Abstract: An additively manufactured assembly including an additively manufactured component with an edge oriented with respect to a recoater blade direction and an non-contact support that does not form a part of the additively manufactured component, the additively manufactured support located adjacent the edge. A method of additively manufacturing a component includes additively manufacturing an component with an edge oriented with respect to a recoater blade direction simultaneous with additively manufacturing an non-contact support that does not form a part of the component, the additively manufactured support located adjacent the edge.

Abstract: An additive manufacturing process includes simultaneously constructing a component and a non-contacting thermal support for the component. The non-contacting thermal support includes a three dimensional negative of the component. The non-contacting thermal support transfers heat from the component into a heat sink.

Abstract: A metal powder reconditioning apparatus and method recondition contaminated residual powder from an additive manufacturing device. The apparatus and method include a reducing chamber that receives contaminated residual powder resulting from an additive manufacturing process and remove oxygen from the contaminated residual powder to produce reconditioned powder. The reconditioned powder may be reused in the additive manufacturing process, or may be stored in a non-oxidizing atmosphere for later reuse.

Abstract: A method of obtaining a sample of materials includes building a product through an additive manufacturing process. A capsule is formed with an internal chamber inside of the capsule. The capsule is formed during the building of the additive manufacturing product. A sample of powder is encapsulated inside the internal chamber as the capsule is built. The internal chamber is hermetically sealed from an exterior environment to retain the sample of powder in the internal chamber.

Abstract: A method for operating an additive manufacturing apparatus, the method comprises directing a first energy beam along a surface contour vector in a build plane. A second energy beam is directed along a plurality of substantially parallel hatch vectors disposed in the build plane inward of the surface contour vector. A sum of the surface contour vector and the plurality of hatch vectors define a processed powder region in the build plane. A third energy beam is directed along an offset contour vector in the build plane. The offset contour vector includes a plurality of unprocessed powder regions in the build plane between the surface contour vector and the plurality of hatch vectors.

Abstract: An additive manufacturing apparatus is disclosed which includes a movable platform. The movable platform has a plurality of fasteners and an upper surface, and at least one indexing feature. An upper surface of a movable platform is coupled with an indexing device such that movement of either one corresponds to movement of the other.

Abstract: An abradable seal for a gas turbine engine includes a seal body that has a seal side and a non-seal side. The seal body includes an abradability characteristic that varies by locality.

Abstract: A component includes a support structure made with an additive manufacturing process with a first end and a second end, and an object made with an additive manufacturing process with a first end and a second end, where the first end of the object is attached to the second end of the support structure. A cross-sectional area of the first end of the object is larger than a cross-sectional area of the second end of the support structure. A method of making an object, the method includes manufacturing a support structure with an additive manufacturing process. An object is manufactured on top of and connected to the support structure with an additive manufacturing process, wherein there is a witness mark created between the support structure and the object. The witness mark is identified. The object is separated from the support structure along the witness mark.

Abstract: A powder-derived, non-finished work piece includes a first body section that has a wall that spans in a vertical direction. The wall has a relatively thin thickness with respect to a length and a width of the wall. A second body section is arranged next to, but spaced apart from, the first body section. A gusset connects the first body section and the second body section. The gusset extends obliquely from the wall of the first body section with respect to the vertical direction such that the gusset is self-supporting. The first body section has a geometry that corresponds to an end-use component exclusive of the gusset.

Abstract: A metal powder reconditioning apparatus and method recondition contaminated residual powder from an additive manufacturing device. The apparatus and method include a reducing chamber that receives contaminated residual powder resulting from an additive manufacturing process and remove oxygen from the contaminated residual powder to produce reconditioned powder. The reconditioned powder may be reused in the additive manufacturing process, or may be stored in a non-oxidizing atmosphere for later reuse.

Abstract: The invention relates to an additive manufacturing apparatus and method. According to the invention, an additive manufacturing apparatus includes a material supply system. The material supply system delivers layers of partially sintered pulverant material to an additive manufacturing device.

Abstract: A component inspection system comprises a sensor apparatus and a template having a component side and an opposing inspection side. The inspection side includes a plurality of inspection bosses projecting therefrom, each of the plurality of inspection bosses having a first coupling and a sensor aperture. Each aperture is disposed axially through each respective boss to the component side of the template. The sensor apparatus includes a receptacle for retaining a sensor. The receptacle has a second coupling configured to individually engage with each of the plurality of first couplings for removably securing the sensor apparatus to a respective at least one of the plurality of inspection bosses.

Abstract: A component inspection system comprises a sensor apparatus and a template having a component side and an opposing inspection side. The inspection side includes a plurality of inspection bosses projecting therefrom, each of the plurality of inspection bosses having a first coupling and a sensor aperture. Each aperture is disposed axially through each respective boss to the component side of the template. The sensor apparatus includes a receptacle for retaining a sensor. The receptacle has a second coupling configured to individually engage with each of the plurality of first couplings for removably securing the sensor apparatus to a respective at least one of the plurality of inspection bosses.