Abstract: A method of fabricating a component is provided. The method includes depositing particles onto a build platform. The method also includes distributing the particles to form a build layer. The method further includes operating a consolidation device to consolidate a first plurality of particles along a scan path to form a component. The component includes a top surface spaced apart from the build platform and an outer surface. The outer surface extends between the build platform and the top surface, and at least a portion of the outer surface faces a substantially particle-free region of the build platform.

Abstract: Methods of additively manufacturing a three-dimensional object include irradiating a first build plane region using a first energy beam defining a beam diameter, the first energy beam travelling along a first oscillating path in a first direction to consolidate a first wall defining a thickness perpendicular to the first direction, wherein a build material adjacent a first side of the first wall and the build material adjacent a second side of the first wall, opposite the first side of the first wall, remains unconsolidated; and wherein the thickness of the first wall is greater than the beam diameter.

Abstract: Methods and systems for fabricating a component by consolidating a first portion of a particulate include a louvered particulate containment wall positioned around the component and a second portion of the particulate. At least one louver is coupled to the particulate containment wall adjacent at least one opening in the particulate containment wall. The particulate containment wall is positionable between a first position in which the louver prevents the second portion of the particulate from flowing through the passage and a second position in which the second portion of the particulate is able to flow through the passage. The methods include switching the particulate containment wall from the first position to the second position and allowing the second portion of the particulate to flow out of the interior space through the at least one opening.

Abstract: In one aspect, an additive manufacturing system is provided. The additive manufacturing system includes a build platform, a first plurality of particles positioned on the build platform, and a particle containment system positioned on the build platform. The particle containment system includes a particle containment wall. The particle containment wall at least partially surrounds the first plurality of particles and includes a second plurality of particles consolidated together. The particle containment wall includes a top end spaced apart from the build platform, an inner face positioned against the first plurality of particles and extending between the build platform and the top end, and an outer face that faces a substantially particle-free region, the outer face positioned opposite the inner face and extending between the build platform and the top end.

Abstract: An additive manufacturing system includes a first laser device configured to generate a first laser beam and a second laser device configured to generate a second laser beam. The laser scanning devices include a first laser scanning device and a second laser scanning device. The first laser scanning device is configured to selectively direct the first laser beam from the first laser devices across a powder bed along a plurality of first hatching paths and a first contour path along a contour of the solid component. The second laser scanning device is configured to selectively direct the second laser beam from the second laser devices across the powder bed along a plurality of second hatching paths and a second contour path along the contour of the solid component. The first contour path includes a first hook extending into the plurality of second hatching paths.

Abstract: Methods and systems for fabricating a component by consolidating a first portion of a particulate include a louvered particulate containment wall positioned around the component and a second portion of the particulate. At least one louver is coupled to the particulate containment wall adjacent at least one opening in the particulate containment wall. The particulate containment wall is positionable between a first position in which the louver prevents the second portion of the particulate from flowing through the passage and a second position in which the second portion of the particulate is able to flow through the passage. The methods include switching the particulate containment wall from the first position to the second position and allowing the second portion of the particulate to flow out of the interior space through the at least one opening.

Abstract: A method of fabricating a component is provided. The method includes depositing particles onto a build platform. The method also includes distributing the particles to form a build layer. The method further includes operating a consolidation device to consolidate a first plurality of particles along a scan path to form a component. The component includes a top surface spaced apart from the build platform and an outer surface. The outer surface extends between the build platform and the top surface, and at least a portion of the outer surface faces a substantially particle-free region of the build platform.

Abstract: An additive manufacturing system includes a build platform, a plurality of particles positioned on the build platform defining a build layer, a first and second region within the build layer, and at least one consolidation device. The first region and the second region each including a portion of the plurality of particles. The at least one consolidation device is configured to consolidate the plurality of particles within the build layer into a solid, consolidated portion of said build layer. The consolidation device is further configured to consolidate at least one of the plurality of particles within the build layer and the solid, consolidated portion of the build layer into a molten volume of transfer material. The consolidation device is further configured to transfer a portion of the molten volume of transfer material within the first region from the first region to the second region.

Abstract: Methods and systems for fabricating a component by consolidating a first portion of a particulate include a louvered particulate containment wall positioned around the component and a second portion of the particulate. At least one louver is coupled to the particulate containment wall adjacent at least one opening in the particulate containment wall. The particulate containment wall is positionable between a first position in which the louver prevents the second portion of the particulate from flowing through the passage and a second position in which the second portion of the particulate is able to flow through the passage. The methods include switching the particulate containment wall from the first position to the second position and allowing the second portion of the particulate to flow out of the interior space through the at least one opening.

Abstract: A method of fabricating a component is provided. The method includes depositing particles onto a build platform. The method also includes distributing the particles to form a build layer. The method further includes operating a consolidation device to consolidate a first plurality of particles along a scan path to form a component. The component includes a top surface spaced apart from the build platform and an outer surface. The outer surface extends between the build platform and the top surface, and at least a portion of the outer surface faces a substantially particle-free region of the build platform.

Abstract: An additive manufacturing system includes a first laser device configured to generate a first laser beam and a second laser device configured to generate a second laser beam. The laser scanning devices include a first laser scanning device and a second laser scanning device. The first laser scanning device is configured to selectively direct the first laser beam from the first laser devices across a powder bed along a plurality of first hatching paths and a first contour path along a contour of the solid component. The second laser scanning device is configured to selectively direct the second laser beam from the second laser devices across the powder bed along a plurality of second hatching paths and a second contour path along the contour of the solid component. The first contour path includes a first hook extending into the plurality of second hatching paths.

Abstract: An additive manufacturing system includes a build platform, at least one first consolidation device, and at least one second consolidation device. The at least one first consolidation device is configured to direct at least one first energy beam to a first face of a component. The first face has a first orientation. The at least one second consolidation device is configured to simultaneously direct at least one second energy beam toward a second face of the component as the first consolidation device directs the at least one first energy beam toward the first face. The second face has a second orientation different from the first orientation.

Abstract: Methods and systems for fabricating a component by consolidating a first portion of a particulate include a louvered particulate containment wall positioned around the component and a second portion of the particulate. At least one louver is coupled to the particulate containment wall adjacent at least one opening in the particulate containment wall. The particulate containment wall is positionable between a first position in which the louver prevents the second portion of the particulate from flowing through the passage and a second position in which the second portion of the particulate is able to flow through the passage. The methods include switching the particulate containment wall from the first position to the second position and allowing the second portion of the particulate to flow out of the interior space through the at least one opening.

Abstract: An additive manufacturing system includes a build platform, a plurality of particles positioned on the build platform defining a build layer, a first and second region within the build layer, and at least one consolidation device. The first region and the second region each including a portion of the plurality of particles. The at least one consolidation device is configured to consolidate the plurality of particles within the build layer into a solid, consolidated portion of said build layer. The consolidation device is further configured to consolidate at least one of the plurality of particles within the build layer and the solid, consolidated portion of the build layer into a molten volume of transfer material. The consolidation device is further configured to transfer a portion of the molten volume of transfer material within the first region from the first region to the second region.

Abstract: A method of manufacturing a component using an additive manufacturing system is provided. The method includes providing a build file on a controller of the additive manufacturing system. The build file includes at least one generating function, at least one seed value, and at least one function parameter. The method also includes generating a curve that corresponds to the component based on the at least one generating function, the at least one seed value, and the at least one function parameter. The method further includes positioning a material on a surface. The method further includes determining, using the controller, a plurality of set points for a consolidation device. The plurality of set points are located along the curve. The method also includes operating the consolidation device of the additive manufacturing system to consolidate the material.

Abstract: A method of fabricating a component is provided. The method includes depositing particles onto a build platform. The method also includes distributing the particles to form a build layer. The method further includes operating a consolidation device to consolidate a first plurality of particles along a scan path to form a component. The component includes a top surface spaced apart from the build platform and an outer surface. The outer surface extends between the build platform and the top surface, and at least a portion of the outer surface faces a substantially particle-free region of the build platform.

Abstract: An additive manufacturing system includes a build platform, at least one first consolidation device, and at least one second consolidation device. The at least one first consolidation device is configured to direct at least one first energy beam to a first face of a component. The first face has a first orientation. The at least one second consolidation device is configured to simultaneously direct at least one second energy beam toward a second face of the component as the first consolidation device directs the at least one first energy beam toward the first face. The second face has a second orientation different from the first orientation.

Abstract: A method for repairing a structure in an additive manufacturing system is provided. The method includes detecting a defect in a structure formed using an additive manufacturing process, the structure including a first surface that faces a powder containing region and a second surface that faces a substantially powder free region, generating a supplemental scan path that covers at least a portion of the structure based on a location of the detected defect, and controlling a consolidation device, based on the supplemental scan path, to remedy the defect.

Abstract: In one aspect, an additive manufacturing system is provided. The additive manufacturing system includes a build platform, a first plurality of particles positioned on the build platform, and a particle containment system positioned on the build platform. The particle containment system includes a particle containment wall. The particle containment wall at least partially surrounds the first plurality of particles and includes a second plurality of particles consolidated together. The particle containment wall includes a top end spaced apart from the build platform, an inner face positioned against the first plurality of particles and extending between the build platform and the top end, and an outer face that faces a substantially particle-free region, the outer face positioned opposite the inner face and extending between the build platform and the top end.

Abstract: A method for repairing a structure in an additive manufacturing system is provided. The method includes detecting a defect in a structure formed using an additive manufacturing process, the structure including a first surface that faces a powder containing region and a second surface that faces a substantially powder free region, generating a supplemental scan path that covers at least a portion of the structure based on a location of the detected defect, and controlling a consolidation device, based on the supplemental scan path, to remedy the defect.