Abstract: An additive manufacturing system includes a laser array including a plurality of laser devices. Each laser device of the plurality of laser devices generates an energy beam for forming a melt pool in a powder bed. The additive manufacturing system further includes at least one optical element. The optical element receives at least one of the energy beams and induces a predetermined power diffusion in the at least one energy beam.

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 of additively manufacturing a three-dimensional object include irradiating a first build plane region using a first energy beam, irradiating a second build plane region using a second energy beam, and irradiating an interlace region between the first build plane region and the second build plane region. Irradiating the interlace region comprises directing the first energy beam along a first oscillating path and directing the second energy beam along a second oscillating path intersecting and overlapping with the first oscillating path.

Abstract: Additive manufacturing methods and systems are disclosed including irradiation devices for an additive manufacturing machine for additively manufacturing three-dimensional objects. The irradiation device includes a beam generation device configured to provide an energy beam travelling on a nominal beam path trajectory and an optical modulator comprising a reflective optic downstream from the beam generating device, wherein the optical modulator is configured to actuate the reflective optic to modify a position of the energy beam from the nominal beam path trajectory. The irradiation device further includes an optical scanner disposed downstream from the optical modulator, wherein the optical scanner is configured to translate the nominal beam path trajectory along a build plane of the additive manufacturing machine.

Abstract: An additive manufacturing system includes a laser array including a plurality of laser devices. Each laser device of the plurality of laser devices generates an energy beam for forming a melt pool in a powder bed. The additive manufacturing system further includes at least one optical element. The optical element receives at least one of the energy beams and induces a predetermined power diffusion in the at least one energy beam.

Abstract: An additive manufacturing system includes a laser array including a plurality of laser devices. Each laser device of the plurality of laser devices generates an energy beam for forming a melt pool in a powder bed. The additive manufacturing system further includes at least one optical element. The optical element receives at least one of the energy beams and induces a predetermined power diffusion in the at least one energy beam.

Abstract: An additive manufacturing (AM) apparatus is provided, having a build unit including a powder delivery mechanism, a powder recoating mechanism, and an irradiation beam directing mechanism. The AM apparatus further includes a rotatable build platform having an inner diameter and an outer diameter. A fluid flow mechanism includes an inlet body forming an inlet plenum and a collector body extended from the inlet body. The collector body forms a collector plenum in fluid communication with the inlet plenum. The collector body forms an outlet opening, wherein the outlet opening is positioned proximate to the inner diameter of the rotatable build platform. The outlet opening is configured to provide a flow of fluid toward the outer diameter above the rotatable build platform.

Abstract: A laser calibration device for calibrating an energy beam used in additive manufacturing, the laser calibration device including a body configured to be disposed in an additive manufacturing process chamber; a cover for the body, the cover comprising a plurality of holes; a photodiode; and a coating disposed on the body and configured to optically couple the photodiode with the plurality of holes, wherein the photodiode is configured to sense one or more parameters of the energy beam for determining calibrating instructions for the energy beam.

Abstract: A powder melting device for an additive manufacturing system is provided. The powder melting device includes at least one laser device configured to generate at least one energy beam for forming at least one melt pool in a layer of powdered material. The powder melting device also includes at least two optical elements configured to dynamically induce beam distortion in the at least one energy beam to modify a beam spot incident on the layer of powdered material. The at least two optical elements are configured to induce at least one of an aspect ratio adjustment of the at least one energy beam, an optical powder redistribution between a periphery and a center of the at least one energy beam, and a rotation of the at least one energy beam.

Abstract: An additive manufacturing system is configured to manufacture a component. The additive manufacturing system includes a build platform, a recoater, a monitoring camera, and a controller. The component is disposed on the build platform. The recoater includes a recoater blade configured to spread a powdered build material across the build platform and the component forming a powder bed. The monitoring camera is positioned to image the recoater blade. The monitoring camera is configured to acquire a plurality of images of the recoater blade. The controller is configured to receive the plurality of images from the monitoring camera. The controller is configured to detect defects in the powder bed based on the plurality of images received from the monitoring camera.

Abstract: An additive manufacturing system includes a laser device, a build plate, a first scanning device, and an alignment system. The laser device is configured to generate a laser beam. The build plate has a position relative to the laser device. The first scanning device is configured to selectively direct the laser beam across the build plate. The laser beam generates a melt pool on the build plate. The alignment system includes a fiducial marks projector configured to project a plurality of fiducial marks across the build plate. Each fiducial mark has a location on the build plate. The alignment system also includes an optical detector configured to detect the location of each of the fiducial marks on the build plate. The alignment system is configured to detect the position of the build plate relative to the laser device.

Abstract: A consolidating device for an additive manufacturing system is provided. The consolidating device includes at least one first energy beam generator, at least one second energy beam generator, at least one first lens, at least one second lens, and at least one reflective element. The first energy beam generator is configured to generate a first energy beam. The second energy beam generator is configured to generate a second energy beam. The first lens has a first entrance pupil and is positioned between the first energy beam generator and the layer of material. The second lens has a second entrance pupil and is positioned between the first lens and the layer of material. The first entrance pupil and the second entrance pupil substantially overlap. The reflective element is positioned between the first lens and the second lens, and is configured to reflect the second energy beam onto the layer of material.

Abstract: An additive manufacturing system is configured to manufacture a component. The additive manufacturing system includes a build platform, a recoater, a monitoring camera, and a controller. The component is disposed on the build platform. The recoater includes a recoater blade configured to spread a powdered build material across the build platform and the component forming a powder bed. The monitoring camera is positioned to image the recoater blade. The monitoring camera is configured to acquire a plurality of images of the recoater blade. The controller is configured to receive the plurality of images from the monitoring camera. The controller is configured to detect defects in the powder bed based on the plurality of images received from the monitoring camera.

Abstract: A method of forming a build in a powder bed includes emitting a plurality of laser beams from selected vertical-cavity surface emitting lasers (VCSELs) of at least one VCSEL array onto the powder bed, the selected VCSELs of the at least one VCSEL array corresponding to a pattern of a layer of the build; and simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build.

Abstract: A component is fabricated in a powder bed by moving a laser array across the powder bed. The laser array includes a plurality of laser devices. The power output of each laser device of the plurality of laser devices is independently controlled. The laser array emits a plurality of energy beams from a plurality of selected laser devices of the plurality of laser devices to generate a melt pool in the powder bed. A non-uniform energy intensity profile is generated by the plurality of selected laser devices. The non-uniform energy intensity profile facilitates generating a melt pool that has a predetermined characteristic.

Abstract: A biopsy collecting device includes a needle unit comprising a biopsy specimen. Also, the biopsy collecting device includes an activator unit operatively coupled to the needle unit and including a channel at a bottom surface of the activator unit, wherein the channel is configured to detachably couple the biopsy collecting device to an attaching unit of a spectroscopy system.

Abstract: An additive manufacturing system is configured to manufacture a component. The additive manufacturing system includes a laser device, a build platform, a first scanning device, and an air knife. The laser device is configured to generate a laser beam. The component is disposed on the build platform. The air knife is configured to channel an inert gas across the build platform. The first scanning device is configured to selectively direct the laser beam across the build platform. The laser beam is configured to generate successive layers of a melted powdered build material on the component and the build platform. The build platform is configured to rotate the component relative to the air knife.

Abstract: A control system for use in an additive manufacturing system. A recoating device is configured to distribute powder for forming a component and a recoating motor is configured to move at least one of the powder bed and the recoating device relative to each other. The control system includes at least one vibration sensor configured to collect vibration data, a torque sensor coupled to the recoating motor and configured to collect the torque output data, and an optical sensor configured to collect reflected light data. The control system includes a controller configured to receive the vibration data, receive the torque output data, and receive the reflected light data, the controller further configured to determine at least one powder bed characteristic based on at least one of the data, and control at least one recoating parameter of the recoating device based on the at least one determined powder bed characteristic.

Abstract: An additive manufacturing apparatus includes first and second spaced apart side walls defining a build chamber therebetween. The first and second spaced apart side walls are configured to rotate through an angle ?, about a z-axis along a pre-defined path. A build platform is defined within the first and second spaced apart side walls and is configured to rotate through an angle ? about the z-axis and vertically moveable along the z-axis. The apparatus further includes one or more build units mounted for movement along the pre-defined path. An additive manufacturing method is additionally disclosed.

Abstract: An additive manufacturing system including a consolidation device, a build platform, an optical detector, and a controller is provided. The consolidation device is configured to form a build layer of a component. The build platform is configured to rotate about a build platform rotation axis extending along a first direction. The optical detector is configured to detect locations of at least two alignment marks. The controller is configured to receive locations of the at least two alignment marks from the optical detector. The controller is also configured to determine the locations of the build platform rotation axis and a build platform rotation center point based on a comparison between the at least two alignment marks, wherein the build platform rotation center point lies along the build platform rotation axis. The controller is further configured to control the consolidation device to consolidate a plurality of particles on the build platform.