Abstract: An additive manufacturing system has a build surface supporting a precursor material to be fused by incident light energy. The system includes an optics assembly to direct the incident light energy along a beam path in a first direction toward the build surface, and an energy management system. The energy management system includes a beam block disposed along the beam path. The beam block has an aperture allowing the incident light energy to pass through the beam block in the first direction. The beam block also has a surface to absorb or deflect, away from the beam path, light energy traveling in a second direction different from the first direction. The energy management system also includes a heat sink to receive heat energy from at least a portion of the light energy traveling in the second direction.

Abstract: A hopper for dispensing powder material for an additive manufacturing system includes a gate that is movable along a first direction to open and close a discharge slot and which is pivotable about a pivot axis transverse to the first direction. The first direction can be a horizontal direction and the pivot axis can be parallel to a vertical direction. The gate can have a portion that contacts the hopper, e.g., at a surface including the discharge slot, and is elastically deformed with movement from the open to the closed position.

Abstract: Systems and methods for additive manufacturing are described. In some embodiments, a method of controlling a weld height in an additive manufacturing process includes determining a desired melt pool width based, at least in part, on a desired weld height; selectively activating one or more laser energy sources based, at least in part, on the desired melt pool width; and melting a portion of a layer of material on a build surface via exposure to laser energy from the one or more activated laser energy sources to form a melt pool on the build surface having the desired melt pool width. Systems and methods to the use of staggered laser energy sources are also described.

Abstract: Systems and methods for additive manufacturing are generally described. In some embodiments, an additive manufacturing system may include at least one alignment fixture for accurately positioning one or more optical fibers. The alignment fixture may maintain a desired position and/or orientation of the fiber or endcap. In some embodiments, an additive manufacturing system may include at least one stray light baffle coupled to the alignment fixture for reducing the amount of stray light within the optical system.

Abstract: System and method for dispensing powder material for an additive manufacturing system. A hopper can include a spline configured for rotation to dispense powder material from an exit opening of the hopper. A shield can be provided for one or both ends of the spline to help control powder movement at an interface with the spline, e.g., so powder that passes the interface is trapped in a space. An auger can be provided in a hopper and configured for moving powder in the hopper in two opposed directions in response to rotation of the auger in a single direction. A common drive can be used to move both an auger and spline. One or more load cells can be provided to determine a mass of powder delivered to and/or dispensed from the hopper.

Abstract: Systems and methods for additive manufacturing are generally described. In some embodiments, an additive manufacturing system may include at least one mechanical fixture in the form of a resilient member for accurately positioning one or more optical fibers without the use of adhesives. The resilient member may, in some embodiments, bias each optical fiber (or similarly, an endcap coupled to a distal end of an optical fiber) against an alignment fixture to maintain a desired position and/or orientation of the fiber or endcap. In some embodiments, an additive manufacturing system may include at least one stray light baffle for reducing the amount of stray light within the optical system.

Abstract: Systems and methods for additive manufacturing are generally described. According to certain aspects, endcaps optically coupled to optical fibers of additive manufacturing systems are provided. In some aspects, methods for reducing a power area density of laser energy within an endcap are provided. The endcaps described herein may be used to at least partially mitigate thermal cycling that may result from the transmission of laser energy through interfaces of an additive manufacturing system.

Abstract: Systems and methods for additive manufacturing are generally described. According to certain aspects, endcaps optically coupled to optical fibers of additive manufacturing systems are provided. In some aspects, methods for reducing a power area density of laser energy within an endcap are provided. The endcaps described herein may be used to at least partially mitigate thermal cycling that may result from the transmission of laser energy through interfaces of an additive manufacturing system.

Abstract: Disclosed embodiments are generally related to recoater assemblies for additive manufacturing systems. In some embodiments, a recoater blade may include a plurality of flexible portions that are configured to deflect relative to one another when moved over and past a defect on a build surface. In other embodiments, a recoater assembly may include compliant attachments that exhibit compliances that increase in an outward direction relative to a central portion of a body of the recoater assembly. In still other embodiments, a pair of scoops may be disposed on opposing end portions of a recoater blade and/or recoater assembly to help guide and collect excess powder dispensed onto a build surface.

Abstract: Disclosed embodiments relate to additive manufacturing systems. In some embodiments, an additive manufacturing system may include a plurality of laser energy sources, an optics assembly configured to direct laser energy onto a build surface, and an optical fiber connector positioned between the plurality of laser energy sources and the optics assembly. A first plurality of optical fibers may extend between the plurality of laser energy sources and the optical fiber connector, and a second plurality of optical fibers may extend between the optical fiber connector and the optics assembly. Each optical fiber of the first plurality of optical fibers may be coupled to a corresponding optical fiber of the second plurality of optical fibers within the optical fiber connector.

Abstract: An additive manufacturing system includes an optics assembly. The optics assembly includes a plurality of serially arranged and connected modules. Each module of the plurality of serially arranged and connected modules includes a module housing. Each module housing includes a first end portion and a second end portion. The first end portion includes a first module fitting and the second end portion includes a second module fitting. The first and second module fittings are each configured to form a respective adjustable mechanically interlocking connection with an adjacent module of the optics assembly. At least one module of the plurality of serially arranged and connected modules includes at least one optical component disposed within the associated module housing. The at least one optical component is configured to interact with at least one laser beam as the at least one laser beam passes through the optics assembly.

Abstract: Disclosed embodiments relate to additive manufacturing systems. In some embodiments, an additive manufacturing system may include a plurality of laser energy sources, an optics assembly configured to direct laser energy onto a build surface, and an optical fiber connector positioned between the plurality of laser energy sources and the optics assembly. A first plurality of optical fibers may extend between the plurality of laser energy sources and the optical fiber connector, and a second plurality of optical fibers may extend between the optical fiber connector and the optics assembly. Each optical fiber of the first plurality of optical fibers may be coupled to a corresponding optical fiber of the second plurality of optical fibers within the optical fiber connector.

Abstract: Laser control systems and related methods for controlling arrays of lasers are disclosed. A laser control system may include a first controller configured to generate a trigger signal based on a position of a laser array, and a second controller configured to send a firing signal to one or more lasers of the laser array upon receiving the trigger signal. The one or more lasers may be selected based on a desired pattern of laser energy to be formed at a particular position of the laser array.

Abstract: Systems and methods for additive manufacturing are described. In some embodiments, a method of controlling the one or more laser energy sources of an additive manufacturing system may be based at least in part on a scan angle and/or desired energy density. Systems and methods for controlling melt pool spacing are also described.

Abstract: Aspects described herein relate to additive manufacturing systems and related methods. An additive manufacturing system may include two or more laser energy sources and associated optical fibers. An optics assembly may be constructed and arranged to form a rectangular laser energy pixel associated with each laser energy source. Each pixel may have a substantially uniform power density, and the pixels may be arranged to form a linear array of laser energy pixels on a build surface with no spacing between the pixels. Exposure of a portion of a layer of material on the build surface to the linear array of laser energy pixels may melt the portion of the layer.

Abstract: Methods and apparatuses for additive manufacturing are described. A method for additive manufacturing may include exposing a layer of material on a build surface to one or more projections of laser energy including at least one line laser having a substantially linear shape. The intensity of the line laser may be modulated so as to cause fusion of the layer of material according to a desired pattern as the one or more projections of laser energy are scanned across the build surface.

Abstract: Laser control systems and related methods for controlling arrays of lasers are disclosed. A laser control system may include a first controller configured to generate a trigger signal based on a position of a laser array, and a second controller configured to send a firing signal to one or more lasers of the laser array upon receiving the trigger signal. The one or more lasers may be selected based on a desired pattern of laser energy to be formed at a particular position of the laser array.

Abstract: Build plate assemblies and their methods of use for an additive manufacturing system are disclosed. In some embodiments, a build plate assembly may include a build plate with a build surface and one or more recesses formed in the build plate. One or more inserts may be inserted into the corresponding one or more recesses of the build plate such that a portion of the one or more inserts are accessible through one or more corresponding openings formed in the build surface associated with the recesses.

Abstract: Optics assemblies and their methods of use in additive manufacturing systems are described. In some embodiments, an additive manufacturing system may include a build surface, a plurality of laser energy sources configured to produce a plurality of laser spots on the build surface, and an optics assembly configured to independently control a size of each of the plurality of laser spots and a spacing between the plurality of laser spots on the build surface. The optics assembly may include a plurality of lens arrays, where the plurality of lens arrays is configured to adjust a size of each of the plurality of laser spots on the build surface, and at least one lens. The at least one lens may also be configured to adjust a spacing between the plurality of laser spots on the build surface.

Abstract: Aspects described herein relate to additive manufacturing systems and related methods. An additive manufacturing system may include two or more laser energy sources and associated optical fibers. An optics assembly may be constructed and arranged to form a rectangular laser energy pixel associated with each laser energy source. Each pixel may have a substantially uniform power density, and the pixels may be arranged to form a linear array of laser energy pixels on a build surface with no spacing between the pixels. Exposure of a portion of a layer of material on the build surface to the linear array of laser energy pixels may melt the portion of the layer.