Patent Document ID: 9999924
Application ID: 14832691
Patent Flag: 1

Claim One:
1. An additive manufacturing method, comprising: depositing a layer of metal material; melting a region of the layer of metal material to form a part with a heat source that scans across the region of the layer of metal material to melt the region; monitoring an amount of energy emitted by the heat source by maintaining a path along which the heat source scans the region within a first field of view of a first optical sensor to provide a first information set; monitoring a fixed portion of the region of the layer of metal material with a second optical sensor to provide a second information set, the fixed portion of the region being positioned so that the path extends both into and out of a second field of view of the second optical sensor; and subsequent to melting the region of the layer of metal material, determining whether the first and second information sets indicate the region falls within a known-good range of a baseline dataset associated with the part being produced by the additive manufacturing method by: correlating data included in the second information set with data included in the first information set, wherein the data correlated from the first and second information sets was collected while the heat source passed through the fixed portion of the region; calculating a plurality of state variables using at least a portion of the first information set and at least a portion of the second information set; and comparing the plurality of state variables with a plurality of ranges associated with state variables of the known-good range of the baseline dataset; and adjusting the additive manufacturing operation when the correlated information associated with the layer of metal material indicates an out of parameters event.