Abstract: The present disclosure provides methods and systems for printing a three-dimensional part. The method comprises: receiving in computer memory a digital model of said three-dimensional object; using one or more computer processors to partition said digital model of said three-dimensional part into a plurality of partitions, wherein a given partition of said plurality of partitions comprises a plurality of slices, and wherein a given slice of said plurality of slices comprises a plurality of segments; receiving, from a user, one or more parameters that specify a printing configuration for at least one segment of said plurality of segments; and generating printing instructions based at least in part on said one or more parameters, which printing instructions are usable by a print head to print said three-dimensional object.

Abstract: A device may position a torch assembly relative to a workpiece. A device may initiate a pilot arc between a plasma electrode and a grounded portion of a torch assembly, the grounded portion of the torch assembly grounded using a component with a variable resistance. A device may initiate a wire arc between a first wire element and the workpiece. A device may add material to the workpiece while the torch assembly traverses the workpiece.

Abstract: Systems of weldable wires, powder, and materials comprising an aluminum-magnesium-scandium alloy, and methods for additive manufacturing the alloy are described. The alloy can be additive manufactured in industrial scale. With post treatment, the additive manufactured alloys can have desired properties for aerospace applications.

Abstract: Additively manufactured thrust chambers and thrust chambers with integral fluid manifolds, and hybrid additive manufacturing methods for their production, are provided. Hybrid additive manufacturing techniques may combine a variety of processes including, WAAM, PBF, cold spray and DED, for example, to produce objects with variant dimensional requirements, i.e., large overall size and small features. Hybrid additive manufacturing may be defined as provide various process layers within any manufactured object. These process layers in turn allow for the introduction of variable feature and size distribution throughout the manufactured object. Hybrid process layers according to aspects may also allow the use of a variety of materials or may use a single material across the various process layers.

Abstract: A two-part coupling for use in joining sections of pipe without additional fasteners is disclosed. The two-part coupling includes integral coupling features molded by additive manufacturing technology. The two-part coupling increases reliability, reduces weight, and provides ease of manufacture. The coupling distributes a fluid load so that the coupling can withstand pressures and leak rates in accordance with stringent standards. The two-part coupling can be coupled and de-coupled using a locking and release mechanism built into the integral parts. Assembly is made easier because the geometry of the coupling is amenable to additive manufacturing. Because the two-part coupling requires a lesser degree of precision, machined parts are not required.

Abstract: A valve assembly has a housing and a poppet-carrying portion. The housing includes an inlet port, an outlet port, an opening, and a assembly portion including helical grooves. The poppet-carrying portion is configured to be inserted through the opening and engage with the assembly portion. The poppet-carrying portion comprises a poppet head, a closure including protruding arms, convolutions, and a stopping portion. The convolutions extend between the poppet head and the closure and provide compliance such that the poppet head is movable relative to the closure. The stopping portion extends from the closure toward the poppet head and is spaced apart from the poppet head by a maximum compression distance. At a first fluid pressure, the protruding arms engage with the helical grooves, and the poppet head is positioned in a pre-load position that prevents the fluid from discharging through the outlet port.

Abstract: Process control parameters are predicted to fabricate an object using deposition. An input design geometry is provided for the object. A training data set includes past post-build physical inspection data for a plurality of objects that comprise at least one object that is different from the object to be physically fabricated; and training data generated through a repetitive process of randomly choosing values for each of multiple process control parameters and scoring adjustments to the multiple process control parameters as leading to either undesirable or desirable outcomes, the outcomes based respectively on the presence or absence of defects detected in a fabricated object arising from the process control parameter adjustments. A machine learning algorithm is trained using the provided training data set and a predicted optimal set of the multiple process control parameters is generated for initiating and performing the deposition process to fabricate the object.

Abstract: Systems and methods for localized work return path of additive manufacturing systems are described. Localized grounding connects the printed surface directly to the work return, and shortens the length of grounding and/or the return cables compared to substrate-based grounding.

Abstract: The present disclosure provides a system for printing at least a portion of a three-dimensional (3D) object. The system may comprise a source of at least one feedstock, a support for supporting at least a portion of the 3D object, a feeder for directing at least one feedstock from the source towards the support, and a power supply for supplying electrical current. The system may comprise a controller operatively coupled to the power supply. The controller may receive a computational representation of the 3D object. The controller may direct the at least one feedstock through a feeder towards the support and may direct electrical current through the at least one feedstock and into the support. The controller may subject such feedstock to Joule heating such that at least a portion of such feedstock may deposit adjacent to the support, thereby printing the 3D object in accordance with the computational representation.

Abstract: Disclosed herein are systems and methods for using printing process data to predict quality measures for three-dimensional (3D) printed objects and properties of the materials comprising the 3D objects. Printing may be performed using resistive or Joule printing. The system may include a computer communicatively coupled to a 3D printing apparatus, which may store printing parameters. The 3D printing apparatus may be able to take measurements during a print job, and record those measurements in memory. The 3D printing apparatus may also be able to record printing states before, during, and/or after printing. A combination of printing states, printing parameters, and measurements may be analyzed, for example, by a machine learning algorithm, in order to predict material properties and quality measures.

Abstract: A bellows assembly includes a first compliant portion extending outwardly at a first angle relative to a lateral axis, a second compliant portion, and a third compliant portion extending outwardly at a second angle relative to the lateral axis. The second compliant portion is formed between, and coupled to, the first and third compliant portions. The first angle and the second angle are between about 30 degrees to 80 degrees, such that the first compliant portion and the third compliant portion form inward extending cone shapes.

Abstract: A 3D printer can print a structure by depositing material into a weld pool that is moving relative to a workpiece. A multi-wire process may be utilized to increase the deposition rate of the 3D printer. An electrode wire can supply energy to the weld pool while being fed at a first feed rate into the weld pool. A second wire can be fed into the weld pool at a second feed rate to deposit additional material and thereby speed up the overall material deposition rate. All of the energy in the weld pool may be supplied by the electrode wire. Different materials may benefit from different orientations of the electrode wire and the second wire.

Abstract: The present disclosure provides methods and systems for printing a three-dimensional part. The method comprises: receiving in computer memory a digital model of said three-dimensional object; using one or more computer processors to partition said digital model of said three-dimensional part into a plurality of partitions, wherein a given partition of said plurality of partitions comprises a plurality of slices, and wherein a given slice of said plurality of slices comprises a plurality of segments; receiving, from a user, one or more parameters that specify a printing configuration for at least one segment of said plurality of segments; and generating printing instructions based at least in part on said one or more parameters, which printing instructions are usable by a print head to print said three-dimensional object.

Abstract: Systems of weldable wires, powder, and materials comprising an aluminum-magnesium-scandium alloy, and methods for additive manufacturing the alloy are described. The alloy can be utilized in additive manufacturing to additively manufacture at industrial scales. With post treatment, the additive manufactured alloys can have advantageous properties for aerospace applications.

Abstract: Systems and methods for wire arc additive manufacturing systems that print in horizontal orientations are described. Horizontal WAAM 3D print systems comprise metal 3D print systems in a horizontal orientation with one or more robots operating concurrently on a work piece using one or more wire feeds and a rotating, horizontal build plate.

Abstract: A machinable 3-D printing build plate that can be assembled from a number of different components into the base for a metallic 3-D printing volume and other 3-D printed parts. The build plate can be assembled into a final structure then machined to the required planar tolerance such that the build quality of the part is maintained throughout the build. Additionally, because the baseline printer support structure and support device are comprised of multiple elements, if one or more goes out of tolerance or requires adjustment to accommodate a new print, it may be easily removed, replaced then machined back to the required tolerances.

Abstract: A two-part coupling for use in joining sections of pipe without additional fasteners is disclosed. The two-part coupling includes integral coupling features molded by additive manufacturing technology. The two-part coupling increases reliability, reduces weight, and provides ease of manufacture. The coupling distributes a fluid load so that the coupling can withstand pressures and leak rates in accordance with stringent standards. The two-part coupling can be coupled and de-coupled using a locking and release mechanism built into the integral parts. Assembly is made easier because the geometry of the coupling is amenable to additive manufacturing. Because the two-part coupling requires a lesser degree of precision, machined parts are not required.

Abstract: Disclosed herein are systems and methods for using printing process data to predict quality measures for three-dimensional (3D) printed objects and properties of the materials comprising the 3D objects. Printing may be performed using resistive or Joule printing. The system may include a computer communicatively coupled to a 3D printing apparatus, which may store printing parameters. The 3D printing apparatus may be able to take measurements during a print job, and record those measurements in memory. The 3D printing apparatus may also be able to record printing states before, during, and/or after printing. A combination of printing states, printing parameters, and measurements may be analyzed, for example, by a machine learning algorithm, in order to predict material properties and quality measures.

Abstract: Many embodiments described herein are directed to a printing nozzle capable of producing a high-pressure flow of shielding gas that surrounds a lower pressure flow of shielding gas of the central channel. In certain embodiments, the high-pressure shield gas flow in the internal channels can blow out the material buildup in the nozzle. The high-pressure shielding gas can be concentrically produced around the first low-pressure shielding gas such that it helps to force the first shielding gas into a more laminar flow around the feed material. In several embodiments, a second low-pressure flow of shielding gas can be produced using a secondary cup to increase shielding gas coverage. In various embodiments, a secondary cup surrounds the inner cup, where the gas flow in the central channel and the outer channel can provide shielding gas coverage for the nozzle during printing.

Abstract: The present disclosure provides a system for printing a three-dimensional (3D) object. The system may comprise a source of at least one feedstock, a support for supporting at least a portion of the 3D object, a feeder for directing such feedstock from the source towards the support, and a power supply for supplying electrical current. The system may comprise a controller operatively coupled to the power supply. The controller may receive a computational representation of the 3D object. The controller may direct such feedstock through a feeder towards the support and may direct electrical current through such feedstock and into the support. The controller may subject such feedstock to heating such that at least a portion of such feedstock may deposit adjacent to the support. The controller may direct deposition of additional portions adjacent to the support and may direct an additional feedstock through such feeder and subject to heating.