Abstract: A method of manufacturing a gear shaft including depositing only a first material via directed energy deposition (DED), forming a first portion of the gear shaft via the depositing only the first material via directed energy deposition (DED), forming a transitioning portion of the gear shaft via depositing of a varying ratio of the first material with a second material via DED, and forming a second portion of the gear shaft via the depositing via DED of only the second material.

Abstract: A method of manufacturing a gear shaft including depositing only a first material via directed energy deposition (DED), forming a first portion of the gear shaft via the depositing only the first material via directed energy deposition (DED), forming a transitioning portion of the gear shaft via depositing of a varying ratio of the first material with a second material via DED, and forming a second portion of the gear shaft via the depositing via DED of only the second material.

Abstract: A blade changer includes a housing with a port, a magazine supported within the housing, and a manipulator. The manipulator is operably associated with the magazine and has a reach extending beyond the port to interchange re-coater blades between the magazine and an additive manufacturing system coupled to the port. Additive manufacturing systems and methods of interchanging a deployed re-coater blade with a staged re-coater blade are also described.

Abstract: A solenoid valve includes a valve body defining a valve inlet and a valve outlet in fluid communication with one another by a flow path through the valve body. A magnetic coil is housed with the valve body. An armature within the valve body includes an actuation portion extending along a longitudinal axis, and a valve portion extending along the longitudinal axis and connected to the actuation portion by a transition portion. The actuation portion includes a first material, the valve portion includes a second material different from the first material, and the transition portion includes a gradient material blended from the first material to the second material in a direction from the actuation portion to the valve portion.

Abstract: A method of manufacturing a gear shaft including depositing only a first material via directed energy deposition (DED), forming a first portion of the gear shaft via the depositing only the first material via directed energy deposition (DED), forming a transitioning portion of the gear shaft via depositing of a varying ratio of the first material with a second material via DED, and forming a second portion of the gear shaft via the depositing via DED of only the second material.

Abstract: A blade changer includes a housing with a port, a magazine supported within the housing, and a manipulator. The manipulator is operably associated with the magazine and has a reach extending beyond the port to interchange re-coater blades between the magazine and an additive manufacturing system coupled to the port. Additive manufacturing systems and methods of interchanging a deployed re-coater blade with a staged re-coater blade are also described.

Abstract: A method of manufacturing a gear shaft including depositing only a first material via directed energy deposition (DED), forming a first portion of the gear shaft via the depositing only the first material via directed energy deposition (DED), forming a transitioning portion of the gear shaft via depositing of a varying ratio of the first material with a second material via DED, and forming a second portion of the gear shaft via the depositing via DED of only the second material.

Abstract: A solenoid valve includes a valve body defining a valve inlet and a valve outlet in fluid communication with one another by a flow path through the valve body. A magnetic coil is housed with the valve body. An armature within the valve body includes an actuation portion extending along a longitudinal axis, and a valve portion extending along the longitudinal axis and connected to the actuation portion by a transition portion. The actuation portion includes a first material, the valve portion includes a second material different from the first material, and the transition portion includes a gradient material blended from the first material to the second material in a direction from the actuation portion to the valve portion.

Abstract: An additive manufacturing system includes an energy gun for melting at least a portion of a raw material layer and thereby forming at least in part a slice of a workpiece and a sensor for detecting surface and sub-surface anomalies or physical properties of the portion. The system also includes a positioning mechanism that moves the sensor in at least one of a normal direction and a parallel direction relative to an upper surface of the workpiece.