Lamination molding apparatus

An irradiation device of a lamination molding apparatus includes: at least one laser source, generating a laser beam; a first galvano scanner, scanning the laser beam; a second galvano scanner, scanning the laser beam; and an irradiation controller, controlling the laser source, the first galvano scanner, and the second galvano scanner. Irradiable ranges of the laser beams by using the first galvano scanner and the second galvano scanner respectively include an entire of a molding region. A first X-axis galvano mirror and a first Y-axis galvano mirror of the first galvano scanner and a second X-axis galvano mirror and a second Y-axis galvano mirror of the second galvano scanner are disposed to be plane-symmetric to each other.

ADDITIVELY MANUFACTURING A 3D OBJECT INCLUDING A SECOND MATERIAL

A 3D printer to additively manufacture a 3D object includes a coater, a dispenser, and an energy source. The coater is to coat a first material relative to a print bed to form a selectable number of first layers. The dispenser is to dispense a first fluid agent onto first selected locations of the first layers of the first material. The energy source is to cause fusing at the first selected locations. The dispenser is to also dispense a second fluid agent including a second material to form a selectable number of second layers of the second material at second selected locations on top of the selectable number of first layers. Each second selected location comprises at least some of the fused first selected locations.

EXCHANGEABLE BEAM ENTRY WINDOW FOR AM SYSTEM

Methods and apparatuses for replaceable beam entry windows in additive manufacturing systems are disclosed.

DEVICE FOR THE GENERATIVE PRODUCTION OF A THREE-DIMENSIONAL OBJECT

Многолучевой растровый станок селективного лазерного плавления

Изобретение относится к области аддитивных технологий, а именно к изготовлению деталей методом трёхмерной печати из разных материалов, включая пластмассы, металлы и керамику. Станок содержит полупроводниковые многомодовые лазерные модули, портальную систему, выполненную в виде двух перпендикулярных друг к другу горизонтальным осям передвижения X и Y, каретку, установленную на упомянутых осях. Каретка содержит рабочую головку, которая выполнена с оптической системой фокусировки лазерных лучей. К системе фокусировки через оптоволоконные жгуты подключены полупроводниковые лазерные модули. Головка также содержит две сканирующие головки и установленный между ними механизм подачи проволоки или порошковый бункер с ракелем. Станок также содержит камеру построения с платформой камеры построения, выполненной с возможностью перемещения по вертикальной оси Z и расположенной на платформе камеры построения детали. Оптическая система фокусировки лазерных лучей выполнена таким образом, что лазерные лучи ...

Intelligent monitoring and fault feedback processing system and method for powder bed in printing process

The invention provides an intelligent monitoring and fault feedback processing system and method for a powder bed in the printing process, and the system specifically comprises a monitoring integrated device which comprises a high-definition industrial camera and a PLC industrial control computer system and is used for the real-time monitoring of the powder bed and the input and output of a PLC signal; the air field control assembly comprises a circulating fan, an air blowing box and an air suction box, the circulating fan is used for controlling the air volume and the air speed in real time, the air blowing box serves as a powder bed breadth air blowing channel, and the air suction box serves as a powder bed breadth air suction channel; the powder supply control assembly comprises a stepping motor, a powder supply cylinder precision lead screw, a powder supply cylinder cabin and a powder laying scraper, and the powder supply amount is accurately controlled through the assemblies; and an ...

APPARATUS FOR ADDITIVELY MANUFACTURING COMPONENTS, IN PARTICULAR BY MEANS OF SELECTIVE MELTING OR SINTERING

The invention relates to an apparatus for additively manufacturing components, in particular by means of selective melting or sintering, said apparatus comprising: a light source for generating a light beam; and a machining head which either is coupled to the light source by means of a beam guide so that the light beam is guided to the machining head, or the light source is positioned directly on the machining head so that a light beam can be directed from the machining head onto a machining region, the machining head being movably mounted so that the light beam can be directed to any desired location in the machining region. The invention is characterised in that several machining heads are provided each for directing a light beam on the machining region, and the machining heads are each positioned on a carriage which can be moved along a traverse. This makes it possible to melt or sinter powder simultaneously at several locations. Preferably, the machining heads are positioned on swivel ...

ADDITIVE MANUFACTURING METHOD AND ADDITIVE MANUFACTURING APPARATUS

To maintain the strength of a molded object and to improve the accuracy of the shape thereof. In an additive manufacturing method, a molded object is molded from a material by using an additive manufacturing apparatus 1 including a plurality of light-beam emission units. The additive manufacturing method includes determining a light-beam emission unit for emitting a light beam to at least a part of the molded object from among the plurality of light-beam emission units according to an angle of the part of the molded object with respect to a laminating direction thereof, and emitting the light beam to the part of the molded object from the determined light-beam emission unit.

Additives Fertigungsverfahren und Vorrichtung zur additiven Fertigung

Zur Beibehaltung der Festigkeit eines geformten Gegenstandes und Verbesserung der Genauigkeit der Gestalt desselben. Bei einem additiven Fertigungsverfahren wird ein geformter Gegenstand (100) aus einem Material unter Verwendung einer Vorrichtung (1) zur additiven Fertigung geformt, die eine Mehrzahl von Lichtstrahl-Emissionseinheiten (103, 104) beinhaltet. Das additive Fertigungsverfahren beinhaltet das Bestimmen einer Lichtstrahl-Emissionseinheit zum Ausstrahlen eines Lichtstrahls auf mindestens einen Teil des geformten Gegenstands (100) aus der Mehrzahl von Lichtstrahl-Emissionseinheiten (103, 104) gemäß einem Winkel des Teils des geformten Gegenstands in Bezug auf eine Laminierrichtung desselben, und das Ausstrahlen des Lichtstrahls auf den Teil des geformten Gegenstands (100) von der bestimmten Lichtstrahl-Emissionseinheit.

High Speed Light Valve System

An additive manufacturing system includes a high power laser to form a high fluence laser beam. A 2D patternable light valve having a structure responsive to electron emission is positioned to receive and pattern light received from the high power laser.

THREE-DIMENSIONAL SHAPING METHOD AND THREE-DIMENSIONAL SHAPING DEVICE

УСТРОЙСТВО ДЛЯ ИЗГОТОВЛЕНИЯ ТРЁХМЕРНЫХ ОБЪЕКТОВ

Настоящая полезная модель относится к аддитивному производству, более конкретно к устройствам для изготовления трехмерных объектов. Устройство для изготовления трехмерных объектов содержит собранные в единую конструкцию базовую подложку для формирования трехмерных объектов, источник энергии для формирования ванны расплава на указанной подложке, средство для подачи исходного материала, предназначенного для послойного изготовления трехмерных объектов в зону плавления, герметичную рабочую камеру, вакуумную систему, систему управления для мониторинга и управления условий работы всех блоков системы. В качестве источника энергии для формирования ванны расплава на указанной подложке используют электронно-оптическую систему, в которой применяют три термокатодные электронно-лучевые пушки с использованием отдельных электронных лучей, сходящихся в одной зоне расплава с ускоряющим напряжением, не превышающим 10 кВ, объединенные в едином охлаждаемом корпусе с каналом для подачи исходного материала, ...

System for laser additive manufacturing and additive manufacturing method

The invention discloses a system for laser additive manufacturing and an additive manufacturing method, and relates to the technical field of additive manufacturing. The system for laser additive manufacturing comprises an infrared laser generator, an infrared light collimating lens, a blue light laser generator, a blue light collimating lens, a dichroscope and a focusing lens, and other parts are common matching systems of the laser additive manufacturing system. The thought that multi-wavelength light beams are used for composite machining is adopted, namely, multi-beam low-power pulse type blue laser is used for beam combining treatment at the focus to improve the actual machining area and the energy density of laser output, the energy loss rate of the blue laser in optical fibers is reduced, the laser absorptivity of a high-reflection material is improved, and meanwhile the energy utilization rate of the high-reflection material is improved. And infrared laser with large light spots ...

Laser additive and subtractive composite manufacturing equipment and method with multiple groups of parallel milling processes

The invention discloses laser additive and subtractive composite manufacturing equipment and method with multiple sets of parallel milling processes, and belongs to the technical field of advanced manufacturing, the equipment comprises a machining plane, a scanning galvanometer assembly and a milling head assembly, and the machining plane is used for laying metal powder layers layer by layer; the scanning galvanometer assembly is used for SLM forming of a metal powder layer, is located above the machining plane and comprises a plurality of scanning galvanometer units; the milling head assembly is used for milling after SLM forming of a metal powder layer and comprises a plurality of milling heads arrayed in the width direction of the metal powder layer, and the effective machining breadths of the multiple milling heads are spliced with one another and cover the whole machining plane. And each milling head can reciprocate along the width direction, the length direction and the thickness ...

FUSING IN THREE-DIMENSIONAL (3D) PRINTING

In an example implementation, a fusing module for use in a 3D printing system includes a thermic source to emit light rays for heating a target zone. The fusing module also includes a reflector associated with the thermic source to reflect upward-emitted light rays in a downward direction toward the target zone, and an absorber positioned above the thermic source to absorb light rays that reflect off of the target zone.

METHOD OF OPERATING AN IRRADIATION SYSTEM, IRRADIATION SYSTEM AND APPARATUS FOR PRODUCING A THREE-DIMENSIONAL WORK PIECE WITH POLARIZATION CONTROL

In a method of operating an irradiation system (10) for irradiating layers of a raw material powder with laser radiation in order to produce a three-dimensional work piece (110) at least a section of a raw material powder layer (11) applied onto a carrier (102) is selectively irradiated with linearly polarized laser radiation. An orientation of a plane of polarization of the linearly polarized laser radiation is controlled in dependence on an orientation of a plane of incidence of the linearly polarized laser radiation on the raw material.

METHOD AND DEVICE FOR PRODUCING THREE-DIMENSIONAL OBJECTS

Additive Fertigungsvorrichtung

Eine additive Fertigungsvorrichtung (100) umfasst Folgendes: eine Innenlichtstrahl-Abstrahleinrichtung (121), die einen Innenlichtstrahl (LC) abstrahlt; eine Außenlichtstrahl-Abstrahleinrichtung (122), die einen Außenlichtstrahl (LS) abstrahlt; und eine Steuereinrichtung (130). Wenn ein Schmelzbad mit dem Außenlichtstrahl (LS) bestrahlt wird, steuert die Steuereinrichtung (130) eine Leistungsdichte des Außenlichtstrahls (LS), der eine Leistung pro Flächeneinheit darstellt, derart, dass eine Abkühlgeschwindigkeit des Schmelzbads, die einen Temperaturabfall pro Zeiteinheit darstellt, an einem Gefrierpunkt eines Carbidbinders, der in dem Schmelzbad enthalten ist, 540°C/s oder weniger beträgt, wobei das Schmelzbad durch Bestrahlen eines Materials, das einen Hartstoff und den Carbidbinder enthält, mit dem Innenlichtstrahl ausgebildet wird, um das Material zu schmelzen. Dieses additive Fertigungsverfahren kann Risse verhindern und mit einer einfachen Konfiguration additiv ein geformtes Objekt ...

Methods and apparatus for the manufacture of three-dimensional objects

APPARATUS FOR ADDITIVELY MANUFACTURING COMPONENTS, IN PARTICULAR BY MEANS OF SELECTIVE MELTING OR SINTERING

The invention relates to an apparatus for additively manufacturing components, in particular by means of selective melting or sintering, said apparatus comprising: a light source for generating a light beam; and a machining head which either is coupled to the light source by means of a beam guide so that the light beam is guided to the machining head, or the light source is positioned directly on the machining head so that a light beam can be directed from the machining head onto a machining region, the machining head being movably mounted so that the light beam can be directed to any desired location in the machining region. The invention is characterised in that several machining heads are provided each for directing a light beam on the machining region, and the machining heads are each positioned on a carriage which can be moved along a traverse. This makes it possible to melt or sinter powder simultaneously at several locations. Preferably, the machining heads are positioned on swivel ...

LOCAL SELECTIVE IRRADIATION OF A WORKING AREA WITH A NON-CIRCULAR BEAM SHAPE

The invention relates to a planning device (15) for planning a locally selective irradiation of a working area (11) with an energy beam (7) in order to produce a component (3) from a powder material arranged in the working area (11) by means of the energy beam (7), the planning device (15) being designed to obtain a plurality of irradiation vectors (21) for irradiating a powder material layer arranged in the working area with the energy beam (7), the planning device (15) being designed to determine a vector orientation in a coordinate system in the working area (11) for at least one irradiation vector (21) of the plurality of irradiation vectors (21), and the planning device (15) being designed to specify, for the at least one irradiation vector (21), a beam orientation for a non-circular beam shape (18) of the energy beam (7) in the working area (11) relative to the vector orientation of the at least one irradiation vector (21).

Additive Manufacturing With Photo-Acoustic Tomography Defect Testing

An additive manufacturing method supporting layer by layer testing includes a layer test including generating a hammer beam using laser light having a first wavelength, generating a read-out beam using laser light having a second wavelength, directing the generated hammer beam toward a first layer on a part to provide an acoustic hammer pulse that induces surface movement of the part, and reading the surface movement of the part using the read-out beam directed to a second position on the part. Layers can be added and the layer test repeated.

ADDITIVE MANUFACTURING OF GAS TURBINE COMPONENTS USING CARBON NANOSTRUCTURES

A component for a gas turbine engine can be made via additive manufacturing. During the additive manufacturing process a powder can be used that comprises a superalloy material (12) and carbon nanostructures (14a, 14b). Components made using the powder can have preferred characteristics at certain locations through the use of the carbon nanostructure based additive manufacturing powder.

POWDER BED FUSION METHODS AND RELATED APPARATUS

A method of determining instructions to be executed by a powder bed fusion apparatus, in which an object is built in a layer-by-layer manner by selectively irradiating regions of successively formed powder layers with an energy beam. The method includes determining an exposure parameter for each location within a layer to be irradiated with the energy beam from a primary exposure parameter, the exposure parameters varying with location. An amount each exposure parameter varies from the primary exposure parameter is determined, at least in part, from a geometric quantity of the object derived from the location of the irradiation.

METHOD FOR CALIBRATING AN IRRADIATION DEVICE FOR AN APPARATUS FOR ADDITIVELY MANUFACTURING THREE-DIMENSIONAL OBJECTS

Methods for calibrating an irradiation device for an apparatus for additively manufacturing three-dimensional objects include generating at least two first and two second calibration patterns, in at least two different first positions and at least two different second positions; determining position information relating to the positions of the calibration patterns; generating a calibration quality value relating to a calibration status of the irradiation device; simulating at least two first calibration patterns and at least two second calibration patterns based on at least one changed irradiation parameter; determining a calibration quality value for the simulated calibration patterns; and repeating the simulation and determination of the calibration quality value until a maximum or minimum calibration quality value is reached.

MODULE FOR ADDITIVE MANUFACTURING APPARATUS

MACHINE FOR ADDITIVE MANUFACTURING BY POWDER BED DEPOSITION WITH A CENTRAL GAS SUCTION OR GAS BLOWING MANIFOLD

A machine (10) for additive manufacturing by powder bed deposition comprises a work surface (12), a device (16) for selective consolidation, a device (18) for extracting the fumes, the selective consolidation device emitting at least two beams (F1, F2) of energy or heat. The work surface is divided into at least two work zones (Z1, Z2) adjacent to one another, and a first beam (F1) consolidates the powder in a first work zone (Z1) and a second beam (F2) consolidates the powder in a second work zone (Z2). The fume extraction device (18) comprises at least one central gas suction and/or gas blowing manifold (40) which is mounted to be translationally movable above an overlap zone (ZR) of the different adjacent work zones, and two side gas suction and/or gas blowing manifolds (42, 44) which are fixedly mounted and arranged on either side of the work surface, whcrcin the central manifold (40) extends at least over a maximum dimension of the work surface.

LAMINATION MOLDING APPARATUS

An irradiation device (13) of a lamination molding apparatus includes: at least one laser source (31, 41), generating a laser beam (L1, L2); a first galvano scanner (32), scanning the laser beam (L1); a second galvano scanner (42), scanning the laser beam (L2); and an irradiation controller (30), controlling the laser source, the first galvano scanner, and the second galvano scanner. Irradiable ranges of the laser beams by using the first galvano scanner and the second galvano scanner respectively include an entire of a molding region (R). A first X-axis galvano mirror (32a) and a first Y-axis galvano mirror (32b) of the first galvano scanner (32) and a second X-axis galvano mirror (42a) and a second Y-axis galvano mirror (42b) of the second galvano scanner (42) are disposed to be plane-symmetric (P) to each other.

METHOD FOR ADDITIVE MANUFACTURING BY MEANS OF DUAL SELECTIVE IRRADIATION OF A POWDER BED AND PREHEATING

The invention relates to a method for powder bed additive manufacturing of a component (2). The method comprises the selective irradiation of a layer (10) made of a powder material (7) with a first energy beam (14) and a second energy beam (15), that is different from the first, wherein the second energy beam (15) annularly surrounds the first energy beam (14), and the aselective heating of the layer (10), wherein a large part of the layer (10) is heated to a temperature (T1) that is at least one quarter of the temperature (T2) that the layer (10) is heated to as a result of the selective irradiation. The invention also relates to a corresponding device.

Multi-Spectral Method For Detection of Anomalies During Powder Bed Fusion Additive Manufacturing

Embodiments of the systems can be configured to receive electromagnetic emissions of a substrate (e.g., a build material of a part being made via additive manufacturing) by a detector (e.g., a multi-spectral sensor) and generate a ratio of the electromagnetic emissions to perform spectral analysis with a reduced dependence on location and orientation of a surface of the substrate relative to the multi-spectral sensor. The additive manufacturing process can involve use of a laser to generate a laser beam for fusion of the build material into the part. The system can be configured to set the multi-spectral sensor off-axis with respect to the laser (e.g., an optical path of the multi-spectral sensor is at an angle that is different than the angle of incidence of the laser beam). This can allow the multi-spectral sensor to collect spectral data simultaneously as the laser is used to build the part.

MANUFACTURING DEVICE, METHOD AND COMPUTER PROGRAM PRODUCT FOR THE ADDITIVE MANUFACTURE OF COMPONENTS FROM A POWDER MATERIAL

A manufacturing device for additive manufacture of components includes a beam generation device configured to generate energy beams, a scanner device configured to locally and selectively irradiate a working region with the energy beams, a protective gas device configured to generate a protective gas flow over the working region, and a control device configured to drive the scanner device. The control device is configured to define a first irradiation region along which a first irradiation section is displaced from a first starting position to a first end position, to define a second irradiation region along which a second irradiation section is displaced from a second starting position to a second end position, and to begin irradiation of the second irradiation region when the first irradiation section and the second starting position are not arranged within an interaction zone defined by a protective gas flow direction relative to one another.

ADDITIVE MANUFACTURING METHODS AND SYSTEMS

A method (300) of additively manufacturing a three-dimensional object (114) includes irradiating a first build plane region (152a) using a first energy beam (134a), irradiating a second build plane region (152b) using a second energy beam (134b), and irradiating an interlace region (154) between the first build plane region (152a) and the second build plane region (152b), wherein irradiating the interlace region comprises directing the first energy beam (134a) along a first oscillating path (190), and directing the second energy beam (134b) along a second oscillating path (210) intersecting and overlapping with the first oscillating path (190).

Double-laser additive manufacturing method and device

The invention relates to the technical field of metal 3D printing, in particular to a double-laser additive manufacturing method and device. Comprising the following steps that S1, a first laser emits first laser, and a focusing light spot formed by the first laser forms an induced molten pool on a preset forming path; s2, a second laser emits second laser, a focusing light spot formed by the second laser forms a forming molten pool on the induction molten pool, and the cross section area of the forming molten pool is larger than that of the induction molten pool; s3, a driving device drives the first laser to rapidly stir in the forming molten pool so as to heat a liquid phase in the forming molten pool; the absorption rate of the second laser can be improved through formation of the induction molten pool, further formation of the second laser is facilitated, and waste of energy of the second laser can be reduced.

MEASUREMENT SYSTEM FOR A DEVICE FOR GENERATIVELY PRODUCING A THREE-DIMENSIONAL OBJECT

Calibration method of plurality of scanners in an additive manufacturing apparatus

A method for determining an attribute of an additive manufacturing apparatus including a plurality of scanners, each scanner including beam steering optics for directing a corresponding radiation beam to a working plane in which material consolidated in layers. The method may include controlling the beam steering optics of a pair of the scanners wherein a first scanner of the pair directs a radiation beam to form a feature in the working plane. The feature is within a field of view of a detector of the second scanner of the pair, the detecting radiation from the working plane is collected by the beam steering optics of the second scanner. Further including recording at least one detector value with the detector of the second scanner for the field of view and determining an attribute of the additive manufacturing apparatus from a comparison of the detector value with an expected detector value.

High Energy 3-D Printer Employing Continuous Print Path

High-throughput printing, possible with multiple electron beams, is facilitated by a continuous powder bed preparation process operating in parallel to apply and pre-sinter the powder along a continuous helical path. The sintered powder may be self-supporting to allow unconstrained expansion in the radial direction when high energy is used for powder fusion.

Interface regulation and control device and method for coaxial dual-wavelength laser forming heterogeneous material

The invention discloses an interface regulation and control device and method for a coaxial dual-wavelength laser forming heterogeneous material, and the device comprises an infrared laser light path unit and a green laser light path unit. Infrared laser generated by the infrared laser passes through the infrared laser shaper and then is transmitted to the infrared laser holophote; and green laser generated by the green laser passes through the green laser shaper and then is transmitted to the laser beam combiner to form coupled laser. According to the method, the energy coupling proportion of the coupled laser can be adjusted to change according to a material interface, the laser absorption behavior of an interface material is improved, and interface defects and stress concentration are reduced; according to different laser absorption characteristics and heat conduction characteristics of materials on the two sides of a material interface, the beam diameter and energy distribution of coupled ...

DIODE LASER FIBER ARRAY FOR CONTOUR OF POWDER BED FABRICATION OR REPAIR

CALIBRATING MULTIPLE LASER BEAMS FOR ADDITIVE MANUFACTURING

A method of automated alignment of scanning optics (17A, 17B) includes the steps: irradiating (step 101) an object area (3 A) of a layer of a powdered material (5) provided on a building platform (11) with at least one irradiation beam (15B); irradiating (step 103) a calibration area (21A) of the layer of the powdered material (5) with at least one irradiation beam (15B); guiding (step 105 A) the first irradiation beam (15 A) with the first scanning optic (17A) over the intermediate top face (31) and thereby melting a first calibration pattern (37) into the intermediate top face (31); guiding (step 105B) the second irradiation beam (15B) with the second scanning optic (17B) over the intermediate top face (31) and thereby melting a second calibration pattern (39) into the intermediate top face (31); acquiring (step 107) at least one image (35, 51A, 51B) of the intermediate top face (31); using the at least one image (35, 51 A, 51B), identifying (step 109) image points related to the geometrical ...

LASER-CENTER-DEPENDENT EXPOSURE STRATEGY

In a method for controlling an energy input device (20) of an additive manufacturing device for manufacturing a three-dimensional object by means of same, a beam deflection center (23) above the build plane (7) is assigned to each of the number of beams, proceeding from which center said beam is directed at the build plane (7), wherein each beam deflection center (23) is assigned a projection center (23') corresponding to a perpendicular projection of the position of the beam deflection center (23) onto the build plane (7), wherein at least in a portion of an object cross-section the directions of the motion vectors of the number of beams (22) during scanning of the trajectories (54) are defined such that at each of the solidification locations in said portion the motion vector is at an angle with respect to a connection vector from said solidification location toward the projection center (23') of the beam (22) used, which angle is less than a predetermined maximum angle γ1.

Enclosed additive manufacturing system

A method of additive manufacture is disclosed. The method may include restricting, by an enclosure, an exchange of gaseous matter between an interior of the enclosure and an exterior of the enclosure. The method may further include running multiple machines within the enclosure. Each of the machines may execute its own process of additive manufacture. While the machines are running, a gas management system may maintain gaseous oxygen within the enclosure at or below a limiting oxygen concentration for the interior.

MULTI-MODE LASER DEVICE FOR METAL MANUFACTURING APPLICATIONS

Disclosed is a multi-mode laser device for metal manufacturing applications including additive manufacturing (AM), laser cladding, laser welding, laser cutting, laser texturing and laser polishing. The multi-mode laser device configures off-axis, solid-state diode or diode-pumped lasers into an array to perform precision controlled, direct metal deposition printing, cladding, laser welding, laser cutting, laser texturing and laser polishing through a single device. Dual-mode printing, cladding and welding capability using metal wire and powder feedstock sources in the same device is provided with in-line control, precision wire feed driver/controller, adjustable shield gas diffuser, and nozzles tailored to wire feedstock diameter.

METHOD FOR MONITORING AT LEAST ONE SURFACE OF AN OPTICAL ELEMENT IN AN ADDITIVE MANUFACTURING APPARATUS AND APPARATUS FOR ADDITIVE MANUFACTURING OF AN OBJECT

The invention relates to a method for monitoring at least one surface (17) of an optical element (5) in an additive manufacturing apparatus (1), comprising: - coupling electromagnetic radiation (13) at at least one defined wavelength into the optical element (5) such that the electromagnetic radiation (13) coupled into the optical element (5) is subject to total internal reflection inside the optical element (5); - observing the at least one surface (17) of the optical element (5) from the outside of the optical element (5) with at least one sensor (15) which is sensitive to the electromagnetic radiation (13) at the at least one defined wavelength, and - determining a flaw (21) at at least one spatial position of the at least one surface (17) of the optical element (5) on the basis of a spatially resolved signal of the sensor (15), if electromagnetic radiation (13) at the at least one defined wavelength from the surface (17) is detected in the sensor (15).

Additive manufacturing apparatus utilizing combined electron beam selective melting and electron beam cutting

An additive manufacturing apparatus utilizing combined electron beam selective melting and electron beam cutting. One electron beam emitting, focusing, and scanning device (6) is capable of emitting electron beams (67, 68) in three modes of heating, selective melting, and electron beam cutting. The electron beam in the heating mode is emitted to scan and preheat a powder bed (7). The electron beam (67) in the selective melting mode is emitted to scan and melt powder (71) in a section outline to form a section layer of a component. The electron beam (68) in the electron beam cutting mode is emitted to perform one or more cutting scans on inner and outer outlines (74, 75) of a section of the component to obtain accurate and smooth inner and outer outlines of the section. The heating, melting deposition, and outline cutting processes are repeated to obtain a required three-dimensional physical component.

PRINTHEAD MODULE FOR ADDITIVE MANUFACTURING SYSTEM

METHOD AND APPARATUS FOR IN SITU DEBINDING AND SINTERING OF FILAMENT OR PASTE EXTRUSION ADDITIVE MANUFACTURED METAL OR CERAMIC PARTS

The present invention relates to a method and an apparatus to locally debind and sinter three dimensional dense objects produced by additive manufacturing. The apparatus, therefore, comprises a build platform, at least one heater, an extruder, a monitoring unit and a control unit. In this regard, the extruder is configured to eject building material in layers onto the build platform to form a build part. The heater is configured to heat the build part locally and the monitoring unit is configured to capture data relating the build part. In addition, the control unit is configured to control the extruder and the heater such that a defined ejection point can be driven by the extruder and a defined heating zone and/or heating point can be targeted by the heater.

METHODS OF DEFINING AN INTERLACE PATH FOR AN ADDITIVE MANUFACTURING MACHINE

ABSTRACT OF THE DISCLOSURE A method of additively manufacturing an object (114) may include defining an interlace path (306) for a plurality of energy beams (142, 148) from an energy beam system (134) based at least in part on a route-finding algorithm. The interlace path (306) may delineate a first contour zone (308) (302, 554) of a build plane (130) assigned to a first one of the plurality of energy beams (142, 148) from a second contour zone (308) (304, 556) of the build plane (130) assigned to a second one of the plurality of energy beams (142, 148). An exemplary method may additionally or alternatively include outputting a control command based at least in part on the interlace path (306). The control command may be configured to cause the energy beam system (134) to irradiate a layer of a powder bed (136) with the plurality of energy beams (142, 148).

Additive manufacturing with polygon and galvo mirror scanners

An additive manufacturing system includes a platform, a dispenser to dispense a plurality of layers of feed material on a top surface of the platform, a light source to generate a first light beam and a second light beam, a polygon mirror scanner, a galvo mirror scanner positioned adjacent to the polygon mirror scanner, and a controller. The controller is coupled to the light source, the polygon mirror scanner and the galvo mirror scanner, and the controller is configured to cause the light source and polygon mirror scanner to apply the first light beam to a region of the layer of feed material, and to cause the light source and galvo mirror scanner to apply the second light beam to at least a portion of the region of the layer of feed material.

ROTATIONAL ADDITIVE MANUFACTURING SYSTEMS AND METHODS

Systems and methods for rotational additive manufacturing are disclosed. An apparatus in accordance with an aspect of the present disclosure comprises a build floor, a depositor system configured to deposit a layer of powder onto the build floor, a motor system causing a rotational motion between the depositor system and the build floor, wherein the depositor system deposits the layer of powder during the rotational motion, a receptacle wall configured to contain the powder on the build floor, an energy beam source configured to apply an energy beam in an active area of the layer of powder to selectively fuse a portion of the powder in the active area to form a portion of a build piece and a gas flow system configured to provide a gas flow across the active area while the energy beam selectively fuses the portion of the layer of powder in the active area.

Additive manufacturing system and method

An additive manufacturing system, comprises an energy source device for providing a first energy beam and a second energy beam; and a forging device comprising a forging head. The first energy beam and a substrate are configured to move relative to each other to fuse at least a portion of a material added to the surface of the substrate for forming a cladding layer on the substrate. The forging head is configured to forge the cladding layer during formation of the cladding layer. The second energy beam is configured to heat a forging area of the cladding layer.

METALS-BASED ADDITIVE MANUFACTURING METHODS AND SYSTEMS WITH THERMAL MONITORING AND CONTROL

A metals-based additive manufacturing machine and method are disclosed. The machine and method include a hybrid temperature monitoring system. The hybrid temperature monitoring system includes a Raman spectrometer, a single-element ultrasound transducer, and a phased-array ultrasound pair. The hybrid temperature monitoring system can generate a real-time three-dimensional temperature map of the melt pool and optionally a portion of the metal powder base and/or a formed portion of a desired artifact. The real-time three-dimensional temperature map can be used for optimizing the metals-based additive manufacturing process in real-time or during subsequent process runs.

MELT POOL MONITORING SYSTEM AND METHOD FOR DETECTING ERRORS IN A MULTI-LASER ADDITIVE MANUFACTURING PROCESS

METHOD FOR DETERMINING A SET POINT FOR A THERMAL SENSOR IN AN APPARATUS FOR THE MANUFACTURE OF 3D OBJECTS

A method for determining a set point for a thermal sensor (72) in an apparatus for the layer-by-layer manufacture of a three-dimensional object from particulate material; the method comprising: (a) distributing a layer of particulate material, the layer providing a build bed surface (12); (b) depositing an amount of absorption modifier over at least one of a test region (50) and a surrounding area surrounding the test region; (c) heating the test region (50) over a period of time with a heat source (LI); (d) measuring with the thermal sensor (72) a temperature value TR within the test region (50); (e) distributing a further layer of material over the preceding layer of material, the new layer providing the build bed surface (12); - repeating the steps (b) to (e) of the layer cycle at least until the particulate material within the test region (50) starts to melt, wherein step (b) comprises depositing a further amount of absorption modifier over the test region (50), wherein the further ...

ALIGNMENT OF ENERGY BEAMS IN ADDITIVE MANUFACTURING SYSTEMS AND MACHINES

An additive manufacturing system (100) may include an irradiation device (142) configured to emit an energy beam 9144) having a manufacturing power level selected to additively manufacturing a three-dimensional object (114) by irradiating a powder material (120), and a controller (600 configured to perform one or more beam alignment operations when irradiating the powder material (120). The irradiation device (142) may include a beam source (200), one or more beam positioning elements (202), a beam splitter (204) configured to split a measurement beam (206) from the energy beam (144), and one or more beam sensors (208) configured to determine one or more parameters of the measurement beam (206). The one or more beam alignment operations may include determining position information of the energy beam (144) based on the one or more parameters of the measurement beam (206), and aligning the energy beam (144) with an optical axis of the irradiation device (142) by adjusting a position of the ...

METHOD FOR DETERMINING A SET POINT FOR A THERMAL SENSOR IN AN APPARATUS FOR THE MANUFACTURE OF 3D OBJECTS

A method for determining a set point for a primary thermal sensor (72) in an apparatus for the layer-by-layer manufacture of a three-dimensional object from particulate material; the method comprising a calibration process, comprising: (a) distributing a layer of particulate material, the layer providing a build bed surface (12); (b) measuring a first temperature value TD within a test region (50) with one of a primary thermal sensor (72) and a secondary thermal sensor (74) positioned above the build bed surface (12); (c) depositing an amount of absorption modifier over at least one of the test region (50) and a surrounding area surrounding the test region (50); (d) heating the test region (50) over a period of time; (e) measuring with the primary thermal sensor (72) a second temperature value TR within the test region (50); (f) distributing a further layer of material over the preceding layer of material, the new layer providing the build bed surface (12); - repeating the steps (b) to ...

METHOD OF OPERATING AN IRRADIATION SYSTEM, IRRADIATION SYSTEM AND APPARATUS FOR PRODUCING A THREE-DIMENSIONAL WORK PIECE WITH POLARIZATION CONTROL

In a method of operating an irradiation system (10) for irradiating layers of a raw material powder with laser radiation in order to produce a three-dimensional work piece (110) at least a section of a raw material powder layer (11) applied onto a carrier (102) is selectively irradiated with linearly polarized laser radiation. An orientation of a plane of polarization of the linearly polarized laser radiation is controlled in dependence on an orientation of a plane of incidence of the linearly polarized laser radiation on the raw material.

MODULATING A WORKING BEAM OF AN ADDITIVE MANUFACTURING MACHINE WITH A SOLID-STATE OPTICAL MODULATOR

An irradiation device (142) for an apparatus for additively manufacturing three-dimensional object (114), the irradiation device (142) comprising: a working beam generation device (200) configured to provide a working beam (206); a modulation beam generation device (202) configured to provide a modulation beam (208); a solid-state optical modulator (204) comprising a crystalline material (214) that exhibits a change in refractive index in response to photoexcitation of free electrons (216) within the crystalline material (214); and a power source (218) coupled to the solid-state optical modulator (204), the power source (218) configured to introduce free electrons (216) into the crystalline material (214); wherein the modulation beam (208), when incident upon the crystalline material (214), causes photoexcitation of the free electrons (216) within the crystalline material (214), and the photoexcitation of the free electrons (216) within the crystalline material (214) causes the crystalline ...

METHOD FOR EMISSIONS PLUME MONITORING IN ADDITIVE MANUFACTURING

METHOD FOR DETERMINING A SET POINT FOR A THERMAL SENSOR IN AN APPARATUS FOR THE MANUFACTURE OF 3D OBJECTS

DEVICES, SYSTEMS, AND METHODS FOR USING AN IMAGING DEVICE TO CALIBRATE AND OPERATE A PLURALITY OF ELECTRON BEAM GUNS IN AN ADDITIVE MANUFACTURING SYSTEM

Calibration systems, additive manufacturing systems employing the same, and methods of calibrating include a plurality of electron beam guns. One calibration system includes an imaging device positioned to capture one or more images of an impingement of electron beams emitted from the plurality of electron beam guns on a surface within a build chamber of the electron beam additive manufacturing system and an analysis component communicatively coupled to the imaging device. The analysis component is programmed to receive image data corresponding to the one or more images, determine one or more calibration parameters from the image data, and transmit one or more instructions to the plurality of electron beam guns in accordance with the one or more calibration parameters.

APPARATUS FOR PRODUCING THREE-DIMENSIONAL WORKPIECE COMPRISING A PLURALITY OF POWDER APPLICATION DEVICES

METHOD OF OPERATING AN IRRADIATION SYSTEM, IRRADIATION SYSTEM AND APPARATUS FOR PRODUCING A THREE-DIMENSIONAL WORK PIECE

Disclosed is an irradiation system for irradiating layers of a raw material powder with laser radiation to produce a three-dimensional work piece, the irradiation system comprising an optical unit configured to receive laser radiation having a first polarization state and to output laser radiation having a second polarization state, wherein the irradiation system is configured to selectively irradiate, with the laser radiation having the second polarization state, at least a section of a raw material powder layer applied onto a carrier, wherein the optical unit comprises an optical medium and is configured to define the second polarization state based on an electric field and/or a magnetic field through the optical medium. An apparatus and a method are also disclosed.

IRRADIATION DEVICES WITH LASER DIODE ARRAYS FOR ADDITIVELY MANUFACTURING THREE-DIMENSIONAL OBJECTS

An irradiation device for additively manufacturing three-dimensional objects may include a beam generation device that includes a plurality of laser diode arrays. Respective ones of the plurality of laser diode arrays may include a plurality of diode emitters respectively configured to emit an energy beam. The plurality of laser diode arrays may be longitudinally offset relative to one another, and the plurality of laser diode arrays may be laterally offset relative to one another.

METHOD FOR PROCESS CONTROL IN ADDITIVE MANUFACTURING

CLEANING OF AN OPTICAL ELEMENT OF AN ADDITIVE MANUFACTURING DEVICE

The present invention relates to an additive manufacturing machine (1) comprising: an enclosure (2); a source of energy beams (20) for selectively scanning a powder bed (3a) and consolidating it; an optical element (4) secured in the enclosure (2) and made from a material transparent to electromagnetic waves, the optical element (4) having a surface (5) on which a deposit (7) originating from vaporisation of the powder bed (3a) is able to form; and a system (8) for cleaning the surface (5) of the optical element (4) comprising a plasma generator (11), the plasma generator (11) comprising a power electrode (9), placed facing an opposite surface (6) of the optical element (4), and an earth electrode (10) for generating a plasma (11) by capacitive coupling close to the first surface (5).

Additive manufacturing, spatial heat treating system and method

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. The two-dimensional energy patterning system may be used to control the rate of cooling experienced by each successive additive layer. Accordingly, the system may be used to heat treat the various additive layers.

IRRADIATION DEVICES WITH LASER DIODE ARRAYS FOR ADDITIVELY MANUFACTURING THREE-DIMENSIONAL OBJECTS

An irradiation device for additively manufacturing three-dimensional objects may include a beam generation device that includes a plurality of laser diode arrays. Respective ones of the plurality of laser diode arrays may include a plurality of diode emitters respectively configured to emit an energy beam. The plurality of laser diode arrays may be longitudinally offset relative to one another, and the plurality of laser diode arrays may be laterally offset relative to one another.

METHOD FOR MANUFACTURING A METAL PART BY SELECTIVE POWDER-BED FUSION

The present invention relates to a method for manufacturing a metal part (10) by selective powder-bed fusion, the method comprising the following steps: - depositing at least one powder layer of a metal or metal alloy intended to form the part; - melting, by scanning with the energy beam (BF), at least one region of the powder layer, so that the energy density of the beam allows the powder to be locally heated to a temperature that is higher than a melting point of said powder; - stress-relieving, by scanning with the energy beam (BR), the surface of the part (10) to be manufactured, so that the energy density of the beam allows uniform heating, from said surface, of a layer (14) to be stress-relieved at a temperature that is lower than the melting point.

Three-Dimensional Shaping Method and Three-Dimensional Shaping Apparatus

The three-dimensional shaping method and apparatus employs a plurality of galvano scanners 3 that carry out scanning of laser beams 7 along two-dimensional directions on orthogonal coordinates or cylindrical coordinates by reflection from first mirrors 31 that oscillate on rotation axes 30 that are perpendicular to transmission directions of the laser beams 7 that have been transmitted through dynamic focus lenses 2, and second mirrors 32 that oscillate on rotation axes 30 that are perpendicular to the rotation axes 30 of the first mirrors 31 and are in horizontal directions, with oscillation ranges freely adjustable based on control of an oscillation, and having freely selectable regions on a sintered surface 6 at the focal points of the laser beams 7 irradiated in slanted directions with respect to a surface of a table 4, or locations in their vicinity.

ADDITIVE MANUFACTURING SYSTEMS AND RELATED METHODS UTILIZING OPTICAL PHASED ARRAY BEAM STEERING

Methods and systems for additive manufacturing are described. In one embodiment, laser energy is emitted from one or more laser energy sources, and a phase of the laser energy emitted by each of the laser energy sources is controlled to at least partially control a position of one or more laser beams directed towards a build surface. In some embodiments an optical phased array (OPA) is used to at least partially control the position and/or shape of the one or more laser beams on the build surface. Additionally, in some embodiments one or more mirror galvanometers and/or a moveable portion of a system may be used in coordination with one or more OPA assemblies.

Additive Manufacturing, Bond Modifying System And Method

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. The two-dimensional energy patterning system may be used to control a state of matter of each successive additive layer. Accordingly, the system may be used to alter the chemical bond arrangement of the material forming the various additive layers.

MANUFACTURING DEVICE, METHOD AND COMPUTER PROGRAM PRODUCT FOR ADDITIVELY MANUFACTURING COMPONENTS FROM A POWDER MATERIAL

The invention relates to a manufacturing device (1) for additively manufacturing components (3) from a powder material, comprising - a beam generation device (5) for generating a plurality of energy beams (7), - a scanner device (9) for at least intermittently irradiating a work region (11) in locally selective fashion by means of the energy beams (7), - an inert gas device (15) for generating an inert gas flow with a defined inert gas flow direction (P1), and comprising - a control device (17) configured to control the scanner device (9), wherein - the control device (17) is further configured to: define a first irradiated area (19.1) on the work region (11) for a first energy beam (7.1), a first irradiated portion (21.1) for the first energy beam (7.1) being displaced along said irradiated area from a first start position to a first end position within the first irradiated area (19.1); - define upstream of the first irradiated area (19.1) a second irradiated area (19.2) for a second energy ...

APPARATUS FOR PRODUCING A THREE-DIMENSIONAL WORK PIECE

An apparatus (10) for producing a three-dimensional work piece (46) by irradiating layers of a raw material powder with electromagnetic or particle radiation comprises a process chamber (16) accommodating a carrier (12) and a powder application device (14) for applying a layer of raw material powder onto the carrier (12). The apparatus (10) further comprises an irradiation unit (26) for selectively irradiating the layer of raw material powder with electromagnetic or particle radiation in accordance with a geometry of a corresponding layer of the work piece (18) to be produced. An absorption device (50) which is adapted to absorb heat radiation emitted upon selectively irradiating the layer of raw material powder with electromagnetic or particle radiation is provided in the process chamber (16) and/or in the irradiation unit (26) at such a position that it is capable of absorbing radiation occurring in an interior of the process chamber (16) and/or in an interior of the irraditation unit ...

ADDITIVE MANUFACTURING SYSTEM WITH ASYMMETRIC GAS FLOW HEAD

An additive manufacturing system may include a build surface and an optics assembly movable relative to the build surface. The optics assembly may direct laser energy from one or more laser energy sources toward the build surface to melt a portion of the build surface. The system may further comprise a gas flow head operatively coupled to the optics assembly and moveable relative to the build surface. The gas flow head may define a partially enclosed volume between the optics assembly and the build surface. The gas flow head may generate a non-uniform flow of gas through the gas flow head in a direction that is opposite a direction of motion of the optics assembly. A velocity of the gas flow may be sufficient to entrain particles ejected from the melted portion of the layer of material in order to remove the ejected particles from the partially enclosed volume.

3D PRINTING SYSTEM WITH MOVING BUILD MODULE

A 3D printing system uses heat sources, such as lasers, for manufacturing parts in metal additive manufacturing, such as powder-bed fusion, on one or more movable build modules. The build modules may be moved (e.g., by a conveyor system) into and out of a lasing module. Parts may be manufactured on multiple build modules simultaneously and/or sequentially, in some cases while the build module(s) are moving relative to the heat sources. Sensor(s) are arranged to determine a position, orientation, and/or movement of the build modules and feedback from the sensor(s) may be used to control the heat sources to compensate for motion of the build modules.

METHOD AND DEVICE FOR GENERATING CONTROL DATA FOR AN ADDITIVE MANUFACTURING DEVICE

Described are a method and a control data generation device (54, 54′) for use therein for generating control data (PSD) for a device (1) for the additive manufacture of a manufacturing product (2) in a manufacturing process, in which build-up material (13) is built up and selectively solidified, wherein, for the solidification process, the build-up material (13) is irradiated with at least one energy beam (AL) on a build field (8), and an area of incidence (AF) of the energy beam (AL) on the build field (8) is moved in order to melt the build-up material (13). The control data (PSD) are generated such that the energy beam (AL) has an intensity distribution (GIV), at the area of incidence (AF) on the build field (8), in a section plane (x, y) running perpendicularly to the beam axis (SA) of the energy beam (AL), which intensity distribution has at least one local minimum (MIZ) in a middle region along at least one secant of the intensity distribution (GIV) in the section plane (x, y) and ...

METHOD FOR ADDITIVE MANUFACTURING BY MEANS OF DUAL SELECTIVE IRRADIATION OF A POWDER BED AND PREHEATING

AM APPARATUS

One of the objects of the present application is to provide a technique capable of preventing the generation of excessive metallic vapor during fabrication according to an AM technique. Further, one of the objects of the present application is to provide a technique for reducing machining processing after the fabrication as much as possible or eliminating the necessity thereof. According to one aspect, an AM apparatus configured to manufacture a fabrication object is provided. This AM apparatus includes a first DED nozzle configured to fabricate a contour of a fabrication target and a second DED nozzle configured to fabricate an inner portion of the contour.

METHOD OF APPLYING A PLURALITY OF ENERGY BEAMS IN ADDITIVE MANUFACTURING

A method of applying a plurality of energy beams in the additive manufacture of a component includes a) providing a first and a second energy beam, each set up for the irradiation of a layer of a powder bed, wherein the first beam scans over a first irradiation area and the second beam scans over a second irradiation area, wherein the first and second irradiation areas are substantially arranged adjacent to each other and form part of a manufacturing plane, and b) assigning a scan vector to be scanned in the first irradiation area by the second energy beam, when a melt pool generated by the second energy beam during the scan of the vector is expected to cause less overlap with a powder bed outside of the component's geometry than a melt pool generated by the first energy beam would cause during the scan of the vector.

METHOD AND SYSTEM FOR MANUFACTURING LAMINATED SHAPED PRODUCT

Selective laser melting forming method for space curved-surface thin-wall part

The invention discloses a selective laser melting forming method for a spatial curved-surface thin-wall part, a small pipeline in the part is printed by adopting first laser, other structures of the part are printed by adopting second laser, and the power of the first laser is smaller than that of the second laser. According to the selective laser melting forming method for the space curved-surface thin-wall part, blocking of a small pipeline caused by high energy density of printing laser is avoided, and meanwhile the problem that the diameter deviation of the small pipeline is large due to the high energy density of the printing laser is avoided.

3-DIMENSIONAL SHAPING APPARATUS

A 3-dimensional shaping apparatus manufactures a 3-dimensional shaped object. The 3-dimensional shaping apparatus includes a beam irradiation unit, a spatial light modulator, a splitting optical system, and a scanning unit. The beam irradiation unit emits a light beam. The spatial light modulator spatially modulates the light beam emitted by the beam irradiation unit at least on the first axis. The splitting optical system includes at least one lens array having a plurality of lenses arranged along the first axis and splits the light beam modulated by the spatial light modulator into a plurality of light beams by the lens array. The scanning unit scans the shaping material with the plurality of light beams from the splitting optical system.

Sled configurations and methods of operation for the manufacture of three-dimensional objects

Apparatus (1) for manufacturing a three-dimensional object from a powder, the apparatus (1) comprising: a build bed (201) having a build area (190), wherein successive layers of said three-dimensional object are formed in the build bed (201); a powder distribution sled (300) operable to distribute a layer of powder within the build area (190), the powder distribution sled (300) being driveable in a first direction along a first axis, across the build area (190), and driveable in a second direction, opposite to the first direction, along the first axis; and a print sled (350) operable to deposit a pattern of fluid onto the layer of powder within the build area (190) to define the cross section of said object in said layer, the print sled (350) being driveable in the first direction along a second axis across the build area, and driveable in the second direction along the second axis; wherein the first axis is parallel to, or coaxial with, the second axis; wherein the print sled (350) comprises ...

DEVICES, SYSTEMS, AND METHODS FOR USING AN IMAGING DEVICE TO CALIBRATE AND OPERATE A PLURALITY OF ELECTRON BEAM GUNS IN AN ADDITIVE MANUFACTURING SYSTEM

Calibration systems, additive manufacturing systems employing the same, and methods of calibrating include a plurality of electron beam guns (101). One calibration system includes an imaging device (108) positioned to capture one or more images of an impingement of electron beams (151) emitted from the plurality of electron beam guns (101) on a surface within a build chamber (120) of the electron beam additive manufacturing system (100) and an analysis component (140) communicatively coupled to the imaging device (108). The analysis component (140) is programmed to receive image data corresponding to the one or more images, determine one or more calibration parameters from the image data, and transmit one or more instructions to the plurality of electron beam guns (101) in accordance with the one or more calibration parameters.

APPARATUS AND METHOD FOR PRODUCING A THREE-DIMENSIONAL WORK PIECE

An apparatus for producing a three-dimensional work piece is provided. The apparatus comprises a carrier configured to receive multiple layers of raw material powder, an irradiation unit configured to direct at least two radiation beams to predetermined sites of an uppermost layer of the raw material powder in order to solidify the raw material powder at the predetermined sites, a process chamber defining a volume through which the radiation beams are directed from the irradiation unit to the raw material powder, and a support structure provided outside the process chamber and supporting the irradiation unit. The irradiation unit is not affected by process heat generated within the process chamber, such that positions of individual optical components within the irradiation unit with regard to each other stay constant.

METHODS AND SYSTEMS FOR REPAIRING POWDER CONTAINMENT STRUCTURES

APPARATUS FOR ADDITIVELY MANUFACTURING A THREE-DIMENSIONAL OBJECT

Die Erfindung betrifft eine Vorrichtung (1) zur generativen Herstellung eines dreidimensionalen Objekts (2) durch sukzessive schichtweise selektive Verfestigung von Baumaterialschichten aus verfestigbarem Baumaterial (3) vermittels wenigstens eines Laserstrahls (5), umfassend wenigstens eine Einrichtung (4) zur Erzeugung wenigstens eines Laserstrahls (5) zur schichtweisen selektiven Verfestigung einzelner Baumaterialschichten aus verfestigbarem Baumaterial (3), wobei die Einrichtung (4) wenigstens ein direkt über der Bauebene (9), in welcher selektiv zu verfestigende oder verfestigte Baumaterialschichten ausgebildet sind, anordenbares oder angeordnetes Laserdiodenelement (10) umfasst, welches zur Erzeugung eines direkt auf die Bauebene gerichteten Laserstrahls (5) eingerichtet ist und/oder die Einrichtung (4) wenigstens ein außerhalb einer Baukammer (8) der Vorrichtung (1) angeordnetes Laserdiodenelement (10) und wenigstens ein direkt über der Bauebene (9), in welcher selektiv zu verfestigende ...

METHOD FOR DETERMINING A SET POINT FOR A THERMAL SENSOR IN AN APPARATUS FOR THE MANUFACTURE OF 3D OBJECTS

NOVEL ARCHITECTURES FOR HIGH-THROUGHPUT ADDITIVE MANUFACTURING

A method of forming a part can include selectively activating one or more lasers of a laser array comprising at least 100 lasers based at least partially on a geometry of the part being formed. The method can further include scanning laser spots over a powder bed, the laser sports generated by the activated lasers, and selectively sintering a powder contained in the powder bed with the laser spots to form the part.

ADDITIVE MANUFACTURING MACHINE HEAT FLUX

Laser printing system

The invention describes a laser printing system (100) for illuminating an object moving relative to a laser module of the laser printing system (100) in a working plane (180), the laser module comprising at least two laser arrays of semiconductor lasers and at least one optical element, wherein the optical element is adapted to image laser light emitted by the laser arrays, such that laser light of semiconductor lasers of one laser array is imaged to one pixel in the working plane of the laser printing system, and wherein the laser printing system is a 3D printing system for additive manufacturing and wherein two, three, four or a multitude of laser modules (201, 202) are provided, which are arranged in columns (c1, c2) perpendicular to a direction of movement (250) of the object in the working plane (180), and wherein the columns are staggered with respect to each other such that a first laser module (201) of a first column of laser modules (c1) is adapted to illuminate a first area (y1 ...

OPTICAL ZOOM IN ADDITIVE MANUFACTURING

Optics assemblies and their methods of use in additive manufacturing systems are described. In some embodiments, an additive manufacturing system may include a build surface, a plurality of laser energy sources configured to produce a plurality of laser spots on the build surface, and an optics assembly configured to independently control a size of each of the plurality of laser spots and a spacing between the plurality of laser spots on the build surface. The optics assembly may include a plurality of lens arrays, where the plurality of lens arrays is configured to adjust a size of each of the plurality of laser spots on the build surface, and at least one lens. The at least one lens may also be configured to adjust a spacing between the plurality of laser spots on the build surface.

METHOD AND APPARATUS FOR MONITORING AN OPERATION OF A POWDER BED FUSION ADDITIVE MANUFACTURING MACHINE

A method of monitoring an operation of a powder bed fusion machine (100) is provided, wherein a position (P) of a working plane (WP) relative to a beam control (3) is observed, and wherein a calibration of the machine (100) is triggered once a misalignment (m) of the position (P) occurs and an intensity or amplitude of said misalignment (m) exceeds a predetermined threshold. Moreover, a related apparatus (50) for monitoring a powder bed fusion additive manufacturing operation is provided and a related use of said apparatus.

METHODS AND APPARATUS TO OPTIMIZE STITCH QUALITY IN ADDITIVE MANUFACTURING

Methods and apparatus to optimize stitch quality in additive manufacturing are disclosed. An example apparatus includes at least one memory to store instructions, and processor circuitry to execute the instructions identify at least one keep-out zone (310) of an object (210) build area in which stitching is to be reduced during additive manufacturing, determine a first set of stitch coordinates (302, 303) corresponding to a stitching region (215) of the object (210), the stitching region (215) including a stitch boundary of the stitching region (215), and generate a second set of stitch coordinates (302, 303) reducing stitching in the at least one keep-out zone (310) of the object (210) build area, the second set of stitch coordinates (302, 303) determined using at least one of (1) a local search algorithm or (2) a random coordinate modification algorithm, the second set of stitch coordinates (302, 303) to reduce stitch length or support load balancing.

Multi-laser parallel scanning 3D printing method

The invention relates to a multi-laser parallel scanning 3D printing method, which belongs to the technical field of 3D printers, and comprises the following steps: S1, a plurality of lasers emit laser beams at the same time, and the diameters of all the laser beams are adjusted to the same diameter; s2, the multiple laser beams are reflected through the corresponding galvanometer systems and are emitted to a printing working face; s3, for the reflected laser which is not vertically emitted into the printing working face, light spots, projected to the printing working face, of laser beams are adjusted to be equal-diameter light spots through an edge light spot area compensation method, the center points of the light spots are located on the same straight line, and the edges of the adjacent light spots are in contact; and S4, translating each laser and galvanometer system at the same speed and in the same direction to complete scanning. According to the method, Gaussian energy distribution ...

POWDER BED FUSION ADDITIVE MANUFACTURING WITH LOAD BALANCING FOR MULTIPLE BEAMS

Compensating laser alignment for irregularities in an additive manufacturing machine powderbed

A system for additive manufacturing machine energy beam alignment error compensation includes, a calibration table having x-y planar offsets to correct laser alignment errors representing energy beam positional offsets between beam-steering commanded energy beam locations and fiducial marks generated on a burn-paper, a recoater mechanism that distributes successive layers of powder, one or more sensors monitoring the powderbed surface proximal to the beam scan unit, and a processor unit configured to perform a method. The method including collecting sensor data representing height variations across at least a portion of the powderbed surface, deriving dimensional data from the collected data, analyzing the dimensional data to determine a distribution of differences between the powderbed surface and a reference plane containing the burn-paper when the fiducial marks were generated, and calculating z-axis calibration offset points for inclusion in the calibration table x-y planar offsets.

LOCALISING SENSOR DATA COLLECTED DURING ADDITIVE MANUFACTURING

Multi-directional binder jetting additive manufacturing

The devices, systems, and methods of the present disclosure are directed to powder spreading and binder distribution techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, a powder may be spread to form a layer along a volume defined by a powder box, a binder may be deposited along the layer to form a layer of a three-dimensional object, and the direction of spreading the layer and depositing the binder may be in a first direction and in a second direction, different from the first direction, thus facilitating rapid formation of the three-dimensional object with each passage of the print carriage over the volume. Powder delivery, powder spreading, thermal energy delivery, and combinations thereof, may facilitate consistently achieving quality standards as the rate of fabrication of the three-dimensional object is increased.

PROCESS FOR MANUFACTURING A PART BY LOCAL IRRADIATION OF A MATERIAL BY AT LEAST TWO CONVERGING BEAMS

Manufacturing of a part by local irradiation of a material that can be sintered, melted or photopolymerized, by: providing a volume of the material for manufacturing the part and compressing the volume by applying a pressure; defining, in the volume, a plurality of different target volumes, the combined target volumes defining the part to be manufactured; for each target volume, maintaining the pressure applied to the volume and simultaneously irradiating the target volume with at least two continuous beams that converge in the target volume; releasing the obtained part from the rest of non-irradiated material. The material is partially transparent to the beams; the energy applied to the target volume by each beam is greater than Ethreshold, the sum of the energies applied to the target volume by each of the beams is greater than or equal to Etransformation threshold.