Abstract: An additive manufacturing machine includes an energy beam system situated in a fixed position relative to a reference plane coinciding with an expected location of a build plane, an energy beam system with an irradiation device configured to generate an energy beam and to direct the energy beam upon the build plane, and a position measurement system configured to determine a position of the build plane. A position measurement assembly includes one or more position sensors, and one or more mounting brackets configured to attach the one or more position sensors to an energy beam system of an additive manufacturing machine. The position measurement assembly is configured to determine a position of a build plane with the energy beam system situated in a fixed position relative to a reference plane coinciding with an expected location of the build plane.

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 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 machine includes an energy beam system situated in a fixed position relative to a reference plane coinciding with an expected location of a build plane, an energy beam system with an irradiation device configured to generate an energy beam and to direct the energy beam upon the build plane, and a position measurement system configured to determine a position of the build plane. A position measurement assembly includes one or more position sensors, and one or more mounting brackets configured to attach the one or more position sensors to an energy beam system of an additive manufacturing machine. The position measurement assembly is configured to determine a position of a build plane with the energy beam system situated in a fixed position relative to a reference plane coinciding with an expected location of the build plane.

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: A heat exchanger and a method for additively manufacturing the heat exchanger are provided. The heat exchanger includes a plurality of fluid passageways that are formed by additive manufacturing methods which enable the formation of fluid passageways that are smaller in size, that have thinner walls, and that have complex and intricate heat exchanger features that were not possible using prior manufacturing methods. For example, the fluid passageways may be curvilinear and may include heat exchanging fins that are less than 0.01 inches thick and formed at a fin density of more than four heat exchanging fins per centimeter. In addition, the heat exchanging fins may be angled with respect to the walls of the fluid passageways and adjacent fins may be offset relative to each other.

Abstract: A flow control device for an additive manufacturing system is provided. The flow control device includes a gas supply configured to discharge a gas, a first flow modifier configured to modify at least one flow characteristic of a first portion of the gas, and a second flow modifier configured to cooperate with the first flow modifier to modify the at least on flow characteristic of the first portion of the gas. The second flow modifier is further configured to modify at least one flow characteristic of a second portion of the gas, and the first flow modifier and the second flow modifier are configured to cooperate to direct at least a portion of the first portion and the second portion of the gas towards a melt pool in a plurality of particles.

Abstract: A thermal management system includes a housing, and a monolithic core structure disposed within the housing. An outer surface of the core structure defines at least part of a first passageway. An inner surface of the core structure defines at least part of a second passageway. The core structure includes a separator wall that isolates a first flow passing through the first passageway from a second flow passing through the second passageway. The first passageway is in thermal communication with the second passageway. The core structure includes one or more heat exchanger features, or fins, that are positioned within the first passageway, the second passageway, or both the first and second passageways. The core structure may have a compliant segment coupled to two or more walls.

Abstract: A heat exchanger and a method for additively manufacturing the heat exchanger are provided. The heat exchanger includes a plurality of fluid passageways that are formed by additive manufacturing methods which enable the formation of fluid passageways that are smaller in size, that have thinner walls, and that have complex and intricate heat exchanger features that were not possible using prior manufacturing methods. For example, the fluid passageways may be curvilinear and may include heat exchanging fins that are less than 0.01 inches thick and formed at a fin density of more than four heat exchanging fins per centimeter. In addition, the heat exchanging fins may be angled with respect to the walls of the fluid passageways and adjacent fins may be offset relative to each other.

Abstract: A heat exchanger and a method for additively manufacturing the heat exchanger are provided. The heat exchanger includes a plurality of fluid passageways that are formed by additive manufacturing methods which enable the formation of fluid passageways that are smaller in size, that have thinner walls, and that have complex and intricate heat exchanger features that were not possible using prior manufacturing methods. For example, the fluid passageways may be curvilinear and may include heat exchanging fins that are less than 0.01 inches thick and formed at a fin density of more than four heat exchanging fins per centimeter. In addition, the heat exchanging fins may be angled with respect to the walls of the fluid passageways and adjacent fins may be offset relative to each other.

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: A flow control device for an additive manufacturing system is provided. The flow control device includes a gas supply configured to discharge a gas, a first flow modifier configured to modify at least one flow characteristic of a first portion of the gas, and a second flow modifier configured to cooperate with the first flow modifier to modify the at least on flow characteristic of the first portion of the gas. The second flow modifier is further configured to modify at least one flow characteristic of a second portion of the gas, and the first flow modifier and the second flow modifier are configured to cooperate to direct at least a portion of the first portion and the second portion of the gas towards a melt pool in a plurality of particles.

Abstract: A heat exchanger and a method for additively manufacturing the heat exchanger are provided. The heat exchanger includes a plurality of fluid passageways that are formed by additive manufacturing methods which enable the formation of fluid passageways that are smaller in size, that have thinner walls, and that have complex and intricate heat exchanger features that were not possible using prior manufacturing methods. For example, the fluid passageways may be curvilinear and may include heat exchanging fins that are less than 0.01 inches thick and formed at a fin density of more than four heat exchanging fins per centimeter. In addition, the heat exchanging fins may be angled with respect to the walls of the fluid passageways and adjacent fins may be offset relative to each other.

Abstract: A heat exchanger and a method for additively manufacturing the heat exchanger are provided. The heat exchanger includes a plurality of fluid passageways that are formed by additive manufacturing methods which enable the formation of fluid passageways that are smaller in size, that have thinner walls, and that have complex and intricate heat exchanger features that were not possible using prior manufacturing methods. For example, the fluid passageways may be curvilinear and may include heat exchanging fins that are less than 0.01 inches thick and formed at a fin density of more than four heat exchanging fins per centimeter. In addition, the heat exchanging fins may be angled with respect to the walls of the fluid passageways and adjacent fins may be offset relative to each other.

Abstract: A heat exchanger and a method for additively manufacturing the heat exchanger are provided. The heat exchanger includes a plurality of fluid passageways that are formed by additive manufacturing methods which enable the formation of fluid passageways that are smaller in size, that have thinner walls, and that have complex and intricate heat exchanger features that were not possible using prior manufacturing methods. For example, the fluid passageways may be curvilinear and may include heat exchanging fins that are less than 0.01 inches thick and formed at a fin density of more than four heat exchanging fins per centimeter. In addition, the heat exchanging fins may be angled with respect to the walls of the fluid passageways and adjacent fins may be offset relative to each other.

Abstract: A thermal management system includes a housing, and a monolithic core structure disposed within the housing. An outer surface of the core structure defines at least part of a first passageway. An inner surface of the core structure defines at least part of a second passageway. The core structure includes a separator wall that isolates a first flow passing through the first passageway from a second flow passing through the second passageway. The first passageway is in thermal communication with the second passageway. The core structure includes one or more heat exchanger features, or fins, that are positioned within the first passageway, the second passageway, or both the first and second passageways. The core structure may have a compliant segment coupled to two or more walls.

Abstract: A method of monitoring an additive manufacturing process in which a layer of powdered material is deposited in a recoating process so as to define a build surface, and a directed energy source is used to create a weld pool in the build surface and selectively fuse the powdered material to form a workpiece. The method includes: measuring a vibration signal profile generated by the recoating process; and controlling at least one aspect of the additive manufacturing process in response to the measured vibration signal profile.