Abstract: A process for the layer-by-layer production of three-dimensional objects, through selective melting and solidification of pulverulent substrates is provided. According to the process the construction chamber is inertized with an inertizing gas which is of higher density than air. An apparatus for conducting the process is also provided.

Abstract: The invention relates to a generative production method for producing a component by selectively melting and/or sintering a powder several times consecutively by introducing an amount of heat by means of beam energy, such that the powder particles melt and/or sinter in layers, wherein the powder particles (1) are made of a first material (2) and the powder particles are surrounded by a second material (3) partially or over the entire surface thereof, wherein the second material has a lower melting point than the first material and/or lowers the melting point of the first material when mixed with the first material. The invention further relates to a corresponding powder and to a prototype produced from said powder.

Abstract: A hybrid core for manufacturing high temperature parts includes a non-refractory metal portion and a refractory metal portion wherein at least a portion of the non-refractory metal portion and the refractory metal portion are manufactured by using an additive manufacturing process.

Abstract: There is provided a method for manufacturing a three-dimensional shaped object. The method of the present invention comprises the steps of: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing sintering of the powder of the predetermined portion or melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, and then irradiating another predetermined portion of the new powder layer with the light beam, the steps (i) and (ii) being repeatedly performed in a chamber; wherein a localized gas flow is provided in the chamber, and at least a part of a fume generated by the irradiation of the light beam is entrained by the localized gas flow.

Abstract: Methods of heat treating at least one component of a solid oxide fuel cell (SOFC) system. The method includes heating the at least one component with a rapid thermal process, wherein the rapid thermal process heats at least a portion of the component at a rate of approximately 50° C./sec or more.

Abstract: The present invention comprises a laser sintering powder composition comprising: greater than 30 to 90 wt. % of a hydrogenated styrene-butadiene/styrene-styrene (S(EB/S)S) block copolymer or a hydrogenated styrene-butadiene-styrene (SEBS) block copolymer, or a mixture thereof; 10 to less than 70 wt. % of a C3 to C8 polyolefin, or a mixture of two or more polyolefins, 0 to 20 wt. % mineral oil, 0.2 to 1 wt. % of one or more antioxidants, 0 to 5 wt. % colorant, 0 to 20 wt. % surface modifying agent, wherein the total of the above ingredients is 100 wt. %, and optionally 0 to 5 parts by weight of a powder flow agent, based on 100 weight parts of the laser sintering powder composition. The composition has a melt flow rate of at least 20 grams/10 min. at 190° C./2.16 kg mass. The invention also comprises laser sintered articles and methods for making the same.

Abstract: An apparatus and method for making a three-dimensional object from a solidifiable material using a linear solidification device and contourless object data is shown and described. A voxel matrix is superimposed over an object model defined by three-dimensional object data to determine active voxels that intersect at least a portion of the object model. The active voxels are related to a path generation reference frame of an apparatus for making a three-dimensional object to generate solidification energy source event data that defines scanning (y) axis locations and/or solidification times at which a linear solidification device supplies solidification energy to a solidifiable material.

Abstract: acting on a powder layer in a working zone, containing a device for layering said powder, said device including: means for storing powder, means for distributing powder that travel over the working zone to distribute powder in a layer having a final thickness for additive manufacturing, feeding means that transfer powder from storage means to distributing means, metering means that control the quantity of powder transferred from storage means to distributing means, said machine being wherein: storage means are positioned higher than the working zone, feeding means utilize gravity, feeding means and the metering means move with the distributing means, the machine has two separate working zones and two separate working trays that move independently of one another, each of the working trays is associated with only one working zone, and the layering device is common to both working zones.

Abstract: A powder shaping method comprises: providing a powder on a target surface; providing a laser beam to illuminate the powder so as to form a pre-treated powder; and providing an energy beam to illuminate the pre-treated powder for enabling a shaping process. In addition, a powder shaping apparatus comprises a base, a target surface, a powder supply unit and an energy beam source system. The target surface is disposed on the base and can be fixed or moved on the base. The powder supply unit provides a powder on the target surface. The energy beam source system has a laser source and an energy source, the laser source provides a laser beam to illuminate the powder to form a pre-treated powder, and the energy source provides an energy beam to further illuminate the pre-treated powder to make a shaping process.

Abstract: A stack forming apparatus according to embodiments comprises a nozzle and a controller. The nozzle is configured to selectively inject more than one kind of material to a target and to apply laser light to the injected material to melt the material. The controller is configured to control the kind and supply amount of material to be supplied to the nozzle.

Abstract: An object of the present invention is to easily eliminate fumes inside a chamber, so as to improve a positional accuracy of irradiation with a light beam and a machining accuracy in a method for manufacturing a three-dimensional shaped object. A stacked-layers forming device 1 includes a powder layer forming unit 3, a light beam irradiating unit 4, a base 22 which is fixed and on which a powder layer 32 is formed, a lifting/lowering frame 34 which surrounds the circumference of the base 22 and is freely capable of being lifted and lowered, a cover frame 36 which has a window 36a allowing transmission of light beam in its top surface, and whose bottom surface is opened, and which is disposed on the lifting/lowering frame 34 to form a chamber C, and a gas tank 71 for supplying an ambient gas. The lifting/lowering frame 34 is lowered to reduce the volume of the chamber C, so as to discharge fumes generated inside the cover frame 36, which performs replacement with the ambient gas.

Abstract: The invention pertains to a nuclear fuel assembly grid or a portion or a part of the grid, such as a grid strap and/or an integral flow mixer that is at least partially constructed of a composition containing one or more ternary compounds of the general formula I: Mn+1AXn??(I) wherein, M is a transition metal, A is an element selected from the group A elements in the Chemical Periodic Table, X is carbon or nitrogen, and n is an integer from 1 to 3.

Abstract: There is provided a method for manufacturing a three-dimensional shaped object, the method comprising the repeated steps of: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the powder in the predetermined portion or a melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, followed by the irradiation of a predetermined portion of the powder layer with the light beam, wherein a part of a surface portion of the three-dimensional shaped object is formed as a low-density solidified portion whose solidified density ranges from 50% to 90% so that an application of pressure can be performed by a gas flowing through the low-density solidified portion.

Abstract: An area of a composite laminate structure is reworked by scarfing the area, generating a 3-D map of the scarfed area, and installing a rework patch that is built based on the 3-D map.

Abstract: Improved devices and methods for additive manufacturing of implant components are disclosed, including improvements relating to utilizing support structures, aligning implant designs within the manufacturing apparatus, and making patient-adapted implants.

Abstract: A photostructurable ceramic is processed using photostructuring process steps for embedding devices within a photostructurable ceramic volume, the devices may include one or more of chemical, mechanical, electronic, electromagnetic, optical, and acoustic devices, all made in part by creating device material within the ceramic or by disposing a device material through surface ports of the ceramic volume, with the devices being interconnected using internal connections and surface interfaces.

Abstract: A method for forming a three-dimensional article comprising applying a first powder layer on a work table; directing a first energy causing said first powder layer to fuse in first selected locations to form a first cross section where said first energy beam is fusing a first region with parallel scan lines in a first direction and a second region with parallel scan lines in a second direction; fusing at least one of the scan lines in said first region in said first direction immediately before fusing at least one of said scan lines in said second region in said second direction; applying a second powder layer and directing the energy beam causing said second powder layer to fuse in second selected locations where the energy beam is fusing said first region with parallel scan lines in a third direction and said second region in a fourth direction.

Abstract: The invention relates to the use of a powder made of a polymer, which of two or more components with functionalities suitable for Diels-Alder reactions, or of a powder mixture (dry blend) made of powders respectively of at least one of the reactive components, where these together enter into the Diels-Alder reaction with one another and are capable of a retro-Diels-Alder reaction, in a rapid-prototyping process. The invention further relates to moldings produced with use of said polymer powder through a layer-by-layer shaping process in which regions of a powder layer are melted selectively. The molding here can be removed from the powder bed after cooling and hardening of the regions previously melted layer-by-layer.

Abstract: An example multi-dimensional component building system includes a first chamber having at least one base disposed therein, a second chamber adjacent to and in fluid communication with the first chamber through a first door, and a third chamber adjacent to and in fluid communication with the second chamber through a second door. The second chamber is fluidly sealed from the first chamber if the first door is in a closed position. The second chamber is configured to receive the at least one base via a first transfer mechanism if the fluid parameters of the first chamber are approximately equal to the fluid parameters of the second chamber. The second chamber includes a directed heat source and a build-up material configured to form a component on the at least one base by melting or sintering. The third chamber is fluidly sealed from the second chamber if the first door is in a closed position.

Abstract: A three-dimensional printing process, a swirling device, and a thermal management process are disclosed. The three-dimensional printing process includes distributing a material to a selected region, selectively laser melting the material, and forming a swirling device from the material. The swirling device is printed by selective laser melting. The thermal management process includes providing an article having a swirling device printed by selective laser melting, and cooling a portion of the article by transporting air through the swirling device.

Abstract: There is provided a method for manufacturing a three-dimensional shaped object, the method comprising the repeated steps of: (i) forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the powder in the predetermined portion or a melting and subsequent solidification thereof; and (ii) forming another solidified layer by newly forming a powder layer on the resulting solidified layer, followed by the irradiation of a predetermined portion of the powder layer with the light beam, wherein a heater element is disposed on the solidified layer during the repeated steps (i) and (ii), and thereby the heater element is situated within the three-dimensional shaped object.

Abstract: A method for determining a bed temperature setpoint for use with a powder in a selective laser sintering machine is disclosed. The method includes the step of providing a powder comprising a polymer for use in a selective laser sintering machine. The method further includes the step of determining a ratio of a liquid portion of the powder to a solid portion of the powder as a function of temperature within a temperature range. A bed temperature setpoint is selected in the temperature range corresponding to a desired ratio of the liquid portion of the powder to the solid portion of the powder. A temperature of a bed of a selective laser sintering machine is set to the selected bed temperature setpoint, and a part is built from the powder using the selective laser sintering machine.

Abstract: A method is provided, by which a three-dimensional object is manufactured by a subsequent solidification of layers of a building material in powder form at the positions in the respective layer that corresponds to the cross-section of the object by means of the action of a laser or another energy source, wherein as building material in powder form a material is used which contains the old powder that has remained as unsolidified powder in the manufacturing of one or more previously formed objects and a proportion of new powder that has not been used before in any manufacturing process, characterized in that the building material in powder form is mechanically consolidated when a layer is applied.

Abstract: A method for manufacturing a fluid-leading component includes positioning a base element machined by a material-removing method with a planar upper face in a mounting support. The method at least includes the initial application of a layer section with predetermined dimensions of a particulate material in a predetermined region on the planar upper face of the base element; the heating of the layer section by a heat source in such a manner that the particles of the material within predetermined dimensions bond; and the application thereto and heating of at least one further layer section with predetermined dimensions of a particulate material in a predetermined region. In this way it is possible, in the generative manufacturing method, to obviate the need to provide support structures that subsequently have to be removed, and the base element is a functional part of the component to be manufactured.

Abstract: A laser built up method on an object with different surfaces is provided. The object can be coated locally, which is not possible by the conventional rapid prototyping processes. The object is put into a powder bed, powder is provided on or near the object and the powder is only locally provided on the upper outer surface of the object and then densified.

Abstract: A structural spacecraft component comprising internal microstructure; wherein said microstructure comprises a plurality of parallel layers and a plurality of spacers that connect adjacent parallel layers; wherein said structural spacecraft component is a product of an additive manufacturing process.

Abstract: A powder rapid prototyping method includes steps of forming a thin layer 35a of a powder material, irradiating a heating energy beam to a specific region of the thin layer 35a of the powder material to thereby form a preliminary heating layer 35c whose temperature is elevated, and irradiating the heating energy beam to an inside region of the preliminary heating layer 35c whose temperature is elevated to melt and then solidify the thin layer 35a of the powder material to thereby form a solidified layer, wherein the respective steps are repeatedly implemented to fabricate a rapid prototyping model 51, 52.

Abstract: As implant for the stabilization of bones or vertebrae is provided, the implant being a solid body including a longitudinal axis that defines a longitudinal direction and including a flexible section that has a surface and has a length in the longitudinal direction, the flexible section including at least one cavity located near the surface and having a width in the longitudinal direction that is smaller than the length of the flexible section, the at least one cavity being connected to the surface through at least one slit, and a width of the slit in the longitudinal direction being smaller than the width of the cavity.

Abstract: A tool holder with a main part, a deformable receiving portion for clamping a tool, and at least one blocking element which is designed to engage into a corresponding counter element on the tool in order to prevent the tool from moving axially out of the tool holder. The at least one blocking element is integrally formed with the receiving portion. A clamping system having such a tool holder and a method for producing a receiving portion for such a tool holder are also described.

Abstract: A support material for use in an additive manufacturing system, which compositionally includes a polyglycolic acid polymer, which is at least partially soluble in an aqueous solution, and which is configured for use in the additive manufacturing system for printing a support structure in coordination with printing of a three-dimensional part.

Abstract: An ophthalmic device is formed by additive fabrication, the optical device having an optical surface with a surface roughness on the order of less than 10 microns. A method is provided for making an ophthalmic device including an optical surface having a surface roughness of less than 10 microns by depositing on a stage in a first relative position a first lamina of particulates having a size less than 10 microns and in select configurations less than two microns and certain configurations less than one micron, and, synergistically stimulating the first lamina of particulates to form a first solidified layer.

Abstract: A manufacturing method of a three-dimensional shaped object is capable of suitably forming a solidified layer by subsequent formation of a powder layer. The manufacturing method according to an embodiment of the present invention is performed by repetition of a powder-layer forming and a solidified-layer forming, the repetition including forming a solidified layer by irradiating a predetermined portion of a powder layer with a light beam, thereby allowing a sintering of the powder in the predetermined portion or a melting and subsequent solidification thereof; and forming another solidified layer by newly forming a powder layer on the resulting solidified layer, followed by the irradiation of a predetermined portion of the powder layer with the light beam, wherein a light-beam condition for an irradiation path with an unirradiated portion on both adjacent sides thereof is different from that for another irradiation path with an irradiated portion at an adjacent region.

Abstract: A cup having an inner cavity, for an articulation organ, and a metallic outer layer and in a portion of a spheroid, the outer layer including networks of meshes with nodes and struts, where the struts are tapered struts each having a tapered shape and being arranged such that the tapered shapes are uniformly oriented.

Abstract: A method for manufacturing a three-dimensional biomedical device for fitting in a bone defect having an osteoinductive first area with a controlled porosity and a second area, which is produced by laser technology from an absorbent and from a first powder including one of ceramics, metals, metal alloys, bioactive glasses, lead zirconate titanate and biocompatible polymers, or mixtures thereof, wherein the ratio of the porosities from the second area to the first area is equal or less than one, preferably from 0.001 to 0.9, wherein a virtual object is designed with a computer-aid designed software, and the device is manufactured by laser technology including layering a powder onto a plate (7) so that a layer of a predetermined thickness is formed; the laser beam (8) selectively processes the powder to produce a processed layer, and, thus, layer after layer, the layers are joined together until the biomedical device is formed.

Abstract: A system for fabricating a component includes an additive manufacturing device and a computing device. The additive manufacturing device is configured to fabricate a first component by sequentially forming a plurality of superposed layers based upon a nominal digital representation of a second component, which includes a plurality of nominal digital two-dimensional cross-sections, each corresponding to a layer of the first component.

Abstract: An MRI local coil system for use with an MRI scanner to image a breast, the system comprising a plastic housing and an RF coil system. The RF coil system comprises a conductor and electronics. The electronics comprises a capacitor and a blocking circuit. The conductor and the electronics are disposed within the plastic housing and the conductor is integrally formed with the plastic housing.

Abstract: A powder application apparatus is provided for use in a device for manufacturing work pieces by exposing powder layers to electromagnetic radiation or particle radiation. The powder application apparatus comprises a first powder storage provided in a first part of the powder application apparatus and configured to receive and store raw material powder. The powder application apparatus further comprises a first powder supply channel provided in a second part of the powder application apparatus and configured to discharge raw material powder from the first powder storage onto a carrier located below the apparatus. A first channel opening/closing element is configured to be moved between a first position to allow the discharge of raw material powder from the first powder storage onto the carrier, and a second position in which the discharge of raw material powder from the first powder storage onto the carrier is presented.

Abstract: A three-dimensional biomedical device having an osteoinductive first area with a controlled porosity and a second area, which is produced by laser technology from a powder including one of ceramics, metals, metal alloys, bioactive glasses, lead zirconate titanate and biocompatible polymers, or mixtures thereof. The ratio of the porosities from the second area to the first area is equal or less than one, preferably from 0.001 to 0.9. A method for manufacturing the device for fitting in a bone defect, wherein a virtual object is designed with a computer-aid designed software, and the device is manufactured by laser technology including layering a powder onto a plate (7) so that a layer of a predetermined thickness is formed; the laser beam (8) selectively processes the powder to produce a processed layer, and, thus, layer after layer, the layers are joined together until the biomedical device is formed.

Abstract: An example multi-dimensional component building system includes a first chamber having at least one base, a second chamber adjacent to and in fluid communication with the first chamber through a first door, and a third chamber adjacent to and in fluid communication with the second chamber through a second door. The second chamber is fluidly sealed from the first chamber if the first door is in a closed position. The second chamber includes a directed heat source, a build-up material and is configured to receive the at least one base if the fluid parameters of the first chamber and second chamber are approximately equal. The third chamber is fluidly sealed from the second chamber if the first door is in a closed position. The third chamber is configured to receive the at least one base, having a formed component disposed thereon, if the second door is in an open position.

Abstract: A three-dimensional modeling apparatus includes a stage, a head, a movement mechanism, and a control unit. The head supplies a process liquid that is one of a solution and a dispersion liquid onto the stage to cause a material that constitutes a three-dimensional object to be precipitated out of the process liquid by evaporating one of a solvent and a dispersion medium therefrom. The movement mechanism relatively moves the head and the stage. The control unit controls a drive of the movement mechanism to form the three-dimensional object.

Abstract: The present invention relates to a polymer powder which comprises nylon-11, and to the use of this powder for shaping processes, and also to moldings produced from this polymer powder. The shaping processes are layer-by-layer processes which use powders, where regions of the respective layer are selectively melted via introduction of electromagnetic energy. The selectivity may—with no intention of restricting the invention thereto—be achieved via masks, application of inhibitors, of absorbers, or of susceptors, or via focusing of the energy introduced. After cooling, the regions then solidified can be removed in the form of moldings from the powder bed. Compared with moldings composed of conventional powders, the moldings constructed using the inventive powder by one of the inventive processes exhibit marked advantages in terms of component properties, particularly surface finish.

Abstract: A method for forming a three-dimensional article through successive fusion of parts of a powder bed, which parts corresponds to successive cross sections of the three-dimensional article, said method comprising the steps of: providing a model of said three dimensional article, providing a first powder layer on a work table, directing a first energy beam from a first energy beam source over said work table causing said first powder layer to fuse in first selected locations according to said model to form a first cross section of said three-dimensional article, directing a second energy beam from a second energy beam source over said work table causing said first powder layer to fuse in second selected locations according to said model to form the first cross section of said three-dimensional article, wherein said first and second locations of said first powder layer are at least partially overlapping each other.

Abstract: A method and apparatus used to produce control data for building up a product layer by layer using freeform sintering and/or melting with a high energy beam. The correspondingly controlled apparatus for production of the products is further disclosed. The high energy beam is applied under the guidance of the control data set. Before beginning the freeform sintering and/or freeform melting, a compensation data set and/or a compensation function to compensate for manufacturing related effects caused by the sintering and/or melting is determined. The control data set is based upon a product target geometry data set and the compensation data set and/or the compensation function.

Abstract: A continuous-wave (CW) ultraviolet (UV) curing system for solid freeform fabrication (SFF) is provided, wherein the curing system is configured to provide an exposure of UV radiation for one or more layers of UV-curable material. One or more UV exposures may initiate curing of a curable material in the layer dispensed by a solid freeform fabrication apparatus. One approach to provide the single or multiple UV exposures is the use of one or more UV LEDs, which generate UV radiation without generating any substantial amounts of infrared (IR) radiation at the same time. This allows for the curing process to be energy efficient and also allows for the SFF system to be far less complex.

Abstract: The present invention relates to an improved method of grinding polyaryletherketones, providing very good yields and the production of powders of polyaryletherketones with an average diameter below 100 ?m having a narrow size distribution with few fine particles (Dv10>15 ?m).

Abstract: Embodiments of the invention is directed to a manufacturing process to mold and cast custom softening polymers into complex shaped devices, said process comprising the steps of: creating a 3D mold or shell; injecting the shell with a polymer or pre-polymer; cooling or curing the polymer in a short period of time; and forming a device.

Abstract: Waste reduction, including hazardous waste reduction in photoimaging processes can be accomplished by improving diffusional resolution of cationic curable compositions. The addition of fluorinated polymers including fluorinated surfactants provides improved diffusional resolution in cationic and/or radical based photoimaging formulations allowing for image accuracy improvements, and reduced product and process waste quantity and disposal cost. These fluorinated surfactants also allow for increased cure speed, and non-hazardous constituent formulations that result in less wasted material and time.

Abstract: The present invention relates to a polymer powder which comprises nylon-11, and to the use of this powder for shaping processes, and also to moldings produced from this polymer powder. The shaping processes are layer-by-layer processes which use powders, where regions of the respective layer are selectively melted via introduction of electromagnetic energy. The selectivity may—with no intention of restricting the invention thereto—be achieved via masks, application of inhibitors, of absorbers, or of susceptors, or via focusing of the energy introduced. After cooling, the regions then solidified can be removed in the form of moldings from the powder bed. Compared with moldings composed of conventional powders, the moldings constructed using the inventive powder by one of the inventive processes exhibit marked advantages in terms of component properties, particularly surface finish.

Abstract: A method for producing three-dimensional work pieces comprises the steps of supplying gas to a process chamber accommodating a carrier and a powder application device, applying a layer of raw material powder onto the carrier by means of the powder application device, selectively irradiating electromagnetic or particle radiation onto the raw material powder applied onto the carrier by means of an irradiation device, discharging gas containing particulate impurities from the process chamber, and controlling the operation of the irradiation device by means of a control unit such that a radiation beam emitted by at least one radiation source of the irradiation device is guided over the layer of raw material powder applied onto the carrier according to a radiation pattern containing a plurality of scan vectors.

Abstract: A means for modifying a building space for a device for manufacturing a three-dimensional object by layerwise solidification of a powdery building material at the locations corresponding to the object in the respective layers comprises one or several small supports (32) or one or several building space partitioning elements (20) on a building platform (2), thereby the device has one or several small building areas (22.1, 22.2, 22.3), in which the powdery material may be efficiently used and different powder materials may be processed.