Abstract: A method, apparatus, and program for additive manufacturing. In one aspect, the additive manufacturing method includes irradiating a build material (416) to form a first solidified portion within a first scan region (812A) using an irradiation source (401) of a build unit (400). At least one of the build unit and a build platform may be moved to irradiate a second scan region (812B), wherein an irradiation source (401) directing mechanism is adjusted to compensate for a misalignment between the first scan region and the second scan region (640).

Abstract: An additive manufacturing machine (910) includes a build unit (920) including a powder dispenser (906) having a hopper (904) for receiving a volume of additive powder (902). A powder supply system (1000) includes a powder supply source (940) and a conveyor (1024) for transporting dispensed additive powder (902) to the hopper (904). A supply sensing system (1060) monitors the additive powder (902) that is dispensed from the powder supply source (940) and transported to the hopper (904) and a hopper sensing system (1040) monitors the additive powder (902) within the hopper (904). Each of these systems includes one or more powder level sensors (1042, 1044, 1062), weight sensors (1050, 1064), and/or vision systems (1054, 1070) for monitoring the additive powder (902).

Abstract: An additive manufacturing apparatus is provided and may include at least one build unit; a build platform; and at least one collector positioned on the apparatus such that the at least one collector contacts an outer surface of a build wall as the build wall is formed during a build. Methods are also provided for manufacturing at least one object.

Abstract: An additive manufacturing machine (910) includes a build unit (920) comprising a powder dispenser (906) including a hopper (1004) for receiving a volume of additive powder (1006). A powder supply system (1000) includes a powder supply source (1010) for providing additive powder (1006) into the hopper (1004) during a refill process. A powder reclamation system (1002) includes a vacuum pump (1030) coupled to a vacuum duct (1034, 1036) defining a suction inlet (1040) positioned for collecting misdirected additive powder (1006) dispensed during the refill process. A return duct (1038) includes a filter mechanism (1050) may filter and return the collected additive powder (1006) back to the powder supply source (1010) for reuse.

Abstract: The present disclosure generally relates to methods and apparatuses (200) for additive manufacturing with improved powder (702) distribution capabilities. One aspect involves a mobile build unit (700) that can be moved around in two to three dimensions by a positioning system, to build separate portions of an object, such as a large object. The mobile build unit (700) may be used with an energy directing device (712) that directs irradiation onto a powder (702) layer. In the case of laser irradiation, the mobile build unit (700) may be used with a gasflow device (713A, 713B) that provides laminar gas flow to a laminar flow zone (714) above the layer of powder (703).

Abstract: A scanning technique for the additive manufacturing of an object. The method comprises the irradiation a portion of a given layer of powder to form a fused region using an energy source. When forming an object layer by layer, the irradiation follows a first irradiation pattern at least partially bounded by a stripe region. When forming the first fused region using a first irradiation pattern a first series of solidification lines are formed, at angle other than 90° with respect to a substantially linear stripe region boundary. A series of second solidification lines are formed that intersecting the end of the first solidification line at a first angle other than 0° and 180° with respect to the first solidification line. A third series of solidification lines are formed that are substantially parallel to a first series of solidification lines and intersect one of the second solidification lines.

Abstract: The present disclosure generally relates to methods of additive manufacturing with control of the energy beam incidence angle that allows for aligning the laser beam angle to directly oppose the building direction of an angled wall. The method includes building an object in an additive manufacturing powder bed where the object includes a surface that is defined by a build vector projecting outward relative to the build plate center at an angle ? relative to normal of the build plate such that 90°>?>0° and the directed energy beam forms an angle ?L2 relative to normal of the build plate such that 270°>?L2>180°, wherein ?L2??=180°±?, and ?<45°. The present methods provide finished objects having overhanging regions with more consistent surface finish and resistance to mechanical strain or stress.

Abstract: The present disclosure generally relates to additive manufacturing systems and methods on a large-scale format. One aspect involves a build unit that can be moved around in three dimensions by a positioning system, building separate portions of a large object. The build unit has an energy directing device that directs, e.g., laser or e-beam irradiation onto a powder layer. In the case of laser irradiation, the build volume may have a gasflow device that provides laminar gas flow to a laminar flow zone above the layer of powder. This allows for efficient removal of the smoke, condensates, and other impurities produced by irradiating the powder (the “gas plume”) without excessively disturbing the powder layer. The build unit may also have a recoater that allows it to selectively deposit particular quantities of powder in specific locations over a work surface to build large, high quality, high precision objects.

Abstract: The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials, in-process monitoring, and closed loop control.

Abstract: The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials, in-process monitoring, and closed loop control.

Abstract: The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials.

Abstract: The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials, in-process monitoring, and closed loop control.

Abstract: A method of fabricating an object by additive manufacturing is provided. The method includes measuring a build surface for building the object, determining which areas of the build surface are depressed, and initiating a build of the object at one of the depressed areas of the build surface. The initial building includes the steps of depositing a given layer of powder at the one depressed area of the build surface, fusing the given layer of powder at the one depressed area, and depositing a subsequent layer of powder at the one depressed area. The steps are repeating until the build surface is at a layer that is unified across the build surface.

Abstract: A method for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The apparatus used in the method includes a build unit and a machining mechanism that are attached to a positioning mechanism, a rotating platform, and a rotary encoder attached to the rotating platform. The method involves rotating the build platform; determining the rotational speed; growing the object and the build wall through repetitive cycles of moving the build unit(s) over and substantially parallel to multiple build areas within the build platform to deposit a layer of powder at each build area, leveling the powder, and irradiating the powder to form a fused additive layer at each build area; machining the object being manufactured; and cutting and removing the build wall. The irradiation parameters are calibrated based on the determined rotational speed.

Abstract: An apparatus for powder-based additive manufacturing is described. The build unit(s) of the apparatus includes a powder delivery mechanism, a powder recoating mechanism and an irradiation beam directing mechanism. The build unit is attached to a positioning mechanism that provides the build unit with independent movements in at least two dimensions. The build platform of the apparatus is rotating and preferably vertically stationary. Embodiments of the build unit that further includes a gas-flow mechanism and the build platform having a dynamically grown wall are also described. An additive manufacturing method using the apparatus involves rotating the build platform and repetitive cycles of moving the build unit(s) in a radial direction to deposit at least one layer of powder, and irradiating a selected portion of the powder to form a fused additive layer.

Abstract: An apparatus for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The build unit(s) of the apparatus includes a powder delivery mechanism, a powder recoating mechanism and an irradiation beam directing mechanism. The build unit and the machining mechanism are attached to a positioning mechanism that provides them with movement. The build platform of the apparatus is rotating and preferably vertically stationary. Embodiments of the build unit that further includes a gas-flow mechanism and the build platform having a dynamically grown wall are also described. A manufacturing method using the apparatus involves rotating the build platform; repetitive cycles of moving the build unit(s) to deposit a powder and irradiating the powder to form a fused additive layer; and machining the object being manufactured.

Abstract: A method for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The apparatus used in the method includes a build unit and a machining mechanism that are attached to a positioning mechanism, a rotating platform, and a rotary encoder attached to the rotating platform. The method involves rotating the build platform; determining the rotational speed; growing the object and the build wall through repetitive cycles of moving the build unit(s) over and substantially parallel to multiple build areas within the build platform to deposit a layer of powder at each build area, leveling the powder, and irradiating the powder to form a fused additive layer at each build area; machining the object being manufactured; and cutting and removing the build wall. The irradiation parameters are calibrated based on the determined rotational speed.

Abstract: A method for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The apparatus used in the method includes one or more build units and a machining mechanism that are attached to a positioning mechanism, and a rotating build platform. The method involves at least rotating the build platform; repetitive cycles of moving the build unit(s) to deposit powder and irradiating at least a selected portion of the powder to form at least one fused layer to form at least one object and a build wall that retains unfused powder about the object; and removing the build wall by rotational machining.

Abstract: The present disclosure generally relates to powder packing for additive manufacturing (AM) methods and systems. Conventional powder packing methods have focused on leveling the bulk powder cone in the powder reservoir. Moreover, such methods may be manual and non-standardized, and they result in operator fatigue and potentially product inconsistencies. Powder packing according to the present disclosure improves standardization and reduces turnaround time, with the potential to lower the cost of AM.

Abstract: The present disclosure generally relates to powder packing for additive manufacturing (AM) methods and systems. Conventional powder packing methods are manual and non-standardized, and they result in operator fatigue and potentially product inconsistencies. Powder packing according to the present disclosure improves standardization and reduces turnaround time, with the potential to lower the cost of AM.