Abstract: Systems and methods for monitoring light emitted from a build surface as well as other sources during an additive manufacturing process are disclosed. Systems and methods for monitoring laser energy directed towards a build surface during an additive manufacturing process are also disclosed.

Abstract: Disclosed embodiments relate to additive manufacturing systems. In some embodiments, an additive manufacturing system includes a fixed build plate, and a build volume extends above the fixed build plate. A boundary of the build volume may be defined by a powder containing shroud that is vertically displaceable relative to the fixed build plate. A powder deposition system is configured to deposit a powder layer along an upper surface of the build volume and the powder deposition is vertically displaceable relative to the fixed build plate. An optics assembly configured to direct laser energy from one or more laser energy sources towards the build volume, and exposure of the powder layer to the laser energy melts at least a portion of the powder layer. In some embodiments, the build plate may be supported by support columns configured to maintain the build plate in a level orientation throughout a build process.

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: Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be adjustable along multiple degrees of freedom relative to a build surface, which may allow for adjustment of a spacing between the recoater assembly and the build surface and/or an orientation of the recoater assembly relative to an orientation of the build surface. In some embodiments, the recoater assembly may be supported by four support columns extending above the build surface, and attachments between the recoater assembly and the support columns may be independently adjustable to adjust the recoater relative to the build surface.

Abstract: Systems and methods for predicting weld and/or part defects during additive manufacturing process are disclosed. Additionally, systems and methods related to controlling an additive manufacturing process using predicted weld and/or build defects are disclosed.

Abstract: An electrostatic recoater having an electrode and dielectric shield mounted to a lower surface of the electrode. The dielectric shield and electrode can be movable relative to each other at an interface and/or the dielectric shield may be removably mounted to the electrode.

Abstract: Additive manufacturing systems and methods related to the selection and use of groups of laser pixels from an array of laser pixels including a plurality of laser pixels are disclosed. According to some embodiments a plurality of laser pixels may be divided into one or more groups of laser pixels based on one or more process parameters and/or based on the identification of failed laser pixels. The groups may be include fewer laser pixels than the overall array of laser pixels. In some embodiments, an additive manufacturing system may switch between laser pixel groups during a manufacturing process to provide redundancy and/or to enable continued operation of the system even when laser pixel failures occur.

Abstract: An additive manufacturing system has an optics assembly to direct laser energy toward a build surface to fuse a portion of a precursor material on the build surface. An optics shield of the additive manufacturing system has a debris shield including an optical window. The optical window permits laser energy to pass through the debris shield and prevents fusion products released during fusion of the precursor material from contacting a portion of the optics assembly. The optics shield has a gas flow passage between the optical window and the build surface. The gas flow passage directs a flow of gas away from the optical window to resist movement of the fusion products through the gas flow passage toward the debris shield.

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: Light energy directed toward a build surface can be deflected by a deflection optical element at a location and at an angle suitable to offset light energy reflected by a melt pool at the build surface from the location. The reflected light energy can be offset a distance to prevent the reflected light energy from traveling a coincident path of incident light energy and to cause the reflected light energy to be received by a light absorbing element.

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: Additive manufacturing systems and related methods directed to load balancing and power optimization for one or more additive manufacturing systems are disclosed. In some embodiments this may include load balancing and power optimization of a plurality of simultaneously running additive manufacturing processes. In some embodiments, one or more additive manufacturing systems may utilize coordinated timing of energy sources, such as laser energy sources, to reduce a maximum combined power during operation of these systems. In other embodiments, the orientations of parts being manufactured may be selected to reduce a maximum energy consumption per layer and/or a variation of energy consumption between layers during additive manufacturing of the parts. The disclosed part orientation and system timing coordination may either be used individually or in combination with one another.

Abstract: Additive manufacturing systems and their methods of use are disclosed. According to some embodiments, a delivery portion of small optical fiber is optically coupled to a large optical fiber by an adiabatic fiber taper. In some instances, an additional reducing taper may be included between the small optical fiber and the adiabatic fiber taper. Increasing the transverse dimension and therefore the cross sectional area of the optical fiber path may reduce the power and/or energy density near the termination of the laser path. Decreased power and/or energy density may provide increased life, reliability, and contamination tolerance of the optic fibers, termination surfaces, and other components located along an optical path connected to a laser energy source.

Abstract: An additive manufacturing system includes a build surface, one or more laser energy sources, and an optics assembly movable relative to the build surface. The optics assembly directs laser energy from the one or more laser energy sources toward the build surface to fuse a portion of a precursor material on the build surface. A gas head is operatively coupled to the optics assembly and movable relative to the build surface. The gas head entrains emitted materials released during fusion of the precursor material. The system also includes a gas head cleaning device having a scraper to remove debris from a surface of the gas head.

Abstract: A support for a build table for use with an additive manufacturing system. Two or more actuators may be coupled to the build table and configured to move the build table in a Z direction, e.g., for deposition of multiple precursor material layers, and rotate the build table about axes parallel to a build surface, e.g., to level the build surface. Couplings for one or more actuator may provide pivotal movement about at least two orthogonal axes and linear movement along only one direction parallel to the build surface.

Abstract: In some embodiments, systems and methods are related to identifying recoating defects based at least in part on imaged light intensities are disclosed. In other embodiments, systems and methods for predicting the formation of part defects during an additive manufacturing process based at least in part on information related to the presence of recoating defects are disclosed.

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: 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: Disclosed embodiments relate to additive manufacturing systems. In some embodiments, an additive manufacturing system includes a fixed build plate, and a build volume extends above the fixed build plate. A boundary of the build volume may be defined by a powder containing shroud that is vertically displaceable relative to the fixed build plate. A powder deposition system is configured to deposit a powder layer along an upper surface of the build volume and the powder deposition is vertically displaceable relative to the fixed build plate. An optics assembly configured to direct laser energy from one or more laser energy sources towards the build volume, and exposure of the powder layer to the laser energy melts at least a portion of the powder layer. In some embodiments, the build plate may be supported by support columns configured to maintain the build plate in a level orientation throughout a build process.

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.