Abstract: A deposition system for casting an object additively by producing multiple production layers having mold regions and object regions defined by the mold regions includes a deposition unit, a first induction heating unit, and an induction heating power supply unit. The deposition unit deposits molten metal in a working area of the object region of the currently-produced production layer according to a building plan defining a deposition path and a deposition velocity. The first induction heating unit heats the working area and is held at a working distance above a height of a current one of the mold regions. The induction heating power supply unit is coupled to the first induction heating unit and provides current at a desired magnitude and frequency. The first induction heating unit generates from the current a magnetic field which extends to the working area.

Abstract: A casting system for producing an object with multiple layers having mold regions and object regions includes a mold construction unit, at least one deposition system, and a controller. The mold construction unit constructs the mold regions of the currently-produced layer. The deposition system includes a movable deposition unit, a first induction heating unit, and an induction heating power supply unit. The movable deposition unit deposits molten metal in a working area along a deposition path and with a deposition velocity. The first induction heating unit heats the working area from a working distance above a height of a current mold region. The power supply unit provides current to generate therefrom a magnetic field extending to the working area. The controller controls the system such that the magnetic field heats a desired zone in the working area to a target temperature.

Abstract: A heating system for heating multiple working areas of a metallic workpiece, one working area after another according to a heating plan, includes at least one induction heating unit, at least one travel unit, and an induction heating power supply unit. The induction heating unit heats the working areas from a working distance which is greater than a predetermined height. The travel unit provides relative motion according to the heating plan between the induction heating unit and the workpiece at a travel velocity. The induction heating power supply unit provides current at a desired magnitude and frequency, generating therefrom a magnetic field which extends to the working area. The induction heating unit includes at least one hairpin coil at a vertical position with respect to the working areas, and a magnetic flux concentrator (MFC) surrounding the hairpin coil. The MFC increases the range of a magnetic field to include the working areas.

Abstract: Methods and systems for additively casting of a metallic object include constructing a mold region of a current production layer before producing the object region of the current production layer; depositing molten metal at a predetermined temperature in working areas at the object region of the current production layer according to a building plan; and moving one or more heaters over the deposition path and heating the working areas. The heating includes (1) heating the working areas to a pre-deposition target temperature before depositing metal on the working areas to affect a bonding of the molten metal with the working areas, and/or (2) heating the working areas to a post-deposition target temperature after depositing metal on the working areas to affect a thermal cooling profile of the working areas. the heating also includes providing annealing heating to earlier production layers by heat conduction through the current production layer.

Abstract: System and method for additive casting of metal objects by constructing production layers having mold regions and object regions includes a mold construction unit to construct a mold region of the current production layer; a Preparation-Deposition-Post (PDP) unit including: a molten metal depositor to deposit molten metal in an object region; a holder for holding the molten metal depositor; at least one induction heating unit; a build table for supporting the vertical stack of production layers; a movable platform to provide relative movement between the PDP unit and the build table; and a controller for controlling the PDP unit and the movable platform to deposit molten metal in a fabrication area, and to control the PDP unit to perform (1) pre-heating the fabrication area before molten metal deposition, to a pre-deposition temperature, and/or (2) post-heating the fabrication area after molten metal deposition, to a post-deposition temperature.

Abstract: A method and an apparatus for additive casting of parts is disclosed. The method may include: depositing, on a build table, a first portion of a mold, such that, the depositing may be performed layer by layer; pouring liquid substance into the first portion of the mold to form a first casted layer; solidifying at least a portion of the first casted layer; depositing a second portion of the mold, on top of the first portion of the mold; pouring the liquid substance into the second portion of the mold to form a second casted layer, on top of at least a portion of the first casted layer; and solidifying at least a portion of the second casted layer. The method may further include joining the first and second casted layers prior to the pouring of a third casted layer.

Abstract: A method and an apparatus for additive casting of parts is disclosed. The method may include: depositing, on a build table, a first portion of a mold, such that, the depositing may be performed layer by layer; pouring liquid substance into the first portion of the mold to form a first casted layer; solidifying at least a portion of the first casted layer; depositing a second portion of the mold, on top of the first portion of the mold; pouring the liquid substance into the second portion of the mold to form a second casted layer, on top of at least a portion of the first casted layer; and solidifying at least a portion of the second casted layer. The method may further include joining the first and second casted layers prior to the pouring of a third casted layer.

Abstract: A method and an apparatus for additive casting of parts is disclosed. The method may include: depositing, on a build table, a first portion of a mold, such that, the depositing may be performed layer by layer; pouring liquid substance into the first portion of the mold to form a first casted layer; solidifying at least a portion of the first casted layer; depositing a second portion of the mold, on top of the first portion of the mold; pouring the liquid substance into the second portion of the mold to form a second casted layer, on top of at least a portion of the first casted layer; and solidifying at least a portion of the second casted layer. The method may further include joining the first and second casted layers prior to the pouring of a third casted layer.

Abstract: The present invention provides a temperature controlled energy transparent window or electrode used to advantage in a substrate processing system. The invention also provides methods associated with controlling lid temperature during processing and for controlling etching processes. In a preferred embodiment the invention provides a fluid supply system for the lid which allows the fluid to flow through a feedthrough and into and out of a channel formed in the window or electrode. The fluid supply system may also mount the window or electrode to a retaining ring which secures the window or electrode to the chamber. In another aspect the invention provides a bonded window or electrode having a first and second plate having a channel formed in the plates so that when the plates are bonded together they form a channel therein through which a temperature controlling fluid can be flowed. An external control system preferably regulates the temperature of the fluid.

Abstract: A plasma sputtering system is disclosed, along with methods of sputtering and methods of arranging an array of magnets disposed within the sputtering system. An embodiment of the sputtering system includes a vacuum chamber. A rotating magnetron is disposed in the vacuum chamber. A target is positioned between the magnetron and a substrate upon which material from the target is to be deposited. The magnetron includes an array of pairs of oppositely poled permanent magnets. A closed loop magnetic path extends between the pairs of oppositely poled magnets of the array. The magnetic path includes an inturn region proximate to an axis of rotation of the magnetron and at least two (e.g., five) indent regions.