Abstract: Aspects of the present disclosure relate to improved laser metal deposition heads. Various embodiments may include a main body, a nozzle seat, a powder flow guide, an inner nozzle, an outer nozzle, and a coolant sleeve. In some embodiments, powder inlets in the main body are angled relative to a primary axis of the laser metal deposition head. In some embodiments, the nozzle seat includes a plurality of powder distribution channels that are also angled relative to the primary axis of the laser metal deposition head.

Abstract: Certain aspects of the present disclosure provide a method for optimizing process parameters for additive manufacturing, including: determining a change to at least one process parameter of a plurality of process parameters while additively manufacturing a first part using an additive manufacturing apparatus according to a build file comprising machine code defining the plurality of process parameters; modifying the build file based on the determined change to the at least one process parameter to generate a modified build file; additively manufacturing a second part using the additive manufacturing apparatus according to the modified build file, wherein: additively manufacturing the first part is performed in a closed-loop control mode, and additively manufacturing the second part is performed in an open-loop control mode.

Abstract: Aspects of the present disclosure relate to. In one example, a method of controlling an additive manufacturing machine includes: determining a material transition between a first machine control code and a second machine control code in a set of machine control codes; determining a material transition time for the determined material transition between the first machine control code and the second machine control code; determining a motion time from the first machine control code and the second machine control code; comparing the material transition time to the motion time; and manipulating the set of machine control codes based on the comparison.

Abstract: Certain aspects of the present disclosure provide a method for setting a working distance of an additive manufacturing system, including: moving a deposition element towards a build surface; detecting, via a contact detection system, a contact between the deposition element and the build surface; stopping the moving of the deposition element in response to detecting the contact between the deposition element and the build surface; and moving the deposition element away from the build surface a determined working distance.

Abstract: Aspects described herein provide a method including: receiving layer data for a part to be additively manufactured, wherein the layer data comprises a plurality of deposition locations; for each respective deposition location of the plurality of deposition locations: determining a surface normal vector for with the respective deposition location; determining a direction of travel vector based on the respective deposition location and at least one other deposition location of the plurality of deposition locations; determining a tool vector for the respective deposition location based on the direction of travel vector for the respective deposition location and the surface normal vector for with the respective deposition location; manipulating a movable element of the additive manufacturing machine to align with the tool vector for the respective deposition location; and depositing material of the part at the respective deposition location.

Abstract: Aspects of the present disclosure relate to. In one example, a method of controlling an additive manufacturing machine includes: measuring a first temperature of a part being processed by the additive manufacturing machine; determining that the first measured temperature exceeds a temperature threshold; activating an auxiliary gas flow; cooling the auxiliary gas flow with a cooling system; and directing the cooled auxiliary gas flow towards the part.

Abstract: Aspects of the present disclosure relate to improved laser metal deposition heads. Various embodiments may include a main body, a nozzle seat, a powder flow guide, an inner nozzle, an outer nozzle, and a coolant sleeve. In some embodiments, powder inlets in the main body are angled relative to a primary axis of the laser metal deposition head. In some embodiments, the nozzle seat includes a plurality of powder distribution channels that are also angled relative to the primary axis of the laser metal deposition head.