this information while measuring said feature in pixels, it was possible to determine the amount of pixels per unit length. 
     Z exp  was the current height of the experimental object in inches when converting from pixels to inches using the previously determined scale. 
     Z theo  was the supposed height of the experimental object if it was assumed that the height is that of the initial CAD model and not what was actually being fabricated. The reason for this was so that the scaling of the x and y-axis would remain proportional with respect to the correct height. Later, the experimentally obtained height from the second optical imaging device could be used to determine a correction for the z-axis. 
     λ exp  was the multiplication factor necessary to make the height of the experimental object in 3D virtual space the same height given in the initial CAD model. 
     
       
         
           
             
               
                 
                   
                       
                   
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                         = 
                         8.717959248 
                       
                     
                   
                 
               
               
                 
                     
                 
               
             
           
         
       
     
     Next, the Z-axis scale factor was applied and the X-axis and Y-axis were scaled by the system  10  accordingly. Further, a 3D model of the scaled experimental 2D data was prepared via the image software. After applying this method and measuring to the newly created 3D model of the experimental build, we found the first dimension of the test component, the x-axis, was 1.01 inches, the second dimension, the y-axis, was 1.04 inch and the third dimension, the z-axis, was 1.00 inch. Next, a 3D scan point cloud with key features was prepared by calibrating and activating the second imaging device  16  whereby the platform  22  was automatically lowered to a correct height and software for the second imaging device  16  was automatically opened and/or activated to collect 3D data. Further, a STL conversion of the point cloud in 3D was prepared and dimensional measures were performed whereby the first dimension, the x-axis, was 1.04 inches, the second dimension, the y-axis, was 1.05 inch and the third dimension, the z-axis, was 1.13 inch. For this example, we ignored the x and y-axis data found from the second optical imaging device; however, it should be noted that discrepancies could exist between the 2D and 3D collected data. These discrepancies could be from various origins including lighting, vibration, build geometry, and etc. 
     In order to perform the calculation, the color images were converted to grey scale and then converted to binary for ease of analyses. Performing this calculation for each image allowed the area of the white particles in pixels to be determined. By knowing the pixel/unit conversion factor, the area in a specified unit system could then be determined or calculated. To determine or detect discrepancies between theoretical and experimental, the particle areas per image were compared. Moreover, the images could have been analyzed on a 
     
       
         
           
             dx 
             dy 
           
         
       
     
     bases to verity the correct amount of material was in the correct amount of area. Extrapolation of this method would have also allowed for volume comparisons to be conducted or performed. 
     For the theoretical data, the Z-axis scale factor was 636 pixels/inch, and, for the experimental data, the Z-axis scale factor was 745.36808 pixels/inch. 
     For the binary data analyses, the output data was in pixel 2  and was converted to in 2 . To perform this calculation, the previously derived scales from the images were converted to areas as follows: 
     Note: this was an example for layer  10  of the cube build. This same procedure was carried out for every layer. 
     
       
         
           
             
               Theoretical 
                
               
                   
               
                
               Area 
                
               
                   
               
                
               Scale 
                
               
                 : 
               
                
               
                   
               
                
               636 
                
               
                   
               
                
               
                 pixels 
                 inch 
               
             
             -&gt; 
             
               
                 
                   ( 
                   
                     636 
                      
                     
                         
                     
                      
                     
                       pixels 
                       inch 
                     
                   
                   ) 
                 
                 
                   2 
                    
                   
                       
                   
                 
               
               -&gt; 
               
                 404496 
                  
                 
                     
                 
                  
                 
                   
                     pixels 
                     2 
                   
                   
                     inch 
                     2 
                   
                 
               
             
           
         
       
       
         
           
             
               Experimental 
                
               
                   
               
                
               Area 
                
               
                   
               
                
               Scale 
                
               
                 : 
               
                
               
                   
               
                
               745.36808 
                
               
                   
               
                
               
                 pixels 
                 inch 
               
             
             -&gt; 
             
               
                 
                   ( 
                   
                     745.36808 
                      
                     
                         
                     
                      
                     
                       pixels 
                       inch 
                     
                   
                   ) 
                 
                 2 
               
               -&gt; 
               
                 555573.575 
                  
                 
                     
                 
                  
                 
                   
                     pixels 
                     2 
                   
                   
                     inch 
                     2 
                   
                 
               
             
           
         
       
     
     Next it was assumed that the x-axis and y-axis were equal which allowed the square root of the area data to be taken to obtain the length of any given side of the x-axis and y-axis. From this data, offset calculations based on the original CAD model were determined. 
     For the offset calculation, the experimental length was 1.053256388 inch, the CAD length value was 1 inch, the offset length equaled CAD length value—Experimental length, and the offset length was −0.053256388 inch. Further, the corrected offset length, which accounted for the first optical imaging device being un-level, was −0.028256388 inch whereby the negative value implied that the length was over the CAD length value. Further, the corrected length equaled “experimental length −0.025 inch” which again accounted for the first optical imaging device being un-level, the corrected length was then 1.02825639 inch, the scale percentage equaled 
     
       
         
           
             
               
                 
                   CAD 
                    
                   
                       
                   
                    
                   Model 
                    
                   
                       
                   
                    
                   Length 
                 
                 
                   Corrected 
                    
                   
                       
                   
                    
                   Length 
                 
               
               * 
               100 
                
               % 
             
             , 
           
         
       
     
     whereby the scale percentage equaled 
     
       
         
           
             
               
                 1 
                  
                 
                     
                 
                  
                 inch 
               
               
                 1.02825639 
                  
                 
                     
                 
                  
                 inch 
               
             
             * 
             100 
              
             % 
              
             
                 
             
              
             or 
              
             
                 
             
              
             97.2520093 
              
             
                 
             
              
             
               % 
               . 
             
           
         
       
     
     This then notified the system that the length of this dimension for this specific layer had a correction factor of 97.25% of its current value. The system could then use this information to correct the next build for this specific layer. As previously stated, this same procedure was carried out for every layer to ensure every layer meets its appropriate dimensions. 
     For the 2D data application, the CAD model scale, .STL scale, or the firmware settings were adjusted to account for the specified offsets that were previously determined by the offset calculation(s). It was noted that an overall scale percentage, determined by averaging the offsets of every layer, was created to simply the build correction for this example. It was also noted that the first layer was neglected in the average in order to account for initial filament flow, a positive offset length meant too small and a negative offset length meant too large and, due to the first optical imaging device being slightly un-level, the 0.025 inch was subtracted from the experimental length values because the images appeared to be 0.025 inch too large. Based on these calculations, it was found that the average scale percentage was 98.23024472%. For ease of adjustment and build correction, the .STL was chosen to be scaled; however, other scaling methods would have been valid. Thus, the X-axis and Y-axis were scaled by 98.23024472%. 
     For the 3D data analyses and application, the 3D data was primarily used for detecting major mechanical errors, component volume, component surface area, and component height of the test component. Notice warping in the test component was detected by the 3D Scan. Based on the 3D scan, the height of the test component was 1.13 inch, and this height was utilized to make a Z-axis scale percentage calculation. The component volume and component surface area were valid means of comparison but were not utilized in this experiment. Thus, the Z-axis scale percentage calculation equal 
     
       
         
           
             
               
                 CAD 
                  
                 
                     
                 
                  
                 Model 
                  
                 
                     
                 
                  
                 Length 
               
               
                 Corrected 
                  
                 
                     
                 
                  
                 Length 
               
             
             * 
             100 
              
             % 
           
         
       
     
     or equaled 
     
       
         
           
             
               
                 1 
                  
                 
                     
                 
                  
                 inch 
               
               
                 1.13 
                  
                 
                     
                 
                  
                 inch 
               
             
             * 
             100 
              
             % 
              
             
                 
             
              
             or 
              
             
                 
             
              
             88.49557522 
              
             
                 
             
              
             
               % 
               . 
             
           
         
       
     
     For the scaling of the subsequently built scaled component, the scaled component was based on the previous determined calculation and scaled by the following values: 
     X-axis=98.23024472%; 
     Y-axis=98.23024472%; and 
     Z-axis=88.49557522%. 
     The new theoretical values were as follows: 
     X-axis=1″*0.9823024472=0.9823024472 inch 
     Y-axis=1″*0.9823024472=0.9823024472 inch 
     Z-axis=1″*0.8849557522=0.8849557522 inch 
     For the scaled component, the scaled .STL of the CAD model was created and repaired and measurements were performed to obtain dimensions of the scaled repaired .STL of the CAD model. Next, the scaled repaired .STL was sliced built and prepared with time-lapse via the image software system and 2D data was automatically collected for the theoretical build of the sliced scaled repaired .STL of the CAD model. For the scaled theoretical data of the second build, the Z-axis scale factor was determined to be 559 pixels/inch. Further, for the scaled theoretical 2D data in 3D, the 3D model was prepared via the image software. Since the previously determined correction offsets were used to scale the second repaired .STL, it was found that first dimension of the scaled theoretical 2D data in 3D was 0.98 inches, the second dimension was 0.98 inches, and the third dimension was 0.88 inches. Assuming the system remained consistent, this build would produce a cube much closer to the theorized 1×1×1 inch values described in the initial CAD model. For the experimental build of the sliced scaled repaired .STL of the CAD model, the scaled repaired .STL was sliced built and prepared time-lapse via the image software which automatically collected 2D data. Still further, the 3D model was prepared via the image software to generate the experimental 2D data in 3D. 
     For the Z-axis scale factor calculation for the experimental data with respect to the scaled component, the calculation was based on the following: 
     
       
         
           
             
               
                 
                   
                       
                   
                    
                   
                     
                       
                         Z 
                         pix 
                       
                       = 
                       
                         77.9922 
                          
                         
                             
                         
                          
                         pixels 
                       
                     
                      
                     
                       
 
                     
                      
                     
                         
                     
                      
                     
                       
                         Scale 
                          
                         
                           : 
                         
                          
                         
                             
                         
                          
                         29.3452 
                          
                         
                             
                         
                          
                         
                           pixels 
                           mm 
                         
                       
                       = 
                       
                         745.36808 
                          
                         
                             
                         
                          
                         
                           pixels 
                           inch 
                         
                       
                     
                      
                     
                       
 
                     
                      
                     
                         
                     
                      
                     
                       
                         Z 
                         
                           ex 
                            
                           
                               
                           
                            
                           p 
                         
                       
                       = 
                       
                         
                           
                             Z 
                             pix 
                           
                           
                             745.36808 
                              
                             
                                 
                             
                              
                             
                               pixels 
                               inch 
                             
                           
                         
                         = 
                         
                           .1046358197 
                            
                           
                               
                           
                            
                           inches 
                         
                       
                     
                   
                 
               
               
                 
                     
                 
               
             
             
               
                 
                   
                     Z 
                     theo 
                   
                   = 
                   
                     
                       .8849557522 
                        
                       
                           
                       
                        
                       inch 
                     
                     ≈ 
                     
                       
                         Z 
                         corrected 
                       
                        
                       
                           
                         
                           
                             
                               ( 
                               
                                 assumption 
                                  
                                 
                                     
                                 
                                  
                                 based 
                                  
                                 
                                     
                                 
                                  
                                 off 
                                  
                                 
                                     
                                 
                                  
                                 
                                   scaled 
                                    
                                   
                                       
                                   
                                   . 
                                   STL 
                                 
                                  
                                 
                                     
                                 
                                  
                                 of 
                                  
                                 
                                     
                                 
                                  
                                 initial 
                                  
                                 
                                     
                                 
                                  
                                 CAD 
                                  
                                 
                                     
                                 
                                  
                                 model 
                               
                               ) 
                             
                              
                             
                               
 
                             
                              
                             
                                 
                             
                              
                             
                               λ 
                               
                                 
                                   e 
                                    
                                   
                                       
                                   
                                    
                                   xp 
                                 
                                  
                                 
                                     
                                 
                               
                             
                           
                           = 
                           
                             
                               scale 
                                
                               
                                   
                               
                                
                               factor 
                                
                               
                                   
                               
                                
                               for 
                                
                               
                                   
                               
                                
                               
                                 Z 
                                 corrected 
                               
                                
                               
                                 
 
                               
                                
                               
                                   
                               
                                
                               
                                 λ 
                                 
                                   ex 
                                    
                                   
                                       
                                   
                                    
                                   p 
                                 
                               
                             
                             = 
                             
                               
                                 
                                   Z 
                                   theo 
                                 
                                 
                                   Z 
                                   
                                     e 
                                      
                                     
                                         
                                     
                                      
                                     xp 
                                   
                                 
                               
                               = 
                               
                                 
                                   
                                     1 
                                      
                                     
                                         
                                     
                                      
                                     inch 
                                   
                                   
                                     Z 
                                     
                                       e 
                                        
                                       
                                           
                                       
                                        
                                       xp 
                                     
                                   
                                 
                                 = 
                                 8.457483821 
                               
                             
                           
                         
                       
                     
                   
                 
               
               
                 
                     
                 
               
             
           
         
       
     
     It was noted that the Z-axis was set to 0.8849557522 inch during X-axis and Y-axis scaling. 
     Next, the calculated Z-axis scale was applied, the X-axis and Y-axis were scaled by the previous offsets and the experimental 2D data in 3D was scaled by preparing the 3D model with the image software. For the dimensional measurements for the scaled experimental 2D data in 3D with respect to the scaled component, the first dimension was approximately 1.02 inches, the second dimension was 1.02 inches, and third dimension was 0.88 inches. Next, the 3D scan point cloud with key features was obtained by calibrating and activating the second imaging device  16  to collect 3D data. Moreover, platform  22  was automatically lowered to a correct height and the imaging software for the second imaging device  16  was automatically opened and/or activated to collect the 3D data. Furthermore, the 3D model was prepared via the image software for obtaining the STL conversion of the point cloud in 3D. For the dimensional measurement for the STL conversion of the point cloud with respect to the scaled component, the first dimension was 1.04 inch, the second dimension was 1.04 inch, and the third dimension was 1.00 inch. Note the x and y-axis (first and second dimension) information from the second optical imaging device was not utilized as previously stated. 
     For the calculation of the particles analysis of binary data with respect to the scaled component, the color images were converted to grey scale and then converted binary for ease of analyses. Performing said calculation for each image determined the area of the white particles in pixels. As the pixel/unit conversion factor was known, the area in a specified unit system was then determined. To determine discrepancies between theoretical and experimental, the particle areas per image were compared. Moreover, the images could have been analyzed on a dx/dy bases to verify the correct amount of material was in the correct amount of area. Furthermore, extrapolating this method would have allowed for volume comparisons to be made as well. It was noted that the Z-axis scale factor was 559 pixels/inch. 
     For the binary data analyses, the output data is in pixel 2  and was converted to in 2 . In order to perform this calculation, the previously derived scales from the images were taken and converted to the following areas: 
     Note: this was an example for layer  10  of the second cube build. This same procedure was carried out for every layer. 
     
       
         
           
             
               
                 Theoretical 
                  
                 
                     
                 
                  
                 Area 
                  
                 
                     
                 
                  
                 Scale 
                  
                 
                   : 
                 
                  
                 
                     
                 
                  
                 569 
                  
                 
                     
                 
                  
                 
                   pixels 
                   inch 
                 
               
               -&gt; 
               
                 
                   
                     ( 
                     
                       569 
                        
                       
                           
                       
                        
                       
                         pixels 
                         inch 
                       
                     
                     ) 
                   
                   
                     2 
                      
                     
                         
                     
                   
                 
                 -&gt; 
                 
                   323761 
                    
                   
                       
                   
                    
                   
                     
                       pixels 
                       2 
                     
                     
                       inch 
                       2 
                     
                   
                 
               
             
             ; 
             and 
           
         
       
       
         
           
             
               Experimental 
                
               
                   
               
                
               Area 
                
               
                   
               
                
               Scale 
                
               
                 : 
               
                
               
                   
               
                
               745.36808 
                
               
                   
               
                
               
                 pixels 
                 inch 
               
             
             -&gt; 
             
               
                 
                   ( 
                   
                     745.36808 
                      
                     
                         
                     
                      
                     
                       pixels 
                       inch 
                     
                   
                   ) 
                 
                 2 
               
               -&gt; 
               
                 555573.575 
                  
                 
                     
                 
                  
                 
                   
                     
                       pixels 
                       2 
                     
                     
                       inch 
                       2 
                     
                   
                   . 
                 
               
             
           
         
       
     
     Next, it was assumed the x-axis and y-axis were equal which allowed for the square root of the area data to be taken to obtain the length of any given side of the x-axis and y-axis. From this data, the offset calculations were determined based on the original CAD model. 
     For the offset calculation with respect to the scaled component, the experimental length was 1.030021839 inch, the value of CAD model length equaled 1 inch, the offset length equaled “CAD length value−experimental length”, the offset length was −0.030021839 inch, and the corrected offset length equaled −0.005021839 inch which accounted for the first optical imaging device being un-level and the negative value implied that the length is over the CAD length value. Moreover, the corrected length equaled “experimental length −0.025 inch” (which accounted for the first optical imaging device being un-level), the corrected length equaled 1.005021839 inch, and the scale percentage equaled 
     
       
         
           
             
               
                 CAD 
                  
                 
                     
                 
                  
                 Model 
                  
                 
                     
                 
                  
                 Length 
               
               
                 Corrected 
                  
                 
                     
                 
                  
                 Length 
               
             
             * 
             100 
              
             % 
              
             
                 
             
              
             or 
              
             
                 
             
              
             
               
                 1 
                  
                 
                     
                 
                  
                 inch 
               
               
                 1.005021839 
                  
                 
                     
                 
                  
                 inch 
               
             
             * 
             100 
              
             % 
              
             
                 
             
              
             or 
           
         
       
       
         
           
             99.50032542 
              
             
                 
             
              
             
               % 
               . 
             
           
         
       
     
     This then notified the system that the length of this dimension for this specific layer had a correction factor of 99.5% of its current value. The system could then use this information to correct the next build for this specific layer. As previously stated, this same procedure was carried out for every layer to ensure every layer meets its appropriate dimensions. 
     For the 2D data application, the CAD model scale, the .STL scale, or the firmware settings were adjusted to account for the specified offsets previously calculated with respect to the scaled component. It was noted that the overall scale percentage was the average of all the layers, the first layer was neglected to account for initial filament flow, the positive offset length meant too small and the negative offset length meant too large, and, due to the first optical imaging device being slightly un-level, 0.025 inch was subtracted from the experimental length values since the images appear 0.025 inches too large. Based on these calculations, the average scale percentage was found to be 99.5131852%. That is to say, the system increased the percentage by which what was actually built matched what was supposed to be built from the first cube build to the second cube build. 
     For the 3D data analyses and application, the 3D data was primarily used for detecting major mechanical errors, component volume, component surface area, and component height. Notice warping was detected by the 3D scan. Based on the 3D scan, the height of the scaled component was 1.00 inch, which was utilized to make a Z-axis scale percentage calculation. The component volume and component surface area were valid means of comparison but were not utilized in this experiment. Moreover, the Z-axis scale percentage calculation equaled 
     
       
         
           
             
               
                 CAD 
                  
                 
                     
                 
                  
                 Model 
                  
                 
                     
                 
                  
                 Length 
               
               
                 Corrected 
                  
                 
                     
                 
                  
                 Length 
               
             
             * 
             100 
              
             % 
              
             
                 
             
              
             or 
              
             
                 
             
              
             
               
                 1 
                  
                 
                     
                 
                  
                 inch 
               
               
                 1.00 
                  
                 
                     
                 
                  
                 inch 
               
             
             * 
             100 
              
             % 
              
             
                 
             
              
             or 
              
             
                 
             
              
             100 
              
             
               % 
               . 
             
           
         
       
     
     Meaning the experimental height for the second cube build matched the supposed height given in the initial CAD model. 
     With respect to a 2D data set comparison, Data Set 1(first build) for the test component showed that the average scale percentage was 98.23024472% and Data Set 2(second build) for the scaled component showed that the average scale percentage improved to be 99.5131852%. From the perspective of the instrumentation, Data Set 1 was analyzed, and an offset for the X-axis and Y-axis was determined and subsequently applied in such a manner as to produce a second scaled component that was smaller in the X-axis and Y-axis by 1.76975528%. Upon production of the second scaled component and analyzing Data Set 2, application of the above-identified changes unexpectedly decreased the component size in the X-axis and Y-axis by 1.28294048% (99.5131852%−98.23024472%) rather than the previously predicted value of 1.76975528%. Though the corrections were close to the value given by the initial CAD model, the system still yielded a discrepancy of approximately 0.49%. However, assuming the system was consistent, this value could be utilized in future calculations. When determining the scale difference which was 0.4868148% (1.76975528%−1.28294048%), the size of the second scaled component was adjusted to meet the correct dimensions within the acceptable tolerances (i.e., within a few hundred thousandths of an inch) by taking the average scale percent determined from Data Set 1 plus the 0.4868148% scale offset. Thus, the method of this experiment was surprisingly effective from the instrumentation perspective in the X-axis and Y-axis such that the system produced the second scaled component with dimensions that matched, or at least substantially matched, the original CAD model dimensions within 0.4868148%. 
     With respect to a 3D data set comparison, Data Set 1(first build) showed that the Z-axis scale percentage for the test component was (1 inch/1.13 inch)*100% or 88.49557522%, and Data Set 2(second build) showed that the Z-Axis Scale Percentage for the second scaled component was (1 inch/1.00 inch)*100% or 100%. From the perspective of the instrumentation, a measurement of the components Z-axis or height was taken from Data Set 1 and the Z-axis offset was determined. Then, said determined Z-axis offset was utilized in the fabrication of the second scaled component to fix any discrepancies or build errors between the original CAD model dimensions and the dimensions of the test component that were determined by the instrumentation. Thus, the method of this experiment was surprisingly effective from the instrumentation perspective in the Z-axis to produce the second scaled component that had dimensional measurements that matched, or at least substantially matched, the original CAD model dimensions. 
     It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems, methods and/or applications. Also, various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art, and are also intended to be encompassed by the following claims.