Abstract: A spray forming method for producing a metallic ingot and metallic powder from a metallic source of metal or metal alloy includes: forming one or more streams of metal or alloy from the source, gas atomizing one or more streams of metal or alloy to form one or more sprays of atomized droplets, directing the spray(s) of droplets through a spray nozzle to a rotatable hot body, depositing the droplets to the hot body to form the ingot, controlling the process parameters 1) temperature of metal or alloy, 2) inlet and outlet pressure of the spray nozzle, 3) rotation speed of the hot body, and/or 4) distance between the hot body and the spray(s) of droplets, and collecting the metallic powder having a predefined size distribution. The process parameters are controlled such that the ingot yield is 60-80% and the metallic powder yield is 40-20%, relative to the metallic source.

Abstract: An additive manufacturing apparatus for building a product according to a planned geometry by successive solidification of a radiation-curable fluid in a solidification layer extending in a vertical direction from a surface of the fluid to a surface of the product. The apparatus includes: a vat holding the fluid; a support holding the product; a mechanism to control feeding of fluid to the solidification layer; a curing radiation source to generate a 2D exposure pattern of curing radiation in the solidification layer. The exposure pattern is defined by a curing radiation pattern geometry and/or curing radiation intensity. A radiation sensor receives radiation from the solidification layer. The radiation sensor generates a sensor signal having information indicative of a solidification process status. A control system is connected to the feed control mechanism and the curing radiation source.

Abstract: An additive manufacturing apparatus for building a product according to a planned geometry by successive solidification of a radiation-curable fluid in a solidification layer extending in a vertical direction from a surface of the fluid to a surface of the product. The apparatus includes: a vat holding the fluid; a support holding the product; a mechanism to control feeding of fluid to the solidification layer; a curing radiation source to generate a 2D exposure pattern of curing radiation in the solidification layer. The exposure pattern is defined by a curing radiation pattern geometry and/or curing radiation intensity. A radiation sensor receives radiation from the solidification layer. The radiation sensor generates a sensor signal having information indicative of a solidification process status. A control system is connected to the feed control mechanism and the curing radiation source.