Abstract:
Methods and apparatuses to fabricate additive manufactured parts with in-process monitoring are described. As parts are formed layer-by-layer, a 3D measurement of each layer or layer group may be acquired. The acquisition of dimensional data may be performed at least partially in parallel with the formation of layers. The dimensional data may be accumulated until the part is fully formed, resulting in a part that was completely inspected as it was built. The as-built measurement data may be compared to the input geometrical description of the desired part shape. Where the part fails to meet tolerance, it may be amended during the build process or rejected.

Description:
FIELD 
       [0001]    The present disclosure relates to methods and apparatuses for quality control of additive manufactured parts. 
       BACKGROUND 
       [0002]    Additive manufacturing, sometimes called 3D printing, is a relatively new technology that is the process of joining materials to make parts from 3D (three-dimensional) model data, usually layer upon layer. Traditional, subtractive manufacturing techniques create shaped objects by removing material from a larger template. Traditional additive techniques, such as welding, molding, bonding and fastening, are not classified as additive manufacturing because those techniques are not driven by a 3D model nor built essentially layer by layer. Additive manufacturing typically uses a bulk stock material, such as a liquid, granular, or solid material, that is selectively formed into a layer according to an electronic input. Layers are built, typically one on top of the last, until the entire part is formed. 
         [0003]    Additive manufacturing allows complex parts to be built without tooling and/or fixtures, and is typically employed for rapid prototyping and non-critical, complex parts. Additive manufacturing may be employed in various industries including consumer products, transportation, aerospace, robotics, medical, military, and academic research. 
         [0004]    Additive manufacturing is typically more material efficient than traditional manufacturing. In traditional manufacturing using casting and machining, a large fraction of the stock material is scrapped. In additive manufacturing, the stock material is selectively used to form a layer. The remaining stock material remains essentially unaffected and available for future use. Further, because of the free form nature of additive manufacturing, complex structures may be formed for little to no additional cost, thus enabling low-cost, high strength-to-weight ratio parts desired for aerospace applications. However, present additive manufacturing techniques have limited applicability to supply critical structural components such as aerospace components because the parts built are not typically easy to inspect, especially very complex parts or parts with enclosed surfaces. 
       SUMMARY 
       [0005]    Apparatuses and methods according to the present disclosure provide non-destructive, in-process inspection of additively manufactured parts. Such as-built measurements allow effective quality control and 100% verification of additively manufactured parts. Aerospace applications generally require effective quality control of structural components. The additive manufacturing methods of the present disclosure generally comprise sequentially forming one or more layers of a part from a stock material, based upon an input geometric description. The methods also comprise synchronously acquiring dimensional data about at least a portion of the formed layers. Further, the methods comprise comparing at least some of the geometric description that drives the forming to the dimensional data that describes the partially fabricated part. If performed iteratively, the forming and acquiring will create a finished part and a 3D model of the part as-built, including any interior surfaces. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a schematic representation of an additive manufacturing apparatus according to the present disclosure. 
           [0007]      FIG. 2  is a schematic representation of the process flow when using an additive manufacturing apparatus according to the present disclosure. 
           [0008]      FIG. 3  is a flow diagram of manufacturing methods according to the present disclosure. 
           [0009]      FIG. 4  schematically represents illustrative, non-exclusive examples of additive manufacturing apparatuses according to the present disclosure. 
       
    
    
     DESCRIPTION 
       [0010]    The present disclosure relates to methods and apparatuses for quality control of additive manufactured parts.  FIGS. 1-2  schematically present apparatuses and uses of the apparatuses for quality control during additive manufacturing. 
         [0011]    Additive manufacturing takes as input a geometric description  50  of the desired fabricated part  60 , for example from CAD software or from a 3D scanner, and transforms the geometric description  50  into thin, virtual, layer-wise cross-sections. The manufacturing process proceeds by sequentially forming layers  62  of stock material  58 , one on top of another, following the pattern of the geometric description  50  cross-sections. As these layers  62  are formed, they are formed to the previously formed layers  62 , creating a partially complete, in-process part  64 . The forming process is typically repeated until all layers are formed and the entire fabricated part  60  is built. 
         [0012]    Additive manufacturing apparatuses  30  work directly from the geometric description  50 , or model, generally requiring no specialized tooling to create the fabricated part  60 . Limitations imposed by traditional manufacturing, like molding and machining, do not generally apply. Thus, fabricated parts  60  may take more free-form shapes than traditionally manufactured parts. 
         [0013]    An additive manufacturing apparatus  30  with quality control according to the present disclosure comprises a deposition device  32 , to form the layers  62 , a dimensional measuring device  34 , to acquire dimensional data  54  of one or more layers  62  already formed, and a controller  36  programmed to perform and/or control the methods, including forming, acquiring, and comparing, as described further below. The controller  36  includes, and optionally is, a computer  38 . 
         [0014]    Apparatuses  30  may further comprise a fabrication chamber  40  where layers  62  are formed on the in-process part  64 . Where the apparatus  30  includes a fabrication chamber  40 , the deposition device  32  and/or the dimensional measuring device  34  may be at least temporarily, and in some embodiments fully, located within the fabrication chamber  40 . In particular, the deposition device  32  is typically located within the fabrication chamber  40  while one or more layers  62  are being formed. Likewise, the dimensional measuring device  34  is typically located within the fabrication chamber  40  while one or more layers  62  are being measured. 
         [0015]    Apparatuses  30  may further comprise a base tray  44  that generally supports the in-process part  64 , and, in particular, is the underlying support for the first of the layers  62 . As the fabricated part  60  is a three dimensional object, the apparatus  30  also may include one or more stages to move the deposition device  32  and the in-process part  64 , on the optional base tray  44 , relative to each other. In this way, the region where a portion of a new layer  62  is formed may be moved. Generally, the formation region is moved laterally in two dimensions to selectively form a layer  62 . When the layer is complete, the formation region is moved axially (e.g., vertically) relative to the in-process part  64 , such that the apparatus  30  is prepared to create another layer  62  above the last one. Lateral motion may be achieved by one or more lateral stages  45 , while axial motion may be achieved by one or more axial stages  46 . The stages may be configured to move the deposition device  32  and/or the in-process part  64 , optionally on the base tray  44 . 
         [0016]    Apparatuses  30  may further comprise a stock material supply  48 . The stock material supply  48  holds a supply of stock material  58  available to the deposition device  32  to form a layer  62 . The stock material supply  48  may optionally supply the apparatus  30  with stock material  58  in response to stock material  58  consumed in the formation of layers  62 . 
         [0017]    Generally, the apparatus  30  may be configured to perform one or more types of additive manufacturing techniques. The different techniques differ in the ways in which the layers  62  are formed and in which stock materials  58  are compatible. Apparatuses  30  may perform different techniques and/or use different stock materials  58  at different times and/or upon different layers  62 . Additionally or alternatively, the different techniques and/or different stock materials  58  may be used simultaneously and/or upon the same layer  62 . Illustrative, non-exclusive additive manufacturing techniques include selective laser sintering, direct metal laser sintering, selective heat sintering, electron beam freeform fabrication, electron beam melting, stereolithography, direct droplet deposition, fused deposition modeling, and extrusion. Various techniques and/or combinations of techniques may require the deposition device  32  to include one or more of a laser scanner, a laser, a light source, a heat source, and an electron beam. 
         [0018]    Selective laser sintering is a technique that uses a powerful laser to selectively fuse powdered thermoplastic, ceramic, or metal stock material  58  by scanning cross-sections, derived from the geometric description  50 , on the surface of a powder bed. After each layer  62  is complete the powder bed with the in-process part  64  is lowered by one layer  62  thickness, a new layer of powdered stock material  58  is applied on top, and the process is repeated until the completed fabricated part  60  is formed. 
         [0019]    Direct metal laser sintering is a technique that is similar to selective laser sintering except that it uses a laser beam powerful enough to melt and fuse metal powder grains. The resulting fabricated parts  64  typically have mechanical properties equivalent to bulk materials, with a homogenous structure and no unintentional voids. 
         [0020]    Selective heat sintering is a technique that is similar to selective laser sintering except that the heat to melt the powdered stock material  58  is supplied by a finely controlled thermal deposition device  32 , similar to a thermal print head. 
         [0021]    Electron beam freeform fabrication and electron beam melting are techniques that use a focused ion beam in a vacuum to selectively melt and solidify metallic stock material  58  into layers  62 . Electron beam freeform fabrication uses a metallic wire stock material  58 . Electron beam melting uses a metallic powder stock material  58 . 
         [0022]    Stereolithography is a class of techniques that use photopolymerization to form a solid fabricated part  60  from a liquid including a photopolymer stock material  58 . A light pattern, typically of ultraviolet (UV) light, may be projected upon a thin layer of stock material  58  which selectively cures the stock material  58  into a solid layer  62 . Additionally or alternatively, the light pattern may be written on the thin layer of stock material  58  by a laser scanner. In some embodiments, the stock material  58  may be a thick volume of a viscous liquid and/or a gel. In that case, photopolymerization may be initiated by a multiphoton process (a non-linear absorption of light). Typically, multiphoton techniques use focused infrared (IR) and/or near-infrared (NIR) laser beams scanned through the stock material  58 . Photopolymerization only occurs within the focal volume of the light beam. Typically, the beam is swept through the stock material  58  in three dimensions, creating a freeform photopolymerized fabricated part  60 . Multiphoton techniques may also be used with thin, liquid stock material  58  as with other stereolithography techniques. 
         [0023]    Direct droplet deposition is a class of techniques that eject microdroplets of liquid stock material  58  from the deposition device  32 . The stock material  58  may be molten metallic or thermoplastic, in which case the droplets solidify soon after being deposited on a substrate, e.g., a layer  62  and/or the base tray  44 . The stock material  58  may be a photopolymer, in which case the droplets require exposure to curing light to solidify. The stock material  58  may be a chemical component of a catalyst-binder system or a catalyst-resin system. All components of the system may be deposited by droplets, or one or more components may be deposited onto a bed of the remaining components. Such techniques also may incorporate inert materials into the fabricated part  60 . For example, direct droplet deposition may be used to create sand cast molds incorporating sand bound by binder e.g., by depositing catalyst droplets onto beds of binder coated sand. 
         [0024]    Fused deposition modeling and extrusion are techniques that melt and/or extrude thermoplastic or metal stock material  58  into a layer  62 . The deposition device  32  has a heated nozzle that can selectively emit melted stock material  58 . The emitted stock material  58  rapidly hardens after leaving the nozzle. 
         [0025]    Apparatuses  30  generally build fabricated parts  60  from fused layers  62  of stock material  58 . Stock materials  58  are typically stored and/or supplied by a stock material supply  48 . Stock materials  58  generally have a liquid, solid, and/or granular form, and are generally not gaseous. Illustrative, non-exclusive stock materials include a plastic, a polymer, a photopolymer, an acrylic, an epoxy, a thermoplastic, an ABS plastic, a polycarbonate, a polylactic acid, a biopolymer, a starch, a plaster, a wax, a clay, a metal, a metal alloy, a eutectic metal, a metal powder, an iron alloy, a stainless steel, a maraging steel, an aluminum alloy, a titanium alloy, a nickel alloy, a magnesium alloy, a cobalt chrome alloy, and a ceramic. 
         [0026]    Apparatus  30  may be configured to use multiple stock materials  58  during the fabrication of a single fabricated part  60 . For example, the stock material supply  48  may supply more than one type of stock material  58 . Additionally or alternatively, apparatus  30  may include more than one deposition device  32  and/or more than one stock material supply  48 . When an apparatus  30  is so configured, a single fabricated part  60  may be made of multiple stock materials  58 , for example, several metal alloys. Different portions of a fabricated part  60 , for example an engine turbine, may be made with different materials optimized for different qualities, e.g., one end may be optimized for strength while the other is optimized for heat resistance. Additionally or alternatively, optional support structure, which may be formed with the layers  62 , may be formed of a different stock material  58  than the in-process part  64 . 
         [0027]    Apparatuses  30  comprise a dimensional measuring device  34  which optionally includes one or more energy detectors  42  and/or one or more energy emitters  43 . The dimensional measuring device  34  is configured to acquire dimensional data  54  as the layers  62  are being formed, accumulating the layer-wise dimensional data  54 . When data at all the desired layers has been acquired, the accumulated, in-process dimension data  54  becomes the output dimensional data  56  that describes the geometric dimensions of the fabricated part  60  as-built. 
         [0028]    Dimensional data  54  may be acquired with a variety of techniques. For the in-process parts  64 , which may be delicate and may have steep geometries, non-contact techniques are generally used, i.e., no physical probe touches the in-process part  64  and/or the layers  62 . Non-contact techniques all generally detect some form of energy emanating from the sample being probed. Suitable energy forms include light, heat, and sound. When the energy is in the form of light, the light may include one or more of visible light, infrared (IR) light, near-infrared (NIR) light, and ultraviolet (UV) light. Energy detectors  42  suitable for light detection include photodetectors, for example a photodiode, a position sensitive device, an array detector, and a CCD (charge coupled device). Energy detectors  42  suitable for heat detection include infrared imagers. Energy detectors  42  suitable for sound detection include ultrasonic transducers. 
         [0029]    The dimensional measuring device  34  may use machine vision, 3D optical scanning, photogrammetry, and/or structured light imaging. Depending on the configuration, the dimensional measuring device  34  may generate 2D (two-dimensional) and/or 3D geometric measurements of the in-process part  64 . Machine vision is a technique that uses electronic imaging and algorithms to extract geometric information from images of the in-process part  64 . 3D optical scanning is a technique which uses light reflection, often from a laser, to calculate the surface geometry of the in-process part  64 . Typically the surface location is calculated from the time-of-flight or from triangulation. Photogrammetry is a technique that determines the geometry of the in-process part  64  through analysis of electronic images, commonly multiple images from different angles. Structured light imaging is a technique that projects a pattern of light onto the in-process part  64  and calculates the surface profile from detected distortions of the pattern reflected by the surface of the in-process part  64 . 
         [0030]    If the dimensional measure device  34  includes and uses an energy emitter  43 , the energy emitter imparts energy onto the in-process part  64  and/or the layers  62 . Generally, for non-contact measurement, the energy is a radiative form, such as light, heat, and/or sound. Whatever the form of energy, the energy emitter  43  does not typically impart enough energy to damage or otherwise interfere with the in-process part  64 , the layers  62 , or any of the stock material  58 . Energy emitters  43  suitable for light emission include lamps, wide-field illuminators, structured illuminators, lasers, laser scanners, flash lamps, and modulated illuminators. Further, dimensional measuring device  34  may be configured to use ambient light as a supplement or alternative to a light energy emitter  43 . Accordingly, an energy detector  42  may be configured to detect ambient light reflected and/or transmitted by the in-process part  64 . Energy emitters  43  suitable for heat emission include heaters. Energy emitters  43  suitable for sound emission include ultrasonic transducers. 
         [0031]    Dimensional data  54  acquired by the dimensional measuring device  34  may be 2D and/or 3D. If the dimensional data  54  acquired from a layer  62  is 2D then potential variations in the layer  62  thickness might remain unmeasured. In-process dimensional data  54 , accumulated from one or more layers  62 , and output dimensional data  56 , accumulated from all layers  62 , are inherently 3D. Dimensional data  54 , and output dimensional data  56 , may include, optionally may be, a point cloud, a polygon mesh, and/or a 3D representation. Dimensional data  54  additionally may include, or optionally may be, an image and/or a 2D layer representation. The dimensional data  54  and the output dimensional data  56  independently may be collected and/or stored with a lateral resolution of about 0.01 μm, about 0.02 μm, about 0.05 μm, about 0.1 μm, about 0.2 μm, about 0.5 μm, about 1 μm, about 2 μm, about 5 μm, about 10 μm, about 15 μm, about 20 μm, about 30 μm, about 40 μm, about 50 μm, about 100 μm, about 150 μm, about 200 μm, about 300 μm, about 400 μm, or about 500 μm; and/or about 0.01-50 μm, about 0.01-5 μm, about 0.02-2 μm, about 0.2-500 μm, about 0.2-50 μm, about 0.2-10 μm, about 1-500 μm, about 1-50 μm, about 1-20 μm, about 5-500 μm, about 5-100 μm, or about 5-50 μm. The dimensional data  54  and the output dimensional data  56  independently may be collected and/or stored with an axial resolution of about 0.05 μm, about 0.1 μm, about 0.2 μm, about 0.5 μm, about 1 μm, about 2 μm, about 5 μm, about 10 μm, about 15 μm, about 20 μm, about 30 μm, about 40 μm, about 50 μm, about 100 μm, about 150 μm, about 200 μm, about 300 μm, about 400 μm, or about 500 μm; and/or about 0.05-50 μm, about 0.05-10 μm, about 0.2-5 μm, about 0.5-500 μm, about 0.5-100 μm, about 0.5-50 μm, about 0.5-10 μm, about 2-100 μm, about 2-40 μm, about 10-40 μm, about 40-100 μm, or about 40-500 μm. 
         [0032]    Apparatuses  30 , and deposition devices  32 , form each layer  62  following the pattern of the geometric description  50 . Generally, the geometric description  50  is an input to the apparatus  30  operation, and thus is predetermined. Additionally or alternatively, the geometric description  50  may be provided to the apparatus  50  in smaller data sets, corresponding to the one or more layers  62  being formed. The geometric description  50  may include, and optionally is, a point cloud, a polygon mesh, a 2D layer representation and/or a 3D surface representation. In addition to describing at least some of the fabricated part  60 , the geometric description  50  may include a description of one or more support structures—structures that provide temporary support of the in-process part  64  and/or layer  62  during the fabrication process. Support structures may be a component of apparatus  30  or may be built with the fabricated part  60 . 
         [0033]    Turning to  FIG. 3 , manufacturing methods  10  for additive manufactured parts with quality control are schematically represented. Manufacturing methods  10  comprise sequentially forming  12  one or more layers  62  based upon a geometric description  50 , synchronously acquiring  14  dimensional data  54  about at least a portion of the layers  62 , and comparing  16  the geometric description  50  with the dimensional data  54 . Forming  12  may be achieved using the techniques and devices described above, including use of apparatuses  30 . Manufacturing methods  10  may comprise supplying  20  stock material  58 , optionally using a stock material supply  48 . 
         [0034]    The geometric description  50  of the desired fabricated part  60  may be decomposed into a series of layer-by-layer descriptions of the fabricated part  60 . Forming  12  generally includes serially forming the individual layers  62  from the layer descriptions. Forming  12  may include forming a select number of layers  62 , where the selected layers include at least one, and less than all, of the layers  62 . Each forming  12  results in an in-process part  64 , which initially includes the initially selected layers, and which, as forming  12  continues, eventually may include all of the layers  62 , and hence the entire fabricated part  60 . In addition to layers  62 , each forming  12  may include forming one or more temporary support structures that may support layers  62  of the in-process part  64 . The thickness of each layer  62  formed may be about 0.2 μm, about 0.5 μm, about 1 μm, about 2 μm, about 5 μm, about 10 μm, about 15 μm, about 20 μm, about 30 μm, about 40 μm, about 50 μm, about 100 μm, about 150 μm, about 200 μm, about 300 μm, about 400 μm, or about 500 μm; and/or about 0.2-100 μm, about 0.2-10 μm, about 0.5-10 μm, about 5-500 μm, about 5-100 μm, about 5-50 μm, about 10-40 μm, about 40-100 μm, or about 40-500 μm. The minimum feature size of each layer  62  formed may be about 0.05 μm, about 0.1 μm, about 0.2 μm, about 0.5 μm, 1 μm, about 2 μm, about 5 μm, about 10 μm, about 15 μm, about 20 μm, about 30 μm, about 40 μm, about 50 μm, about 100 μm, about 150 μm, about 200 μm, about 300 μm, about 400 μm, or about 500 μm; and/or about 0.05-100 μm, about 0.05-10 μm, about 0.1-2 μm, about 1-500 μm, about 1-50 μm, about 1-20 μm, about 5-500 μm, about 5-100 μm, or about 5-50 μm. 
         [0035]    If the geometric description  50  includes any features smaller than the minimum feature size, those features may be misformed. To avoid attempting to form features smaller than the minimum feature size, the geometric description  50  may be filtered to remove features smaller than the minimum feature size. If, upon inspection, features smaller than the minimum feature size are observed on the fabricated part  60 , those features may be spurious features, a result of machine malfunction rather than the design input. 
         [0036]    The acquiring  14  is synchronous with the forming  12 . This means that acquiring  14  is proximate in time with forming  12 . Acquiring  14  may be performed sequentially after the forming  12 , or may be performed at least partially concurrently with the forming  12 . Forming  12  may begin before acquiring  14  begins. Forming  12  may end before acquiring  14  begins and/or before acquiring  14  ends. 
         [0037]    Generally, the total time for forming  12  and acquiring  14  combined does not substantially differ from the total time for forming  12  alone. The acquisition time, the time to complete the acquiring  14 , may not be significantly more than, may be about equal to, may be less than or equal to, or may be significantly less than the formation time, the time to complete the forming  12 . The acquisition time may be less than about 1%, about 10%, about 50%, about 100%, or about 200% of the formation time; or about 1-200%, 1-100%, or 10-50% of the formation time. 
         [0038]    Acquiring  14  may include collecting dimensional data  54  about the in-process part  64 , a portion of the in-process part  64 , the layers  62 , or a portion of the layers  62 . Where the acquiring  14  collects dimensional data  54  about only a portion of the in-process part  64  or the layers  62 , dimensional data  54  may be accumulated to construct a complete model of the in-process part  64  or the layers  62 . 
         [0039]    Manufacturing methods  10  may comprise repeating  18  the forming  12  and the acquiring  14 , and/or may comprise repeating  18  the forming  12 , the acquiring  14 , and the comparing  16 . Repeating  18  may iterate for two or more cycles. Generally, repeating  18  is ceased once the fabricated part  60  is complete (all layers  62  are formed). 
         [0040]    After the fabricated part  60  is complete, all layers  62  are formed, and/or the repeating  18  has ceased, the fabricated part  60  part may be subject to one or more post-processing steps  22 . Illustrative, non-exclusive example post-processing steps  22  include inspecting the fabricated part, removing a spurious feature from the fabricated part, removing a support structure, surface finishing the fabricated part, annealing the fabricated part, hardening the fabricated part, cleaning the fabricated part, and coating the fabricated part. 
         [0041]    Manufacturing methods  10  comprise comparing  16  the input geometric description  50  and the acquired dimensional data  54 . Comparing  16  compares at least a portion of the geometric description  50  (i.e., the virtual model of the fabricated part) with at least a portion of the dimensional data  54  (i.e., the actual dimensions of the fabricated part as-built). Comparing  16  may occur as the forming  12  and/or acquiring  14  are occurring, or may occur after the fabricated part  60  is complete. Comparing  16  may include reporting and/or visualizing one or both of some portion of the geometric description  50  and some portion of the dimensional data  54 . Visualizing may include outputting to a display device images representative of the comparing  16 . Additionally or alternatively, comparing  16  may include reporting and/or visualizing dimensions derived from the geometric description  50  and/or the dimensional data  54 . 
         [0042]    Comparing  16  typically includes calculating a measured difference between the geometric description  50  and the dimensional data  54 . The measured difference may be reported, visualized, or used to affect further processing. For example, the measured difference may be compared to a predetermined tolerance limit. If the measured difference is out of tolerance (outside of, greater than, equal to, or less than the predetermined tolerance limit, as circumstances dictate), the manufacturing methods  10  (including forming  12  and repeating  18 ) may be ceased, avoiding building a non-compliant fabricated part  60 . Ceasing may include an immediate halt, decomposing the in-process part  64 , destruction of the in-process part  64 , and/or rendering the in-process part visibly non-compliant. Additionally or alternatively, if the measured difference is out of tolerance, comparing may include indicating the result of the comparison and/or the need for post-processing  22 , such as inspecting, removing a spurious feature, decomposing, destroying, or marking the indicated fabricated part  60 . 
         [0043]    The measured difference may be used in a feed-back or feed-forward manner to affect the forming  12 . Forming  12  may be based upon forming parameters, such as processing speed, resolution, stock material composition, temperature, and energy applied to the stock material. Where forming  12  is based upon forming parameters, the measured difference may be used to adjust current and/or future forming  12 . In particular, where the measure difference is approaching the predetermined tolerance limit, forming parameters may be adjusted to avoid becoming out of tolerance on the next iteration. Additionally or alternatively, where the measured difference is sufficiently different than the predetermined tolerance limit, forming parameters may be adjusted to conserve resources (e.g., time, material, energy) on the next iteration. 
         [0044]    Comparing  16  may compare optional support structure if included in the geometric description  50  and the dimensional data  54 . Additionally or alternatively, comparing  16  may filter, or otherwise exclude, portions of geometric description  50  and/or dimensional data  54  that correspond to optional support structure. By excluding support structure information, the true, as-built fabricated part dimensions may be compared with the intended design. 
         [0045]    Turning now to  FIG. 4 , illustrative, non-exclusive examples of additive manufacturing apparatuses  30  with integrated quality control inspection are schematically presented, with the apparatuses  30  optionally being configured to perform and/or facilitate methods  10  according to the present disclosure. Where appropriate, the reference numerals from the schematic illustrations of  FIG. 1-3  are used to designate corresponding components of apparatuses  30 ; however, the examples of  FIG. 4  are non-exclusive and do not limit apparatuses  30  to the illustrated embodiments of  FIG. 4 . That is, apparatuses  30  are not limited to the specific embodiments represented in  FIG. 4 , and apparatuses  30  may incorporate any number of the various aspects, configurations, characteristics, properties, etc. that are illustrated in and discussed with reference to the schematic representations of  FIGS. 1-3 , as well as variations thereof, without requiring the inclusion of all such aspects, configurations, characteristics, properties, etc. For the purpose of brevity, each previously discussed component, part, portion, aspect, region, etc. or variants thereof may not be discussed, illustrated, and/or labeled again with respect to  FIG. 4 ; however, it is within the scope of the present disclosure that the previously discussed features, variants, etc. may be utilized with the illustrated embodiments of  FIG. 4 . 
         [0046]    In  FIG. 4 , apparatus  30  is generally an additive manufacturing machine with a deposition device  32  and an integrated dimensional measuring device  34  for quality control. The deposition device  32  optionally includes a stock material supply  48 . The dimensional measuring device  34  optionally includes one or more detectors  42  (two illustrated) and one or more emitters  43  (one illustrated). In this illustration, the dimensional measuring device  34  is illustrated as an optical dimensional measuring device  34 . The layers  62  and the in-process part  64  are formed on a base tray  44 . The base tray may optionally carry a stock material supply  48 . To assist forming layers  62  on the base tray  44 , the deposition device  32  may translate along a lateral stage  45 , and the base tray  44  may translate along an axial, or vertical, stage  46 . The apparatus  30  optionally comprises a fabrication chamber  40  which encloses the deposition device  32 , the dimensional measuring device  34 , the base tray  44 , and the layers  62  as formed. 
         [0047]    The deposition device  32  may be configured to move away from the base tray  44  and the in-process part  64 , leaving a clear path for non-contact, e.g., optical, interrogation of the in-process part  64  by the dimensional measuring device  34 . Additionally or alternatively, the deposition device  32  may afford a clear path to a portion of the in-process part  64  and may move relative to the in-process part  64  to sequentially expose all portions of the in-process part  64 . In such case, the dimensional measuring device  34  may collect dimensional data  54  on portions of the in-process part  64  as portions are exposed by the deposition device  32 . Further, the dimensional measuring device  34  may be configured to reject data corresponding to the deposition device  32  when the deposition device  32  obscures measurement of a portion of the in-process part  64 . Accordingly, the acquiring  14  may be performed at least partially concurrently with the forming  12 . 
         [0048]    The whole apparatus  30  is controlled by a controller  36 , which is optionally a computer  38 . The controller  36  coordinates the operation of the deposition device  32  and the dimensional measuring device  34 , and may be programmed to perform any of the manufacturing methods  10  previously described. 
         [0049]    Illustrative, non-exclusive examples of inventive subject matter according to the present disclosure are described in the following enumerated paragraphs: 
         [0050]    A1. A manufacturing and quality control method for fabricating a fabricated part from a series of layers, the method comprising: 
         [0051]    sequentially forming one or more layers of the series of layers, using additive manufacturing from a stock material and based upon a geometric description, to form an at least partially completed in-process part; 
         [0052]    synchronously acquiring dimensional data about at least a portion of the one or more layers; and 
         [0053]    comparing at least a portion, optionally all, of the geometric description to at least some, optionally all, of the dimensional data. 
         [0054]    A2. The method of paragraph A1, wherein the synchronously acquiring includes acquiring dimensional data about the in-process part after each layer of the series of layers is formed. 
         [0055]    A3. The method of paragraph A1, wherein the synchronously acquiring includes acquiring dimensional data about the in-process part after each instance of two or more layers of the series of layers are formed. 
         [0056]    A4. The method of any of paragraphs A1-A3, wherein the synchronously acquiring is performed sequentially after the sequentially forming or is performed at least partially concurrently with the sequentially forming. 
         [0057]    A5. The method of any of paragraphs A1-A4, wherein the sequentially forming begins before the synchronously acquiring begins. 
         [0058]    A6. The method of any of paragraphs A1-A5, wherein the sequentially forming ends before the synchronously acquiring begins. 
         [0059]    A7. The method of any of paragraphs A1-A6, wherein the sequentially forming ends before the synchronously acquiring ends. 
         [0060]    A8. The method of any of paragraphs A1-A7, wherein the sequentially forming takes a formation time to complete, wherein the synchronously acquiring takes an acquisition time to complete, and wherein the acquisition time is not significantly more than, is about equal to, is less than or equal to, or is significantly less than the formation time. 
         [0061]    A9. The method of any of paragraphs A1-A8, wherein the sequentially forming takes a formation time to complete, wherein the synchronously acquiring takes an acquisition time to complete, and wherein the acquisition time is less than about 1%, about 10%, about 50%, about 100%, or about 200% of the formation time; or about 1-200%, 1-100%, 10-50% of the formation time. 
         [0062]    A10. The method of any of paragraphs A1-A9, further comprising: 
         [0063]    repeating the sequentially forming and the synchronously acquiring until each layer in the series of layers is formed into the fabricated part. 
         [0064]    A11. The method of any of paragraphs A1-A10, further comprising: 
         [0065]    repeating the sequentially forming, the synchronously acquiring, and the comparing until each layer in the series of layers is formed into the fabricated part. 
         [0066]    A12. The method of any of paragraphs A10-A11, further comprising: 
         [0067]    after the fabricated part is formed, completing one or more post-fabrication processing steps selected from the group of inspecting the fabricated part, removing a spurious feature from the fabricated part, removing a support structure, surface finishing the fabricated part, annealing the fabricated part, hardening the fabricated part, cleaning the fabricated part, and coating the fabricated part. 
         [0068]    A13. The method of any of paragraphs A1-A12, wherein the comparing includes reporting at least some, optionally all, of the dimensional data and/or dimensions derived from the dimensional data. 
         [0069]    A14. The method of any of paragraphs A1-A13, wherein the comparing includes reporting a difference between the dimensional data and the geometric description. 
         [0070]    A15. The method of any of paragraphs A1-A14, wherein the comparing includes visualizing at least some, optionally all, of the dimensional data. 
         [0071]    A16. The method of any of paragraphs A1-A15, wherein the comparing includes visualizing at least some, optionally all, of the geometric description. 
         [0072]    A17. The method of any of paragraphs A1-A16, wherein the comparing includes visualizing a difference between the dimensional data and the geometric description. 
         [0073]    A18. The method of any of paragraphs A15-A17, wherein the visualizing includes outputting to a display device images representative of the comparing. 
         [0074]    A19. The method of any of paragraphs A1-A18, wherein the comparing includes calculating a measured difference between the dimensional data and the geometric description. 
         [0075]    A19.1. The method of paragraph A19, wherein the comparing includes comparing a predetermined tolerance limit to the measured difference. 
         [0076]    A19.2. The method of any of paragraphs A19-A19.1, further comprising: 
         [0077]    ceasing the sequentially forming and/or the repeating the sequentially forming of the in-process part if the measured difference is outside of, greater than, equal to, or less than a predetermined tolerance limit. 
         [0078]    A19.3. The method of any of paragraphs A19-A19.2, further comprising: 
         [0079]    indicating the need for post-fabrication processing if the measured difference is outside of, greater than, equal to, or less than a predetermined tolerance limit. 
         [0080]    A19.4. The method of any of paragraphs A19-A19.3, wherein the sequentially forming includes sequentially forming based upon forming parameters, the method further comprising: 
         [0081]    adjusting the forming parameters based upon the measured difference; 
         [0082]    optionally wherein the forming parameters include one or more of processing speed, resolution, stock material composition, temperature, and energy applied to the stock material. 
         [0083]    A20. The method of any of paragraphs A1-A19.4, wherein the comparing includes excluding from further comparing an element of the geometric description that corresponds to optional support structure. 
         [0084]    A21. The method of any of paragraphs A1-A20, wherein the comparing includes excluding from further comparing an element of the dimensional data that corresponds to optional support structure. 
         [0085]    A22. The method of any of paragraphs A13-A21, wherein the comparing is performed by a computer. 
         [0086]    A23. The method of any of paragraphs A1-A22, further comprising: 
         [0087]    supplying the stock material. 
         [0088]    A24. The method of any of paragraphs A1-A23, wherein the stock material is one or more of a plastic, a polymer, a photopolymer, an acrylic, an epoxy, a thermoplastic, an ABS plastic, a polycarbonate, a polylactic acid, a biopolymer, a starch, a plaster, a wax, a clay, a metal, a metal alloy, a eutectic metal, a metal powder, an iron alloy, a stainless steel, a maraging steel, an aluminum alloy, a titanium alloy, a nickel alloy, a magnesium alloy, a cobalt chrome alloy, and a ceramic. 
         [0089]    A25. The method of any of paragraphs A1-A24, wherein the stock material is one or more of solid, granular, and liquid. 
         [0090]    A26. The method of any of paragraphs A1-A25, wherein the stock material is not gaseous. 
         [0091]    A27. The method of any of paragraphs A1-A26, wherein the geometric description is predetermined. 
         [0092]    A28. The method of any of paragraphs A1-A27, wherein the geometric description includes a description of the fabricated part, and/or the one or more layers. 
         [0093]    A29. The method of any of paragraphs A1-A28, wherein the geometric description includes, optionally is, a point cloud, a polygon mesh, a 2D layer representation and/or a 3D surface representation. 
         [0094]    A30. The method of any of paragraphs A1-A29, wherein the geometric description includes a description of one or more support structures. 
         [0095]    A31. The method of any of paragraphs A1-A30, wherein the forming includes one or more of selective laser sintering, direct metal laser sintering, selective heat sintering, electron beam freeform fabrication, electron beam melting, stereolithography, direct droplet deposition, fused deposition modeling, and extrusion. 
         [0096]    A32. The method of any of paragraphs A1-A31, wherein the sequentially forming includes forming one or more support structures. 
         [0097]    A33. The method of any of paragraphs A1-A32, wherein a thickness of each of the one or more layers is about 0.2 μm, about 0.5 μm, about 1 μm, about 2 μm, about 5 μm, about 10 μm, about 15 μm, about 20 μm, about 30 μm, about 40 μm, about 50 μm, about 100 μm, about 150 μm, about 200 μm, about 300 μm, about 400 μm, or about 500 μm; and/or about 0.2-100 μm, about 0.2-10 μm, about 0.5-10 μm, about 5-500 μm, about 5-100 μm, about 5-50 μm, about 10-40 μm, about 40-100 μm, or about 40-500 μm. 
         [0098]    A34. The method of any of paragraphs A1-A33, wherein a minimum feature size of each of the one or more layers is about 0.05 μm, about 0.1 μm, about 0.2 μm, about 0.5 μm, 1 μm, about 2 μm, about 5 μm, about 10 μm, about 15 μm, about 20 μm, about 30 μm, about 40 μm, about 50 μm, about 100 μm, about 150 μm, about 200 μm, about 300 μm, about 400 μm, or about 500 μm; and/or about 0.05-100 μm, about 0.05-10 μm, about 0.1-2 μm, about 1-500 μm, about 1-50 μm, about 1-20 μm, about 5-500 μm, about 5-100 μm, or about 5-50 μm. 
         [0099]    A35. The method of any of paragraphs A1-A34, wherein the synchronously acquiring includes detecting energy emanating from the portion of the one or more layers. 
         [0100]    A35.1. The method of paragraph A35, wherein the detecting includes detecting one or more of light, heat, and sound emanating from the portion of the one or more layers, optionally wherein the light includes one or more of visible light, IR light, NIR light, and UV light. 
         [0101]    A36. The method of any of paragraphs A1-A35, wherein the synchronously acquiring includes non-contact detection. 
         [0102]    A37. The method of any of paragraphs A1-A36, wherein the synchronously acquiring does not include contacting the portion of the one or more layers. 
         [0103]    A38. The method of any of paragraphs A1-A37, wherein the synchronously acquiring includes use of one or more of machine vision, 3D optical scanning, photogrammetry, and structured light imaging. 
         [0104]    A39. The method of any of paragraphs A1-A38, wherein the synchronously acquiring includes using a photodetector configured to receive light from the portion of the one or more layers; optionally wherein the photodetector includes one or more of a photodiode, a position sensitive device, an array detector, and a CCD. 
         [0105]    A40. The method of any of paragraphs A1-A39, wherein the synchronously acquiring includes imparting energy to the portion of the one or more layers; optionally wherein the energy does not, optionally does not significantly, interfere with the forming, and/or does not, optionally does not significantly, damage the portion of the one or more layers. 
         [0106]    A40.1. The method of paragraph A40, wherein the imparting includes illuminating with light, wherein the illuminating optionally includes one or more of transmitting ambient light, wide-field illumination, structured illumination, scanned point illumination, flash illumination, and modulated illumination. 
         [0107]    A41. The method of any of paragraphs A1-A40.1, wherein the dimensional data includes, and optionally is, a point cloud, a polygon mesh, an image, a 2D layer representation and/or a 3D surface representation. 
         [0108]    A42. The method of any of paragraphs A1-A41, wherein the dimensional data has an axial resolution of about 0.05 μm, about 0.1 μm, about 0.2 μm, about 0.5 μm, about 1 μm, about 2 μm, about 5 μm, about 10 μm, about 15 μm, about 20 μm, about 30 μm, about 40 μm, about 50 μm, about 100 μm, about 150 μm, about 200 μm, about 300 μm, about 400 μm, or about 500 μm; and/or about 0.05-50 μm, about 0.05-10 μm, about 0.2-5 μm, about 0.5-500 μm, about 0.5-100 μm, about 0.5-50 μm, about 0.5-10 μm, about 2-100 μm, about 2-40 μm, about 10-40 μm, about 40-100 μm, or about 40-500 μm. 
         [0109]    A43. The method of any of paragraphs A1-A42, wherein the dimensional data has a lateral resolution of about 0.01 μm, about 0.02 μm, about 0.05 μm, about 0.1 μm, about 0.2 μm, about 0.5 μm, about 1 μm, about 2 μm, about 5 μm, about 10 μm, about 15 μm, about 20 μm, about 30 μm, about 40 μm, about 50 μm, about 100 μm, about 150 μm, about 200 μm, about 300 μm, about 400 μm, or about 500 μm; and/or about 0.01-50 μm, about 0.01-5 μm, about 0.02-2 μm, about 0.2-500 μm, about 0.2-50 μm, about 0.2-10 μm, about 1-500 μm, about 1-50 μm, about 1-20 μm, about 5-500 about 5-100 μm, or about 5-50 μm. 
         [0110]    A44. The method of any of paragraphs A1-A43, wherein the sequentially forming includes depositing the stock material using a deposition device; wherein the synchronously acquiring includes detecting energy emanating from the portion of the one or more layers using an energy detector, and includes moving the deposition device relative to the in-process part to at least partially expose the energy detector to the energy emanating from the portion of the one or more layers. 
         [0111]    A45. The method of any of paragraphs A1-A44, wherein the sequentially forming includes depositing the stock material using a deposition device; wherein the synchronously acquiring includes detecting energy emanating from the portion of the one or more layers and energy emanating from the deposition device, and includes rejecting data corresponding to energy emanating from the deposition device. 
         [0112]    A46. A fabricated part formed by the method of any of paragraphs A1-A43. 
         [0113]    B1. An additive manufacturing apparatus, comprising: 
         [0114]    a deposition device; 
         [0115]    a dimensional measuring device; and 
         [0116]    a controller programmed to control the method of any of paragraphs A1-A45; 
         [0117]    wherein the deposition device is configured to perform the sequentially forming, and wherein the dimensional measuring device is configured to perform the synchronously acquiring. 
         [0118]    B2. The apparatus of paragraph B1, further comprising one or more of: 
         [0119]    a fabrication chamber; 
         [0120]    a base tray; 
         [0121]    a lateral stage; 
         [0122]    an axial stage; and 
         [0123]    a stock material supply. 
         [0124]    B3. The apparatus of any of paragraphs B1-B2, wherein the deposition device is configured to perform one or more of selective laser sintering, direct metal laser sintering, selective heat sintering, electron beam freeform fabrication, electron beam melting, stereolithography, direct droplet deposition, fused deposition modeling, and extrusion. 
         [0125]    B4. The apparatus of any of paragraphs B1-B3, wherein the deposition device includes one or more of a laser scanner, a laser, a light source, a heat source, and an electron beam. 
         [0126]    B5. The apparatus of any of paragraphs B1-B4, wherein the dimensional measuring device includes an energy detector, and optionally includes an energy emitter, and optionally when depending from paragraph B2 wherein the energy detector and energy emitter are positioned within the fabrication chamber. 
         [0127]    B5.1. The apparatus of paragraph B5, wherein the energy detector includes one or more of a machine vision device, a 3D optical scanner, a photodetector, a photodiode, a position sensitive device, an array photodetector, and a CCD. 
         [0128]    B5.2. The apparatus of any of paragraphs B5-B5.1, wherein the energy emitter includes one or more of a lamp, a wide-field illuminator, a structured illuminator, a laser, a laser scanner, a flash lamp, and a modulated illuminator. 
         [0129]    B6. The apparatus of any of paragraphs B1-B5.2, wherein when the apparatus comprises a fabrication chamber, the dimensional measuring device is at least temporarily within the fabrication chamber. 
         [0130]    B7. The apparatus of any of paragraphs B1-B6, wherein the controller includes, and optionally is, a computer. 
         [0131]    As used herein, the terms “selective” and “selectively,” when modifying an action, movement, configuration, or other activity of one or more components or characteristics of an apparatus, mean that the specific action, movement, configuration, or other activity is a direct or indirect result of user manipulation of an aspect of, or one or more components of, the apparatus. 
         [0132]    As used herein, the terms “adapted” and “configured” mean that the element, component, or other subject matter is designed and/or intended to perform a given function. Thus, the use of the terms “adapted” and “configured” should not be construed to mean that a given element, component, or other subject matter is simply “capable of” performing a given function but that the element, component, and/or other subject matter is specifically selected, created, implemented, utilized, programmed, and/or designed for the purpose of performing the function. It is also within the scope of the present disclosure that elements, components, and/or other recited subject matter that is recited as being adapted to perform a particular function may additionally or alternatively be described as being configured to perform that function, and vice versa. Similarly, subject matter that is recited as being configured to perform a particular function may additionally or alternatively be described as being operative to perform that function. 
         [0133]    The various disclosed elements of apparatuses and steps of methods disclosed herein are not required to all apparatuses and methods according to the present disclosure, and the present disclosure includes all novel and non-obvious combinations and subcombinations of the various elements and steps disclosed herein. Moreover, one or more of the various elements and steps disclosed herein may define independent inventive subject matter that is separate and apart from the whole of a disclosed apparatus or method. Accordingly, such inventive subject matter is not required to be associated with the specific apparatuses and methods that are expressly disclosed herein, and such inventive subject matter may find utility in apparatuses and/or methods that are not expressly disclosed herein.