Abstract: A method for removing excess powder from a part for a vehicle during an additive manufacturing process, comprises defining parameters for a part, defining parameters for a removal tool comprising a plurality of links to create a chain-like structure, simultaneously creating the part and the removal tool via additive manufacturing, wherein the part defines an interior passageway and the removal tool is created within the interior passageway and, upon completion of the creation of the part and the removal tool, the removal tool is surrounded by excess powder in the interior passageway, and wherein each link of the plurality of links are created with a gap between adjacent links of the plurality of links, and removing the removal tool from the interior passageway, forcing at least some of the excess powder out of the interior passageway.

Abstract: Methods and systems for additive manufacturing are provided. An exemplary method includes calculating a slice area distribution of a desired 3D design including slice areas of slices of the desired design, wherein the slices have an initial slice area differential. The method further includes obtaining a slice area distribution of a sacrificial 3D design comprising slice areas of slices of the sacrificial design. The method includes planning a 3D layout of the desired and sacrificial design, wherein at each respective parallel plane in the layout a total slice area includes a respective slice area of the desired design and a respective slice area of the sacrificial design, and wherein the layout has a total slice area differential that is less than the initial slice area differential. Also, the method includes generating instructions for printing slices of the desired design and the sacrificial design according to the layout.

Abstract: Systems and methods are provided for printing sections of a part with integral locating and joining features. A system for joining part sections of a part having at least two separate sections includes a locating feature and a joining feature. The locating feature includes structures integrally formed with the sections to locate them relative to one another. The joining feature includes structures integrally formed with the sections to lock the sections together.

Abstract: Systems and methods are provided for cleaning surfaces of a workpiece. The system includes a housing defining an enclosure, a holding structure within the enclosure that is configured to support a workpiece, a first powder removal device that is configured to propel a first media toward the holding structure such that the first media contacts the workpiece while the workpiece is supported by the holding structure, a first sensing device that is configured to detect surface characteristics of the workpiece while the workpiece is supported by the holding structure, and a controller configured to, by a processor: detect a powder material on a surface of the workpiece based on the surface characteristics, and selectively operate the first powder removal device to remove the powder material from the surface with the first media while the workpiece is supported by the holding structure.

Abstract: Methods and systems for additive manufacturing are provided. An exemplary method includes calculating a slice area distribution of a desired 3D design including slice areas of slices of the desired design, wherein the slices have an initial slice area differential. The method further includes obtaining a slice area distribution of a sacrificial 3D design comprising slice areas of slices of the sacrificial design. The method includes planning a 3D layout of the desired and sacrificial design, wherein at each respective parallel plane in the layout a total slice area includes a respective slice area of the desired design and a respective slice area of the sacrificial design, and wherein the layout has a total slice area differential that is less than the initial slice area differential. Also, the method includes generating instructions for printing slices of the desired design and the sacrificial design according to the layout.