Abstract: Disclosed embodiments relate to additive manufacturing systems. In some embodiments, an additive manufacturing system may include a plurality of laser energy sources, an optics assembly configured to direct laser energy onto a build surface, and an optical fiber connector positioned between the plurality of laser energy sources and the optics assembly. A first plurality of optical fibers may extend between the plurality of laser energy sources and the optical fiber connector, and a second plurality of optical fibers may extend between the optical fiber connector and the optics assembly. Each optical fiber of the first plurality of optical fibers may be coupled to a corresponding optical fiber of the second plurality of optical fibers within the optical fiber connector.

Abstract: Systems and methods for additive manufacturing are generally disclosed. Additive manufacturing may be performed in a continuous manner and/or semi-continuous manner by transporting one or more build plates relative to printheads that comprise a plurality of energy source arrays and/or binderjet arrays that may be selectively activated to form a desired pattern in a material layer disposed on the one or more build plates.

Abstract: Systems and methods for additive manufacturing are generally described. In some embodiments, an additive manufacturing system may include at least one mechanical fixture in the form of a resilient member for accurately positioning one or more optical fibers without the use of adhesives. The resilient member may, in some embodiments, bias each optical fiber (or similarly, an endcap coupled to a distal end of an optical fiber) against an alignment fixture to maintain a desired position and/or orientation of the fiber or endcap. In some embodiments, an additive manufacturing system may include at least one stray light baffle for reducing the amount of stray light within the optical system.

Abstract: Methods and apparatuses for additive manufacturing are described. A method for additive manufacturing may include exposing a layer of material on a build surface to one or more projections of laser energy including at least one line laser having a substantially linear shape. The intensity of the line laser may be modulated so as to cause fusion of the layer of material according to a desired pattern as the one or more projections of laser energy are scanned across the build surface.

Abstract: Methods and apparatuses for additive manufacturing are described. A method for additive manufacturing may include exposing a layer of material on a build surface to one or more projections of laser energy including at least one line laser having a substantially linear shape. The intensity of the line laser may be modulated so as to cause fusion of the layer of material according to a desired pattern as the one or more projections of laser energy are scanned across the build surface.

Abstract: Systems and methods for additive manufacturing are generally described. According to certain aspects, endcaps optically coupled to optical fibers of additive manufacturing systems are provided. In some aspects, methods for reducing a power area density of laser energy within an endcap are provided. The endcaps described herein may be used to at least partially mitigate thermal cycling that may result from the transmission of laser energy through interfaces of an additive manufacturing system.

Abstract: Disclosed are systems, devices, and methods for additive manufacturing that allow for control of composition and/or porosity of components being manufactured. More particularly, in exemplary embodiments, a secondary material can be used in conjunction with a primary feedstock material in a spatially controlled manner during an additive manufacturing process to control a composition of materials and/or porosity of a manufactured component. Systems, devices, and methods for additive manufacturing are also disclosed that allow for control of a pressure of an atmosphere surrounding a build surface during an additive manufacturing process. More particularly, a pressure of an atmosphere surrounding a build surface can be raised to a pressure greater than standard atmospheric pressure. Various features of the exemplary embodiments of the systems, devices, and methods disclosed can be used together to further control for composition and/or porosity and quality of a manufactured part.

Abstract: Additive manufacturing systems and related methods are disclosed. In some embodiments, an additive manufacturing system includes a build surface, one or more laser energy sources configured to emit laser energy, an optical phased array operatively coupled to the one or more laser energy sources, and a Risley prism assembly comprising a plurality of wedge prisms. The optical phased array includes one or more phase shifters operatively coupled to the one or more laser energy sources and configured to control a phase of the laser energy. The optical phased array is configured to direct the laser energy towards the Risley prism assembly, and the Risley prism assembly is configured to direct the laser energy towards the build surface.

Abstract: Systems and methods for additive manufacturing are described. In some embodiments, a method of controlling the one or more laser energy sources of an additive manufacturing system may be based at least in part on a scan angle and/or desired energy density. Systems and methods for controlling melt pool spacing are also described.

Abstract: 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.

Abstract: Methods and apparatuses for additive manufacturing are described. A method for additive manufacturing may include exposing a layer of material on a build surface to one or more projections of laser energy including at least one line laser having a substantially linear shape. The intensity of the line laser may be modulated so as to cause fusion of the layer of material according to a desired pattern as the one or more projections of laser energy are scanned across the build surface.

Abstract: Aspects described herein relate to additive manufacturing systems and related methods. An additive manufacturing system may include two or more laser energy sources and associated optical fibers. An optics assembly may be constructed and arranged to form a rectangular laser energy pixel associated with each laser energy source. Each pixel may have a substantially uniform power density, and the pixels may be arranged to form a linear array of laser energy pixels on a build surface with no spacing between the pixels. Exposure of a portion of a layer of material on the build surface to the linear array of laser energy pixels may melt the portion of the layer.

Abstract: Methods and apparatuses for additive manufacturing are described. A method for additive manufacturing may include exposing a layer of material on a build surface to one or more projections of laser energy including at least one line laser having a substantially linear shape. The intensity of the line laser may be modulated so as to cause fusion of the layer of material according to a desired pattern as the one or more projections of laser energy are scanned across the build surface.

Abstract: Aspects described herein relate to additive manufacturing systems and related methods. An additive manufacturing system may include two or more laser energy sources and associated optical fibers. An optics assembly may be constructed and arranged to form a rectangular laser energy pixel associated with each laser energy source. Each pixel may have a substantially uniform power density, and the pixels may be arranged to form a linear array of laser energy pixels on a build surface with no spacing between the pixels. Exposure of a portion of a layer of material on the build surface to the linear array of laser energy pixels may melt the portion of the layer.

Abstract: Disclosed embodiments relate to additive manufacturing systems. In some embodiments, an additive manufacturing system may include a plurality of laser energy sources, an optics assembly configured to direct laser energy onto a build surface, and an optical fiber connector positioned between the plurality of laser energy sources and the optics assembly. A first plurality of optical fibers may extend between the plurality of laser energy sources and the optical fiber connector, and a second plurality of optical fibers may extend between the optical fiber connector and the optics assembly. Each optical fiber of the first plurality of optical fibers may be coupled to a corresponding optical fiber of the second plurality of optical fibers within the optical fiber connector.

Abstract: Disclosed are systems, devices, and methods for additive manufacturing that allow for control of composition and/or porosity of components being manufactured. More particularly, in exemplary embodiments, a secondary material can be used in conjunction with a primary feedstock material in a spatially controlled manner during an additive manufacturing process to control a composition of materials and/or porosity of a manufactured component. Systems, devices, and methods for additive manufacturing are also disclosed that allow for control of a pressure of an atmosphere surrounding a build surface during an additive manufacturing process. More particularly, a pressure of an atmosphere surrounding a build surface can be raised to a pressure greater than standard atmospheric pressure. Various features of the exemplary embodiments of the systems, devices, and methods disclosed can be used together to further control for composition and/or porosity and quality of a manufactured part.

Abstract: Aspects described herein relate to additive manufacturing systems and related methods. An additive manufacturing system may include two or more laser energy sources and associated optical fibers. An optics assembly may be constructed and arranged to form a rectangular laser energy pixel associated with each laser energy source. Each pixel may have a substantially uniform power density, and the pixels may be arranged to form a linear array of laser energy pixels on a build surface with no spacing between the pixels. Exposure of a portion of a layer of material on the build surface to the linear array of laser energy pixels may melt the portion of the layer.

Abstract: Methods and apparatuses for additive manufacturing are described. A method for additive manufacturing may include exposing a layer of material on a build surface to one or more projections of laser energy including at least one line laser having a substantially linear shape. The intensity of the line laser may be modulated so as to cause fusion of the layer of material according to a desired pattern as the one or more projections of laser energy are scanned across the build surface.