Patent Description:
Additive manufacturing is a process in which a three-dimensional object is formed. In additive manufacturing, successive layers of material may be formed to create an object. Objects created using additive manufacturing may be of almost any shape.

Additive manufacturing may be used for a number of different purposes. For example, additive manufacturing is used to manufacture parts or prototypes for parts that are used in objects such as aircraft, automobiles, ships, trains, machinery, medical devices, and other suitable objects.

Additive manufacturing is used to manufacture parts using materials. These materials may be, for example, metals, polymers, ceramic materials, metal alloy, titanium, thermoplastics, and other suitable types of materials.

Additive manufacturing may be performed using a number of different technologies. For example, additive manufacturing may be performed by melting or softening a material to produce layers. This type of manufacturing may include selective laser melting, direct metal laser sintering, selective laser sintering, fused deposition modeling, or other suitable techniques.

In another example, additive manufacturing may be performed using metal wire processes. For example, an electron-beam wire feed system is an additive manufacturing system that feeds wire through a nozzle. The wire fed through the nozzle is melted by an electron-beam. This type of manufacturing is referred to as electron-beam additive manufacturing (EBAM). In another example, the wire may be melted using a laser beam. This type of additive manufacturing uses electron beams or lasers, which are often used for fabricating metal parts.

The melting of the wire forms oversized layers that become a preform for the part. A preform is an object that is further processed to form the part. These oversized layers may then be machined, or otherwise processed, to form the final shape for the part.

A preform design for the preform manufactured using the wire based additive manufacturing system is based on the part design for the part. These designs are electronic files, such as computer-aided design (CAD) files. For example, a designer modifies the part design to create the preform design. Thereafter, the designer sends the preform design to manufacturers for review.

A first manufacturer reviews the preform design and provides feedback with respect to the feasibility and cost for manufacturing a preform. A second manufacturer may review the preform design to identify the feasibility of machining the preform to form the part.

The first manufacturer may consider rules that are present with respect to laying down the wire to form the preform using an additive manufacturing system. For example, locations for the substrate, the direction that the wire is laid down, how a wire can be laid on a prior wire, and other rules are present.

The second manufacturer may consider other rules for machining a preform to form the part. Depending on the type of tools used for machining the preform to form the features in the part, different amounts of excess material may be needed to form different types of parts. For example, a part with holes, groups, protrusions, or other features may require different amounts of excess material in the preform to properly form those features when machining the preform.

Additionally, the review also may include cost estimates for manufacturing the preform, manufacturing the part from the preform, or some combination thereof. The cost to manufacture the part may be based on how much material is used for the preform, the cost to create a program for the additive manufacturing system, the cost to create a program for the machining system for machining the preform to form the part, and other factors.

The manufacturers provide feedback to the designer after reviewing the preform design. The designer may make modifications to the preform design based on the feedback from the manufacturer. For example, the preform design may not be usable for manufacturing a preform. As another example, the manufacturer may return a cost estimate that may be greater than desired for manufacturing the part using the preform manufactured from the preform design. As a result, the preform design may be changed to make the preform more feasible for machining to form the part. As another example, the preform design may be changed to reduce the amount of material resulting in the cost identified for manufacturing the part being reduced. This type of design modification and review may occur several times to finalize the preform design.

The steps involved in creating the preform design, reviewing the preform design, returning feedback, and modifying the preform design as needed may be performed several times. Currently, the steps may take more time than desired in creating the preform design for the preform to manufacture a part. Additionally, the creation and modification of the preform design is subjective based on people creating the preform design and reviewing the preform design.

For example, it would be desirable to have a method and apparatus that overcome a technical problem with the time and effort needed to create a preform design.

ZHENZHEN QUAN ET AL in "Additive manufacturing of multi-directional preforms for composites: opportunities and challenges", XP055210471, describes Additive manufacturing of multi-directional preforms for composites: opportunities and challenges.

<CIT> describes additive typology optimized manufacturing for multi-functional components.

<CIT> describes preforms for use in manufacturing composite structures and methods of making such preforms.

An embodiment of the present disclosure provides an apparatus. The apparatus comprises a part manager. The part manager identifies parameters for a part. Further, the part manager identifies a number of additional parameters used in manufacturing the part from a preform. Yet further, the part manager automatically generates a preform design for the preform using the parameters for the part and the number of additional parameters, wherein the preform design enables manufacturing the preform using an additive manufacturing system.

Another embodiment of the present disclosure provides a method for managing a part. The method comprises identifying, by a computer system, parameters for the part. Further, the method comprises identifying, by the computer system, a number of additional parameters used in manufacturing the part from a preform. Yet further, the method comprises automatically generating, by the computer system, a preform design for the preform using the parameters for the part and the number of additional parameters, wherein the preform design enables manufacturing the preform using an additive manufacturing system in a manufacturing environment.

Yet another embodiment of the present disclosure provides a preform management system. The preform management system comprises a part manager. The part manager identifies parameters for a part, and identifies a number of additional parameters for manufacturing the part from a preform. Further, the part manager generates a preform design for the preform. Yet further, the part manager displays the preform design on a display system. Still further, the part manager outputs feasibility information about the preform, wherein the preform design enables manufacturing the preform using an additive manufacturing system.

The illustrative embodiments, however, as well as a preferred mode of use, further objectives, and features thereof, will best be understood by reference to the following detailed description of an illustrative embodiment of the present disclosure when read in conjunction with the accompanying drawings, wherein:.

The illustrative embodiments recognize and take into account one or more different considerations. The illustrative embodiments recognize and take into account that the current steps performed by the designer and manufacturer to create a preform design to manufacture a preform and then process the preform to form a part may not be as accurate as desired.

The illustrative embodiments recognize and take into account that this technical issue may arise from the current steps used to create preform designs. The illustrative embodiments recognize and take into account that designers often do not consider one or more of the thickness of layers formed by a particular type of additive manufacturing system, the directions for laying wires, the direction in which layers are built on the substrate, substrate locations, excess material, and other considerations that affect the amount of material needed to form a preform when creating a preform design from a part design.

The illustrative embodiments recognize and take into account that considering all of the different considerations may take more time than desired and also cost more than desired. If fewer factors are taken into account, then the feasibility and cost estimates for manufacturing a preform and then processing the preform to form a part may not be as accurate as desired.

Thus, the illustrative embodiments provide a method and apparatus for managing the part. In one illustrative example, a computer system identifies parameters for a part and identifies a number of additional parameters used in manufacturing the part from a preform. The computer system also automatically generates a preform design for the preform using the parameters for the part and the number of additional parameters, wherein the preform design enables manufacturing the preform using an additive manufacturing system in a manufacturing environment.

With reference now to the figures and, in particular, with reference to <FIG>, an illustration of a block diagram of a part environment is depicted in accordance with an illustrative embodiment. In this illustrative example, part environment <NUM> includes part manufacturing system <NUM> that operates to manufacture parts <NUM>. Parts <NUM> may be used to manufacture object <NUM> or perform maintenance on object <NUM>.

Object <NUM> may take a number of different forms. For example, object <NUM> may be selected from one of a mobile platform, a stationary platform, a land-based structure, an aquatic-based structure, or a space-based structure. More specifically, object <NUM> may be a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, a power plant, a bridge, a dam, a house, a manufacturing facility, a building, or other suitable objects. Object <NUM> may also be selected from one of an engine, an engine housing, a flap, a horizontal stabilizer, a strut, a generator, a computer, a speaker, a biomedical device, a communications device, or some other suitable object.

In this illustrative example, part <NUM> in parts <NUM> may be manufactured using preform <NUM>. As depicted, preform <NUM> is manufactured by additive manufacturing system <NUM>. Preform <NUM> may be processed by machining system <NUM> to form part <NUM>.

Additive manufacturing system <NUM> includes one or more pieces of equipment that create preform <NUM> by forming successive layers of one or more materials. As depicted, additive manufacturing system <NUM> may include at least one of an electron beam additive manufacturing system, a powder based electron beam additive manufacturing system, a wire based electron beam additive manufacturing system, a laser additive manufacturing system, a selective heat sintering system, a laser sintering system, a fusion deposition modeling system, or some other suitable system that performs additive manufacturing.

As used herein, the phrase "at least one of", when used with a list of items, means different combinations of one or more of the listed items may be used, and only one of each item in the list may be needed. In other words, "at least one of" means any combination of items and number of items may be used from the list, but not all of the items in the list are required. The item may be a particular object, thing, or a category.

Of course, any combination of these items may be present. In some illustrative examples, "at least one of" may be, for example, without limitation, two of item A; one of item B; and ten of item C; four of item B and seven of item C; or other suitable combinations.

In the illustrative example, machining system <NUM> includes one or more pieces of equipment that remove materials from preform <NUM> to form part <NUM>. As depicted, machining system <NUM> may be selected from at least one of a lathe, a milling machine, an electrical discharge machining system, a water jet cutting system, a laser cutting system, or some other suitable piece of equipment.

In this illustrative example, part manager <NUM> manages parts <NUM>, including part <NUM>. Part manager <NUM> may be implemented in software, hardware, firmware, or a combination thereof. When software is used, the operations performed by part manager <NUM> may be implemented in program code configured to run on hardware, such as a processor unit. When firmware is used, the operations performed by part manager <NUM> may be implemented in program code and data and stored in persistent memory to run on a processor unit. When hardware is employed, the hardware may include circuits that operate to perform the operations in part manager <NUM>.

In the illustrative examples, the hardware may take a form selected from at least one of a circuit system, an integrated circuit, an application specific integrated circuit (ASIC), a programmable logic device, or some other suitable type of hardware configured to perform a number of operations. With a programmable logic device, the device may be configured to perform the number of operations. The device may be reconfigured at a later time or may be permanently configured to perform the number of operations. Programmable logic devices include, for example, a programmable logic array, a programmable array logic, a field programmable logic array, a field programmable gate array, and other suitable hardware devices. Additionally, the processes may be implemented in organic components integrated with inorganic components and may be comprised entirely of organic components, excluding a human being. For example, the processes may be implemented as circuits in organic semiconductors.

Computer system <NUM> is a physical hardware system and includes one or more data processing systems. When more than one data processing system is present, those data processing systems are in communication with each other using a communications medium. The communications medium may be a network. The data processing systems may be selected from at least one of a computer, a server computer, a tablet, or some other suitable data processing system.

As depicted, part manager <NUM> identifies parameters <NUM> for part <NUM>. Parameters <NUM> may be obtained from part design <NUM>. Part design <NUM> may be a computer aided design (CAD) model, a two-dimensional model, or a three-dimensional model of part <NUM>. Parameters <NUM> in part design <NUM> are information about part <NUM>. For example, parameters <NUM> include dimensions for part <NUM> and may also include at least one of materials, processes, inspection information, tolerances, manufacturing excesses, finishing operations, grain direction, machining techniques, or other suitable parameters about part <NUM>.

For example, parameters <NUM> may include parameters relating to machining techniques, such as waterjet, laser, thermal, or other suitable machining techniques. As another example, parameters <NUM> include parameters that take into account considerations for the preform that are needed to perform finishing operations, such as paint, prime anodize, or other suitable types of finishing operations.

Part manager <NUM> also identifies a number of additional parameters <NUM> used in manufacturing part <NUM> from preform <NUM>. As used herein, "a number of", when used with reference to items, means one or more items. For example, a number of additional parameters <NUM> is one or more of additional parameters <NUM>.

In this illustrative example, the number of additional parameters <NUM> is information used in creating preform design <NUM> for preform <NUM>. As depicted, the number of additional parameters <NUM> is selected from at least one of a build direction, a substrate location, a substrate thickness, an additive material offset, a plate excess, a substrate excess, a material density, an additive layer thickness, a plate thickness, or some other suitable type of parameter.

As depicted, the number of additional parameters <NUM> selected and the values for the number of additional parameters <NUM> may be using considerations selected from at least one of considerations for forming preform <NUM> from preform design <NUM> based on the particular type of additive manufacturing system, considerations for processing preform <NUM> by machining system <NUM> to form part <NUM>, or other suitable types of factors that may be used in creating preform design <NUM>. Other considerations may include, for example, selections of material, costs, the manner in which material lays up to form layers, excess material needed for machining, excess material needed to handle the preform, environmental concerns, and other suitable considerations.

In this illustrative example, part manager <NUM> automatically generates preform design <NUM> for preform <NUM> using parameters <NUM> for part <NUM> and the number of additional parameters <NUM>. As depicted, automatically generating preform design <NUM> means that part manager <NUM> generates preform design <NUM> without needing to receive user input to create preform design <NUM>. Preform design <NUM> enables manufacturing preform <NUM> using additive manufacturing system <NUM>.

Further, part manager <NUM> may manufacture preform <NUM> using preform design <NUM>. In other words, part manager <NUM> may control the operation of additive manufacturing system <NUM> to manufacture preform <NUM> using preform design <NUM>.

For example, part manager <NUM> may generate instructions for additive manufacturing system <NUM> using preform design <NUM> and the number of additional parameters <NUM>. Preform <NUM> is manufactured using the instructions and additive manufacturing system <NUM>. As depicted, the instructions are used by additive manufacturing system <NUM> to form preform <NUM> for part <NUM>. The instructions are selected from at least one of commands, program code, source code, machine code, or some other suitable types of instructions that may be used to control additive manufacturing system <NUM>.

After preform <NUM> has been manufactured using additive manufacturing system <NUM>, part manager <NUM> may process preform <NUM> to form part <NUM>. For example, part manager <NUM> may machine preform <NUM> to form part <NUM> by controlling machining system <NUM>.

With reference now to <FIG>, an illustration of a block diagram showing data flow in managing a part is depicted in accordance with an illustrative embodiment. In the illustrative examples, the same reference numeral may be used in more than one figure. This reuse of a reference numeral in different figures represents the same element in the different figures.

In this illustrative example, computer system <NUM> has display system <NUM> and input system <NUM>. Display system <NUM> is a physical hardware system and includes one or more display devices on which graphical user interface <NUM> may be displayed. The display devices may include at least one of a light emitting diode (LED) display, a liquid crystal display (LCD), an organic light emitting diode (OLED) display, or some other suitable device on which graphical user interface <NUM> can be displayed.

Operator <NUM> is a person that may interact with part manager <NUM> via graphical user interface <NUM>. This interaction may be through user input <NUM> to graphical user interface <NUM> generated by input system <NUM> in computer system <NUM>. Input system <NUM> is a physical hardware system and may be selected from at least one of a mouse, a keyboard, a trackball, a touchscreen, a stylus, a motion sensing input device, a cyberglove, or some other suitable type of input device.

As depicted, part manager <NUM> in computer system <NUM> receives a selection of part design <NUM> for part <NUM> in user input <NUM>. The selection in user input <NUM> may be a selection of a computer aided design (CAD) file or some other file in which part design <NUM> is located.

Part manager <NUM> uses the selection in user input <NUM> to identify part design <NUM>. With the identification of part design <NUM>, part manager <NUM> identifies parameters <NUM> for part <NUM> from part design <NUM>.

Further, part manager <NUM> also may receive the number of additional parameters <NUM> as part of selection <NUM> in user input <NUM>. The number of additional parameters <NUM> may be received directly in user input <NUM>. In other illustrative examples, the number of additional parameters <NUM> may be received as the identification of a file in which the number of additional parameters <NUM> is located. In still other illustrative examples, the number of additional parameters <NUM> may be located in a default configuration file that is identified by part manager <NUM> without requiring the user input <NUM>.

With the identification of parameters <NUM> for part <NUM> and the identification of additional parameters <NUM>, part manager <NUM> automatically generates preform design <NUM>. Generation of preform design <NUM> occurs automatically such that additional user input from operator <NUM> or some other operator is unnecessary to generate preform design <NUM>. For example, preform design <NUM> is not made by user input <NUM> from operator <NUM> modifying part design <NUM> displayed in graphical user interface <NUM> on display system <NUM>.

In this illustrative example, part manager <NUM> may repeat identifying the number of additional parameters <NUM> and automatically generating preform design <NUM> until preform design <NUM> meets a number of desired goals. The desired goals may correspond to the feasibility and cost for manufacturing a preform. The desired goals may also correspond the feasibility and cost of machining the preform to form the part. In performing these operations, part manager <NUM> changes the number of additional parameters <NUM>.

For example, values for the number of additional parameters <NUM> may be changed by entering values in user input <NUM>. By changing the values, the amount of material, the time needed, or the difficulty in manufacturing preform <NUM> may be reduced.

Further, the particular additional parameters in the number of additional parameters <NUM> used may be changed. In other words, one or more different parameters may be used for the number of additional parameters <NUM>.

Part manager <NUM> also may generate output <NUM>. In this illustrative example, output <NUM> is information related to preform design <NUM>. In particular, output <NUM> may be generated using preform design <NUM>.

For example, output <NUM> may include evaluation information <NUM> that is used to determine whether to repeat identifying the number of additional parameters <NUM> and automatically generating preform design <NUM> with parameters <NUM> and changes to the number of additional parameters <NUM>. Evaluation information <NUM> is generated using preform design <NUM>. In this manner, iterations of preform design <NUM> may be generated until preform design <NUM> meets desired goals.

For example, evaluation information <NUM> identified by part manager <NUM> may include at least one of a weight for preform <NUM> in <FIG>, a cost estimate for preform <NUM>, a manufacturing time for preform <NUM>, a machining time to form part <NUM> in <FIG> from preform <NUM>, a type of part, or other suitable information that may be used to evaluate the feasibility of manufacturing preform <NUM> using preform design <NUM>, manufacturing part <NUM> from preform <NUM>, or some combination thereof.

The change to preform design <NUM> also may be made in response to analyzing evaluation information <NUM>. In this illustrative example, the analysis of evaluation information <NUM> may be made by at least one of part manager <NUM>, operator <NUM>, or some other entity.

For example, if evaluation information <NUM> indicates that the cost estimate for manufacturing preform <NUM> from preform design <NUM> is greater than desired, the number of additional parameters <NUM> may be changed in an effort to reduce the cost estimate. Changes to the number of additional parameters <NUM> results in a change in preform design <NUM> that may more closely meet a number of goals for preform design <NUM>.

As another illustrative example, output <NUM> also may include visualization <NUM>. Visualization <NUM> is a visualization of preform design <NUM> that is displayed in graphical user interface <NUM> on display system <NUM>. For example, preform design <NUM> may be displayed in graphical user interface <NUM> by a computer-aided design application running on computer system <NUM>.

Visualization <NUM> may be viewed by operator <NUM> to determine whether to make changes to the number of additional parameters <NUM>. If changes are made in the values or which parameters are used for the number of additional parameters <NUM>, preform design <NUM> may be automatically generated using these changes.

In this manner, iterations of preform design <NUM> also may be made through visualization <NUM>. These changes to the number of additional parameters <NUM> may result in a change to preform design <NUM> made by part manager <NUM>.

Further, output <NUM> may be used for other purposes in managing part <NUM>. For example, evaluation information <NUM> in output <NUM> may be used to manage the manufacturing of at least one of preform <NUM> or part <NUM> in <FIG>. As another example, evaluation information <NUM> in output <NUM> may be used to determine whether preform <NUM> should be manufactured using additive manufacturing system <NUM> in <FIG>. As yet another example, output <NUM> may be used to select a particular type of system in additive manufacturing system <NUM> to manufacture preform <NUM>.

In one illustrative example, one or more technical solutions are present that overcome a technical problem with the time and effort needed to create a preform design. As a result, one or more technical solutions may provide a technical effect in which preform design <NUM> is generated automatically without requiring user input <NUM>.

Further, the generation of preform design <NUM> is an improvement over currently used techniques in which human operators create preform designs using computer-aided design applications. For example, part manager <NUM> automatically generates part design <NUM> without needing user input <NUM> from operator <NUM>.

As described above, one or more the illustrative examples provide a method and apparatus that overcome a technical problem with the time and effort needed to create a preform design. In the illustrative example, part manager <NUM> automatically generates preform design <NUM> from parameters <NUM> for part design <NUM> and a number of additional parameters <NUM> used in manufacturing preform <NUM>.

In the illustrative example, part manager <NUM> allows for changes to preform design <NUM> to be made more quickly as compared to currently used techniques. Further, part manager <NUM> generates preform design <NUM> without needing operator <NUM> to modify part design <NUM> displayed in graphical user interface <NUM> to form preform design <NUM>. By eliminating the need for this operation, preform design <NUM> may be generated more quickly and accurately as compared to currently used techniques.

Further, with the use of additional parameters <NUM> in conjunction with parameters <NUM> from part design <NUM>, preform design <NUM> may be generated by part manager <NUM> in a manner that takes into account different considerations desirable for processing preform <NUM> manufactured by additive manufacturing system <NUM> in <FIG> to create part <NUM>.

The illustration of part environment <NUM> and the different components for part environment <NUM> in <FIG> and <FIG> are not meant to imply physical or architectural limitations to the manner in which an illustrative embodiment may be implemented. Other components in addition to or in place of the ones illustrated may be used. Some components may be unnecessary. Also, the blocks are presented to illustrate some functional components. One or more of these blocks may be combined, divided, or combined and divided into different blocks when implemented in an illustrative embodiment.

For example, part environment <NUM> may omit machining system <NUM> in implementations in which part manufacturing system <NUM> manufactures preforms and not parts. As another example, part environment <NUM> excludes additive manufacturing system <NUM> and machining system <NUM>. In this type of implementation, part manager <NUM> in part environment <NUM> may evaluate the feasibility of manufacturing preforms for parts <NUM> from preform designs.

With reference now to <FIG>, illustrations of a process for generating a preform design are depicted in accordance with illustrative embodiments. With reference first to <FIG>, a graphical user interface for identifying additional parameters is depicted in accordance with an illustrative embodiment. In this figure, graphical user interface <NUM> displays window <NUM>. Graphical user interface <NUM> is an example of one implementation for graphical user interface <NUM> that is displayed by part manager <NUM> as shown in block form in <FIG>.

In this illustrative example, window <NUM> includes additional parameters <NUM>. Additional parameters <NUM> may have values set through user input to graphical user interface <NUM>. As depicted, additional parameters <NUM> are parameters for manufacturing a part from a preform.

In this illustrative example, additional parameters <NUM> include additive material offset <NUM>, plate excess <NUM>, substrate excess <NUM>, material density <NUM>, additive layer thickness <NUM>, and plate thickness <NUM>. These additional parameters in additional parameters <NUM> are selected for an electron beam additive manufacturing system that uses wire to form layers for a preform. For example, some of additional parameters <NUM> take into account the manner in which the substrate may be laid up to form a preform that may then be machined to form the part.

As depicted, additive material offset <NUM> is the amount of excess material that is needed for machining a preform to form a part. Plate excess <NUM> is the amount of additional material needed in the plate for tooling features. A plate is a type of substrate on which the layers may be formed through additive manufacturing.

The plate may have different shapes. For example, the plate may be square, rectangular, circular, trapezoidal, or have some other shape. The plate may be planar, curved, or have some other shape. These tooling features may include tooling holes, a flange used to hold a plate in place, and other types of features that are used in manufacturing the preform.

In this illustrative example, substrate excess <NUM> is the amount of material in the substrate that is needed for features that may be part of the preform. For example, the substrate may be selected to have a thickness for a base for the preform. Substrate excess <NUM> also may include excess material that may be machined to form features such as holes, groups, or other features for the preform.

Material density <NUM> is the density of the wire that is heated to form the layers for the preform. As depicted, additive layer thickness <NUM> is the thickness of each layer that is formed during the additive manufacturing process to manufacture the preform. In this illustrative example, plate thickness <NUM> is the amount of excess in the substrate that is needed for a desired plate thickness for the preform.

With reference next to <FIG>, an illustration of a graphical user interface displaying a part design is depicted in accordance with an illustrative embodiment. In this figure, part design <NUM> is displayed in graphical user interface <NUM>. The display of part design <NUM> allows for a selection of facet <NUM> for the substrate location and build direction of the preform.

In this illustrative example, the selection may be made by user input selecting facet <NUM>. In another illustrative example, facet <NUM> may be selected by part manager <NUM> in <FIG> performing an analysis on part design <NUM>. Analysis may select the best facet in part design <NUM> for manufacturing a preform for the part.

The best facet may be varied, depending on the desired goal. For example, if the goal is to avoid forming layers that extend from two directions of the substrate, then the facet may be selected to avoid a preform design with features extending from both sides of the substrate.

In this illustrative example, a facet is a face on part design <NUM>. In this illustrative example, the build direction is the direction of arrow <NUM> perpendicular to facet <NUM> on part design <NUM>. The build direction is the direction that the layers are formed or built up on the substrate.

With reference now to <FIG>, an illustration of the identification of a substrate is depicted in accordance with an illustrative embodiment. In this illustrative example, substrate <NUM> is identified as displayed in graphical user interface <NUM>. Substrate <NUM> is the substrate on which layers are formed by an electron beam additive manufacturing system that uses a wire.

In this illustrative example, substrate <NUM> is identified using additional parameters <NUM> in <FIG>. The identification of substrate <NUM> includes a location, as well as dimensions for substrate <NUM>.

Further, the selected facet is used to identify a substrate. Parameters that may be used to identify the substrate include, for example, additive material offset <NUM> and plate thickness <NUM> in <FIG>.

Turning next to <FIG>, an illustration of cross-sections is depicted in accordance with an illustrative embodiment. In this illustrative example, part manager <NUM> in <FIG> identifies cross-sections <NUM> in part design <NUM>. As depicted, cross-sections <NUM> are parallel to substrate <NUM>.

The thicknesses of the cross-sections <NUM> are identified using additional parameters <NUM> in <FIG>. For example, cross-sections <NUM> are identified using additive layer thickness <NUM> in additional parameters <NUM> in <FIG>.

In <FIG>, an illustration of cross-sections projected onto a substrate is depicted in accordance with an illustrative embodiment. As depicted, two-dimensional geometries <NUM> from cross-sections <NUM> in part design <NUM> in <FIG> are created by part manager <NUM> in <FIG> as shown in graphical user interface <NUM>. In this example, two-dimensional geometries <NUM> are two-dimensional cross-sections. In this illustrative example, two-dimensional geometries <NUM> are created by part manager <NUM> from a projection of cross-sections <NUM> onto substrate <NUM>.

Turning next to <FIG>, an illustration of shaded cross-sections is depicted in accordance with an illustrative embodiment. In this figure, shaded cross-sections <NUM> are shown in graphical user interface <NUM>. Shaded cross-sections <NUM> are created by part manager <NUM> in <FIG> from Boolean unions of two-dimensional geometries <NUM> in <FIG>.

In the illustrative example, the union "C" of two regions, region "A" and region "B", is a new region where any point that was in either region "A" or region "B" or both region "A" and region "B" is in the new region "C. " These two regions may be two cross-sections. Then the "shaded" region for layer "X" is a region that is the union of "X," all of the regions corresponding to layers further from the substrate as "X" and on the same side of and including "X.

With reference now to <FIG>, an illustration of layers for a preform design is depicted in accordance with an illustrative embodiment. As depicted, part manager <NUM> in <FIG> creates layers <NUM> for a preform from shaded cross-sections <NUM> in <FIG>. Layers <NUM> include in-plane excesses. In-plane excesses are the material excesses that extend in the direction of the plane of the layers.

In the illustrative example, cross-sections are a set of curves. The set of curves are initially produced by intersecting a plane with the solid, and subsequent curve sets are generated by geometric operations. The three-dimensional cross-sections are the cross-sections having separation in the direction perpendicular to the substrate.

The two-dimensional cross-sections are formed by the projection of the three-dimensional cross sections onto the substrate plane and the subsequent in-plane curve sets generated by geometric operations. These geometric operations may be, for example, union and offset. With the two-dimensional cross-sections, all of the curves from these cross-sections are in a single plane and can be identified using two coordinates.

In the illustrative examples, layers are the solid layers in the resultant geometry. For example, the layers in the depicted example are non-substrate layers that are formed by the additive manufacturing tool.

Next, in <FIG>, an illustration of layers for a preform on a part design is depicted in accordance with an illustrative embodiment. In this illustrative example, layers <NUM> for a preform are shown on part design <NUM> through an inverse of the transformation shown from <FIG>.

Turning to <FIG>, an illustration of a three-dimensional geometry is depicted in accordance with an illustrative embodiment. In this illustrative example, three-dimensional geometry <NUM> is displayed in graphical user interface <NUM>. Three-dimensional geometry <NUM> is created using layers <NUM> and part design <NUM> in <FIG>.

With reference now to <FIG>, an illustration of a preform design is depicted in accordance with an illustrative embodiment. In this illustrative example, part manager <NUM> in <FIG> creates preform design <NUM> using three-dimensional geometry <NUM> in <FIG>. As depicted, preform design <NUM> includes preform <NUM> and substrate <NUM>.

Turning now to <FIG>, an illustration of output for evaluating a preform design is depicted in accordance with an illustrative embodiment. In this illustrative example, output <NUM> is an example of evaluation information <NUM> in <FIG>. In this illustrative example, output <NUM> is a volumetric analysis of preform design <NUM>. As depicted, output <NUM> includes part weight <NUM>, preform weight <NUM>, substrate weight <NUM>, additive weight <NUM>, plate dimensions <NUM>, and buy to fly <NUM>.

In this illustrative example, part weight <NUM> is the weight of the part corresponding to part design <NUM> after machining a preform manufactured using preform design <NUM> in <FIG>. Preform weight <NUM> is the weight of a preform manufactured using preform design <NUM>. Substrate weight <NUM> is the weight of the substrate on which layers are formed. Additive weight <NUM> is the weight of the layers formed on the substrate.

In this illustrative example, plate dimensions <NUM> are the dimensions of the substrate. Buy to fly <NUM> is a metric used to define how much raw material is wasted when machining is performed on a preform to form a part. For example, if <NUM> pounds of titanium are used to produce a part that weighs <NUM> pounds, buy to fly <NUM> is equal to <NUM>.

The illustration of the graphical user interface in <FIG> is not meant to imply limitations in the manner in which other illustrative embodiments may be implemented. For example, additional parameters <NUM> in <FIG> may change depending on the type of additive manufacturing system used. As depicted, additional parameters <NUM> are parameters for additive manufacturing that utilizes a wire based electron-beam additive manufacturing system. A powder based additive manufacturing system may use other types of parameters in addition to or in place of the ones illustrated in additional parameters <NUM>.

As another example, cross-sections <NUM> in <FIG> are shown only in one direction from substrate <NUM>. Depending on the selection of a facet, the sections may extend in two directions that are opposite to each other and perpendicular to substrate <NUM>.

Turning next to <FIG>, an illustration of a flowchart of a process for managing a part is depicted in accordance with an illustrative embodiment. The process illustrated in <FIG> may be implemented in part environment <NUM> in <FIG>. The different operations may be implemented in part manager <NUM> to manage the manufacturing of preform <NUM> and part <NUM> from preform <NUM> in <FIG>.

The process begins by identifying parameters for a part (operation <NUM>). These parameters may be obtained from a part design for the part. For example, the parameters may be located in a computer-aided design file. In other illustrative examples, these parameters may be located in a file, such as a spreadsheet or some other data structure.

The process then identifies a number of additional parameters used in manufacturing the part from a preform (operation <NUM>). These parameters are used with the parameters for the part to generate a preform design.

The process automatically generates a preform design for the preform using the parameters for the part and the number of additional parameters (operation <NUM>). The preform design enables manufacturing the preform using an additive manufacturing system in a manufacturing environment.

Next, a determination is made as to whether the preform design meets a number of goals (operation <NUM>). In determining whether the preform design meets a number of goals, the preform design may be evaluated using output that is related to the preform design. For example, the output may be a visualization preform design on a display system, valuation information generated for the preform design, or some other suitable information.

If the preform design meets the number of goals, the process terminates. Otherwise, the process returns to operation <NUM> to identify a number of additional parameters. When the number of additional parameters is identified again, the number of additional parameters identified may be different values from the values used previously for the number of additional parameters. In another illustrative example, the number of additional parameters may need to use other types of parameters. Either the values, the type of parameters, or some combination of these two may be used to identify the number of additional parameters.

Turning next to <FIG>, an illustration of a flowchart of a process for managing the manufacturing of a part from a preform is depicted in accordance with an illustrative embodiment. The process begins by applying a policy on manufacturing parts to a preform design for a preform (operation <NUM>). The policy may be one or more rules regarding the manufacturing parts. This policy may include a number of rules relating to weight, cost, tolerances, or other suitable factors that may be used in determining whether a preform is suitable for use in manufacturing a part.

A determination is made as to whether to use an additive manufacturing process to manufacture the preform based on the application of the policy to the design for the preform (operation <NUM>). The process terminates thereafter.

Turning now to <FIG>, an illustration of a flowchart of a process for creating a preform design is depicted in accordance with an illustrative embodiment. The process illustrated in <FIG> may be implemented in part manager <NUM> in part environment <NUM> in <FIG>. The different operations illustrated in <FIG> correspond to the visualizations of operations performed in <FIG>.

The process begins by identifying additional parameters for manufacturing a part from a preform (operation <NUM>). The additional parameters in operation <NUM> are additional parameters <NUM> in <FIG>. The additional parameters describe information such as offsets, excesses, or some combination thereof that are needed to machine the preform to form the part; the location and thicknesses of the substrate; material density; and other suitable information that may be needed to generate the preform design that can be processed to form a part.

The process then identifies a facet for a substrate location (operation <NUM>). In this illustrative example, a facet is a face or side of the preform design. The selection sets the build direction. The build direction is the direction in which layers are formed on a substrate to manufacture the preform.

For example, the facet may be selected such that the layers are formed in one direction from the substrate rather than in two directions. This selection may reduce the cost of manufacturing the preform. In the illustrative example, the facet may be identified by user input or through an analysis to identify optimal facet manufacturing a preform to meet desired goals.

The process then identifies a location for the substrate with respect to the part design (operation <NUM>). In this operation, cross-sections of the three-dimensional geometry for the part design are calculated such that they are parallel to the selected facet. These cross-sections are calculated starting in the plane of the facet and then moving in steps in both directions from the plane in which the facet lies. The size of the step may be set by a substrate optimality resolution parameter. The parameter defines a step size for optimal substrate location.

In this operation, cross-sections of the three-dimensional geometry for the part design are calculated such that they are parallel to the selected facet. These cross-sections are calculated starting in the plane of the facet and steps in both directions from the plane in which the facet lies. The steps are those set by the substrate optimality resolution parameter.

The larger area of the two outer cross-sections is used to determine whether the next cross section should be in the up or down direction. This process is repeated until the desired substrate thickness has been reached. In this illustrative example, the substrate thickness includes excesses.

The process then identifies cross-sections in the three-dimensional part design (operation <NUM>). In this illustrative example, cross-sections of the three-dimensional geometry of the part design are calculated in both directions from the plane of the facet. These cross-sections are calculated using the layer thickness as an offset for each subsequent cross-section until the cross-section is empty. As depicted, the offset is a distance from the substrate.

The process then translates the cross-sections in the three-dimensional geometry of the part design into a two-dimensional form (operation <NUM>). In operation <NUM>, all of the cross-sections are projected onto the substrate, creating cross-sections with two-dimensional geometries. For example, the three-dimensional cross-sections in <FIG>, <FIG>, and <FIG> have separation in the direction perpendicular to the substrate.

The two-dimensional cross-sections in <FIG>, <FIG>, and <FIG> are all in a common plane and could be described using two coordinates. Additionally, the process may also attempt to clean any inconsistencies resulting from poor three-dimensional geometry or degenerate cross-section situations.

The additive manufacturing systems receive instructions, such as programs or commands, to manufacture the preform. Due to a variety of software options, geometry specifications, file types, and computer-aided design (CAD) operator behaviors, the geometry in the geometry kernel might have inconsistencies due to inconsistencies in the geometry or in the ability of the geometric kernel to make process of the file.

As a result, inconsistencies, such as a hole or other connectivity error, may be present in the surface of the part. The hole might lead to a cross-section that does not consist of a number of closed curves. As a result, "cleaning" may be performed in an attempt to close these gaps. In these illustrative examples, the inconsistencies may include gaps, zero length curves, or other inconsistencies that may be present.

The process then creates shaded cross-sections (operation <NUM>). The shaded cross-sections are created using Boolean unions on the two-dimensional geometries created in operation <NUM>. These Boolean unions "shade" the layers farther from the substrate onto those below them. The result will be that, on either side, any cross-section will contain every cross-section that is farther than itself from the substrate.

The process then identifies offset regions for material excesses (operation <NUM>). In operation of <NUM>, the boundaries of the shaded cross-sections are adjusted by offsetting the shaded cross-sections from operation <NUM> and taking into account in-plane material excesses. For example, interior openings may take into account such that the openings do not disappear during formation of the preform.

This adjustment results in two-dimensional cross-sections. These offset regions are regions in which excess material is present such that the preform may be machined to form the part. These regions of excess material also may be regions that are used by tooling in the additive manufacturing system, the machining system, or some combination thereof.

In the list of examples, the cross-sections are considered regions in which groups of points are defined by interior and exterior boundaries. For example, the offset "B" of region "A" by "X" would be the set all of points "p" such that there exists some point in region "A" whose distance from "p" is less than or equal to "X".

Next, the process translates two-dimensional layers into three-dimensional layers (operation <NUM>). In this operation, the process applies an inverse of the transformation from operation <NUM> to the boundary in operation <NUM> and offsets additionally for each layer's distance from the substrate and excess in the build direction.

The process then creates a three-dimensional layer geometry (operation <NUM>). In operation <NUM>, the process creates a cross section of the preform design by stitching together two copies of the curve or curves in operation <NUM>, offset by the layer thickness, and "capping" the result. For example, if a circle is present, this operation would start by creating a tube, and the "capping" would result in a closed cylinder.

The process then generates the substrate extents and the substrate geometry to form a preform design (operation <NUM>). In operation <NUM>, the process applies shading to the cross sections of the substrate from both the top and bottom layers. In this operation, the process also generates a rectangular bounding box around the layer that has as little distance as possible between the edges of the bounding box and the boundary of the layer.

In other words, the bounding box is positioned and sized to have as small of an area as possible while keeping the substrate within the bounding box. In operation <NUM>, the process generates the rectangular solid for the substrate using this rectangular bounding box and the locations determined in operation <NUM>.

The process then generates a volumetric analysis (operation <NUM>) with the process terminating thereafter. The biometric analysis is an example of output <NUM> shown in block form in <FIG>. In operation <NUM>, the process aggregates the volumes of the layers in operation <NUM> to calculate volume and weight of deposited material. In this operation, the process also calculates the volume of the preform and the weight of the substrate from dimensions in the material density.

With the volumetric analysis, a determination may be made as to whether the preform design meets goals in manufacturing a preform that can be machined to form the part. For example, the results of the volumetric analysis may be used for cost analysis or other suitable analysis.

If the result is not desirable, the process in <FIG> may be repeated using different additional parameters. For example, a different type of material may be used with the material density that may have different additive layer thicknesses or material offsets.

The flowcharts and block diagrams in the different depicted embodiments illustrate the architecture, functionality, and operation of some possible implementations of apparatuses and methods in an illustrative embodiment. In this regard, each block in the flowcharts or block diagrams may represent at least one of a module, a segment, a function, or a portion of an operation or step. For example, one or more of the blocks may be implemented as program code, hardware, or a combination of the program code and hardware.

When implemented in hardware, the hardware may, for example, take the form of integrated circuits that are manufactured or configured to perform one or more operations in the flowcharts or block diagrams. When implemented as a combination of program code and hardware, the implementation may take the form of firmware. Each block in the flowcharts or the block diagrams may be implemented using special purpose hardware systems that perform the different operations or combinations of special purpose hardware and program code run by the special purpose hardware.

In some alternative implementations of an illustrative embodiment, the function or functions noted in the blocks may occur out of the order noted in the figures. For example, in some cases, two blocks shown in succession may be performed substantially concurrently, or the blocks may sometimes be performed in the reverse order, depending upon the functionality involved. Also, other blocks may be added in addition to the illustrated blocks in a flowchart or block diagram.

For example, operation <NUM> may be performed prior to operation <NUM> in <FIG>. In another illustrative example, operation <NUM> in <FIG> may be omitted. In yet another illustrative example, the parameters in operation <NUM> may be identified from a configuration file without requiring user input to a graphical user interface.

Turning now to <FIG>, an illustration of a block diagram of a data processing system is depicted in accordance with an illustrative embodiment. Data processing system <NUM> may be used to implement computer system <NUM> in <FIG> and <FIG>. In this illustrative example, data processing system <NUM> includes communications framework <NUM>, which provides communications between processor unit <NUM>, memory <NUM>, persistent storage <NUM>, communications unit <NUM>, input/output (I/O) unit <NUM>, and display <NUM>. In this example, communications framework <NUM> may take the form of a bus system.

Processor unit <NUM> serves to execute instructions for software that may be loaded into memory <NUM>. Processor unit <NUM> may be a number of processors, a multi-processor core, or some other type of processor, depending on the particular implementation.

Memory <NUM> and persistent storage <NUM> are examples of storage devices <NUM>. A storage device is any piece of hardware that is capable of storing information, such as, for example, without limitation, at least one of data, program code in functional form, or other suitable information either on a temporary basis, a permanent basis, or both on a temporary basis and a permanent basis. Storage devices <NUM> may also be referred to as computer readable storage devices in these illustrative examples. Memory <NUM>, in these examples, may be, for example, a random access memory or any other suitable volatile or non-volatile storage device. Persistent storage <NUM> may take various forms, depending on the particular implementation.

For example, persistent storage <NUM> may contain one or more components or devices. For example, persistent storage <NUM> may be a hard drive, a solid state hard drive, a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination of the above. The media used by persistent storage <NUM> also may be removable.

Communications unit <NUM>, in these illustrative examples, provides for communications with other data processing systems or devices. In these illustrative examples, communications unit <NUM> is a network interface card.

Input/output unit <NUM> allows for input and output of data with other devices that may be connected to data processing system <NUM>. For example, input/output unit <NUM> may provide a connection for user input through at least one of a keyboard, a mouse, or some other suitable input device. Further, input/output unit <NUM> may send output to a printer. Display <NUM> provides a mechanism to display information to a user.

Instructions for at least one of the operating system, applications, or programs may be located in storage devices <NUM>, which are in communication with processor unit <NUM> through communications framework <NUM>. The processes of the different embodiments may be performed by processor unit <NUM> using computer-implemented instructions, which may be located in a memory, such as memory <NUM>.

These instructions are referred to as program code, computer usable program code, or computer readable program code that may be read and executed by a processor in processor unit <NUM>. The program code in the different embodiments may be embodied on different physical or computer readable storage media, such as memory <NUM> or persistent storage <NUM>.

Program code <NUM> is located in a functional form on computer readable media <NUM> that is selectively removable and may be loaded onto or transferred to data processing system <NUM> for execution by processor unit <NUM>. Program code <NUM> and computer readable media <NUM> form computer program product <NUM> in these illustrative examples. In one example, computer readable media <NUM> may be computer readable storage media <NUM> or computer readable signal media <NUM>.

In these illustrative examples, computer readable storage media <NUM> is a physical or tangible storage device used to store program code <NUM> rather than a medium that propagates or transmits program code <NUM>. Alternatively, program code <NUM> may be transferred to data processing system <NUM> using computer readable signal media <NUM>. Computer readable signal media <NUM> may be, for example, a propagated data signal containing program code <NUM>. For example, computer readable signal media <NUM> may be at least one of an electromagnetic signal, an optical signal, or any other suitable type of signal. These signals may be transmitted over at least one of communications links, such as wireless communications links, optical fiber cable, coaxial cable, a wire, or any other suitable type of communications link.

The different components illustrated for data processing system <NUM> are not meant to provide architectural limitations to the manner in which different embodiments may be implemented. The different illustrative embodiments may be implemented in a data processing system including components in addition to or in place of those illustrated for data processing system <NUM>. Other components shown in <FIG> can be varied from the illustrative examples shown. The different embodiments may be implemented using any hardware device or system capable of running program code <NUM>.

Illustrative embodiments of the disclosure may be described in the context of aircraft manufacturing and service method <NUM> as shown in <FIG> and aircraft <NUM> as shown in <FIG>. Turning first to <FIG>, an illustration of a block diagram of an aircraft manufacturing and service method is depicted in accordance with an illustrative embodiment. During pre-production, aircraft manufacturing and service method <NUM> may include specification and design <NUM> of aircraft <NUM> in <FIG> and material procurement <NUM>.

During production, component and subassembly manufacturing <NUM> and system integration <NUM> of aircraft <NUM> in <FIG> take place. Thereafter, aircraft <NUM> may go through certification and delivery <NUM> in order to be placed in service <NUM>. While in service <NUM> by a customer, aircraft <NUM> is scheduled for routine maintenance and service <NUM>, which may include modification, reconfiguration, refurbishment, and other maintenance or service.

Each of the processes of aircraft manufacturing and service method <NUM> may be performed or carried out by a system integrator, a third party, an operator, or some combination thereof.

With reference now to <FIG>, an illustration of a block diagram of an aircraft is depicted in which an illustrative embodiment may be implemented. In this example, aircraft <NUM> is produced by aircraft manufacturing and service method <NUM> in <FIG> and may include airframe <NUM> with a plurality of systems <NUM> and interior <NUM>.

Examples of systems <NUM> include one or more of propulsion system <NUM>, electrical system <NUM>, hydraulic system <NUM>, and environmental system <NUM>. Any number of other systems may be included. Although an aerospace example is shown, different illustrative embodiments may be applied to other industries, such as the automotive industry. Apparatuses and methods embodied herein may be employed during at least one of the stages of aircraft manufacturing and service method <NUM> in <FIG>.

In one illustrative example, components or subassemblies produced in component and subassembly manufacturing <NUM> in <FIG> may be fabricated or manufactured in a manner similar to components or subassemblies produced while aircraft <NUM> is in service <NUM> in <FIG>. As yet another example, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during production stages, such as component and subassembly manufacturing <NUM> and system integration <NUM> in <FIG>.

One or more apparatus embodiments, method embodiments, or a combination thereof may be utilized while aircraft <NUM> is in service <NUM>, during maintenance and service <NUM> in <FIG>, or both. The use of a number of the different illustrative embodiments may substantially expedite the assembly of aircraft <NUM>, reduce the cost of aircraft <NUM>, or both expedite the assembly of aircraft <NUM> and reduce the cost of aircraft <NUM>.

For example, one or more illustrative examples may be used to manufacture parts in the different stages. Further, one or more illustrative examples also may be used to determine the feasibility of using preforms for use in manufacturing parts.

Turning now to <FIG>, an illustration of a block diagram of a product management system is depicted in accordance with an illustrative embodiment. Product management system <NUM> is a physical hardware system. In this illustrative example, product management system <NUM> may include at least one of manufacturing system <NUM> or maintenance system <NUM>.

Manufacturing system <NUM> is configured to manufacture products, such as aircraft <NUM> in <FIG>. As depicted, manufacturing system <NUM> includes manufacturing equipment <NUM>. Manufacturing equipment <NUM> includes at least one of fabrication equipment <NUM> or assembly equipment <NUM>.

Fabrication equipment <NUM> is equipment that may be used to fabricate components for parts used to form aircraft <NUM>. For example, fabrication equipment <NUM> may include machines and tools. These machines and tools may be at least one of a drill, a hydraulic press, a furnace, a mold, a composite tape laying machine, a vacuum system, a lathe, or other suitable types of equipment. Fabrication equipment <NUM> may be used to fabricate at least one of metal parts, composite parts, semiconductors, circuits, fasteners, ribs, skin panels, spars, antennas, or other suitable types of parts.

Assembly equipment <NUM> is equipment used to assemble parts to form aircraft <NUM>. In particular, assembly equipment <NUM> may be used to assemble components and parts to form aircraft <NUM>. Assembly equipment <NUM> also may include machines and tools.

These machines and tools may be at least one of a robotic arm, a crawler, a faster installation system, a rail-based drilling system, or a robot. Assembly equipment <NUM> may be used to assemble parts such as seats, horizontal stabilizers, wings, engines, engine housings, landing gear systems, and other parts for aircraft <NUM>.

In this illustrative example, maintenance system <NUM> includes maintenance equipment <NUM>. Maintenance equipment <NUM> may include any equipment needed to perform maintenance on aircraft <NUM>. Maintenance equipment <NUM> may include tools for performing different operations on parts on aircraft <NUM>. These operations may include at least one of disassembling parts, refurbishing parts, inspecting parts, reworking parts, manufacturing replacement parts, or other operations for performing maintenance on aircraft <NUM>. These operations may be for routine maintenance, inspections, upgrades, refurbishment, or other types of maintenance operations.

In the illustrative example, maintenance equipment <NUM> may include ultrasonic inspection devices, x-ray imaging systems, vision systems, drills, crawlers, and other suitable device. In some cases, maintenance equipment <NUM> may include fabrication equipment <NUM>, assembly equipment <NUM>, or both to produce and assemble parts that may be needed for maintenance. In the illustrative example, part manufacturing system <NUM> in <FIG> may be implemented within at least one of manufacturing system <NUM> or maintenance system <NUM>.

Product management system <NUM> also includes control system <NUM>. Control system <NUM> is a hardware system and may also include software or other types of components. Control system <NUM> is configured to control the operation of at least one of manufacturing system <NUM> or maintenance system <NUM>.

In particular, control system <NUM> may control the operation of at least one of fabrication equipment <NUM>, assembly equipment <NUM>, or maintenance equipment <NUM>. In the illustrative example, part manager <NUM> in <FIG> may be implemented as part of control system <NUM> or may be in communication with control system <NUM>.

The hardware in control system <NUM> may be using hardware that may include computers, circuits, networks, and other types of equipment. The control may take the form of direct control of manufacturing equipment <NUM>. For example, robots, computer-controlled machines, and other equipment may be controlled by control system <NUM>.

In other illustrative examples, control system <NUM> may manage operations performed by human operators <NUM> in manufacturing or performing maintenance on aircraft <NUM> in <FIG>. For example, control system <NUM> may assign tasks, provide instructions, display models, or perform other operations to manage operations performed by human operators <NUM>. In these illustrative examples, part manager <NUM> in <FIG> and <FIG> may be implemented in control system <NUM> to manage at least one of the manufacturing or maintenance of aircraft <NUM> in <FIG>.

In the different illustrative examples, human operators <NUM> may operate or interact with at least one of manufacturing equipment <NUM>, maintenance equipment <NUM>, or control system <NUM>. This interaction may be performed to manufacture aircraft <NUM>.

Of course, product management system <NUM> may be configured to manage other products other than aircraft <NUM>. Although aircraft management system <NUM> has been described with respect to manufacturing in the aerospace industry, aircraft management system <NUM> may be configured to manage products for other industries. For example, aircraft management system <NUM> may be configured to manufacture products for the automotive industry as well as any other suitable industries.

Thus, the illustrative embodiments provide a method and apparatus for managing the manufacturing preforms and parts from preforms. As described above, one or more of the illustrative examples provide a method and apparatus that overcome a technical problem with the time and effort needed to create a preform design.

In the illustrative examples, a part manager automatically generates a preform design from parameters for a part design and a number of additional parameters used in manufacturing the preform. The part manager allows for changes to the preform design to be performed more quickly than with currently used techniques.

Further, the part manager generates the preform design without needing the human operator to modify the part design displayed on a graphical user interface. By eliminating the need for this operation, the preform design may be generated more quickly and accurately as compared to currently used techniques.

The output generated by the part manager may be used to evaluate the preform design. For example, the output may include at least one of a visualization of the preform design or evaluation information. This information may be used by at least one of the part manager, the human operator, or some other entity in determining whether a changed preform design is needed. Further, the output may be used to determine whether the parts are suitable for manufacturing through the use of a preform created by an additive manufacturing system, such as a wire based additive manufacturing system.

The description of the different illustrative embodiments has been presented for purposes of illustration and description and is not intended to be exhaustive or limited to the embodiments in the form disclosed. The different illustrative examples describe components that perform actions or operations. In an illustrative embodiment, a component may be configured to perform the action or operation described. For example, the component may have a configuration or design for a structure that provides the component an ability to perform the action or operation that is described in the illustrative examples as being performed by the component.

Claim 1:
A method for managing a part (<NUM>), the method comprising:
identifying, by a computer system (<NUM>), parameters (<NUM>) for the part (<NUM>) from a computer aided design model of the part, wherein the parameters (<NUM>) include dimensions for the part (<NUM>) and parameters relating to suitable machining techniques;
identifying, by the computer system (<NUM>), a number of additional parameters (<NUM>) used in manufacturing the part (<NUM>) from a preform (<NUM>), wherein the number of additional parameters (<NUM>) includes offsets, excesses, or combination thereof needed for machining the preform to form the part, wherein the number of additional parameters further includes a substrate location, a substrate thickness, a material density needed for generating a preform design to be processed to form the part;
automatically generating, by the computer system (<NUM>), a preform design (<NUM>) for the preform (<NUM>) using the parameters (<NUM>) for the part (<NUM>) and the number of additional parameters (<NUM>);
determining whether the preform design meets a number of desired goals corresponding to a feasibility and cost for additive manufacturing of the preform and a feasibility and cost of machining the preform to form the part;
changing values of the additional parameters and repeating identifying, by the computer system (<NUM>), the number of additional parameters (<NUM>) for manufacturing the part (<NUM>) from the preform (<NUM>) until the preform design meets the number of desired goals and automatically generating, by the computer system (<NUM>), the preform design (<NUM>) for the preform (<NUM>) using the parameters (<NUM>) for the part (<NUM>) and the number of additional parameters (<NUM>) for manufacturing the part (<NUM>) from the preform (<NUM>).