Abstract: Apparatus and methods of forming a three-dimensional build object on a substrate (204) include directing an energy beam (202) onto the substrate (204) to form a melt pool (308), wherein the energy beam (202) traverses the substrate (204) in a process direction (322) at a process speed, depositing additive material into the melt pool (308), and measuring energy emitted by the melt pool (308). A thermal signature of the melt pool (308) is determined based on the measured energy. The method further includes identifying a liquidus region (332) of the melt pool (308), a solidus region (334) surrounding the melt pool (308), and a transitional region (336) of the melt pool (308) based on the thermal signature.

Abstract: A machine for additive manufacturing positions a film having additive material relative to a substrate. The additive material is melted onto the substrate or previously formed layers of a workpiece using a laser. The substrate/workpiece and/or the film can be positioned in multiple axes so that complex shapes can be formed without extraneous supporting structures. The film-based delivery of the additive material allows deposition in orientations other than horizontal as is required for powder-only additive manufacturing and also avoids the inconvenience of collecting and recycling unused loose powdered metal.

Abstract: A method of machining a workpiece may include continuously rotating the workpiece, continuously rotating a tool having at least one cutting surface, and positioning the tool relative to the workpiece so that the at least one cutting surface engages the workpiece at a first discrete location at a periphery of the workpiece. The method may further include continuing to rotate the workpiece and the tool so that the at least one cutting surface engages a second discrete location at the periphery of the workpiece, and controlling a tool surface velocity VT relative to the workpiece surface velocity VW so that the first and second discrete locations are discontinuous. The tool may make multiple iterative passes over the workpiece to engage subsequent discrete locations, wherein the first discrete location, second discrete location, and multiple subsequent discrete locations may form a machined surface that extends continuously around the workpiece.

Abstract: Systems and methods for forming a three-dimensional build object on a substrate include controlling an energy beam source in a first mode during a first processing step during which additive material is deposited. Additionally, the method includes controlling the energy beam source in a second mode during a second processing step during which additive material is not deposited. During the first processing step, a feature may be formed by melting additive material as it is deposited into a target area.

Abstract: A system for manufacturing a build object includes an additive manufacturing tool configured to utilize a powdered reactive material to construct the build object. The powdered reactive material includes a plurality of powder beads, wherein each powder bead has a bead diameter that is substantially similar to an ideal bead diameter. The system further includes apparatus configured to selectively shield the build object during additive manufacturing of the build object, by the additive manufacturing tool, using an inert gas. The ideal bead diameter is configured to be a bead diameter at which ignition of the powdered reactive material is inhibited, upon oxidation of the powdered reactive material.

Abstract: A system is provided for manufacturing a part. The system includes a manufacturing machine that includes at least one additive manufacturing tool. The system further includes a computer numerical control (CNC) controller operatively associated with the manufacturing machine and configured to control the at least one additive manufacturing tool based on computer aided manufacturing (CAM) instructions. The system further includes a CAM controller operatively associated with the CNC controller and configured to determine the CAM instructions based on computer aided drafting (CAD) instructions, the CAM instructions including a plurality of CAM operation control functions, each of the plurality of CAM operation control functions correlated with at least one of a plurality of CAD operation control functions of the CAD instructions.

Abstract: A powder delivery system for use in an additive manufacturing device includes a powder control valve configured to selectively divert at least a portion of an input fluid flow to a return line while a remainder of the input flow is delivered to a delivery nozzle. In some embodiments, the powder delivery valve may be modulated to alter the percentage of input flow diverted to the return line. Alternatively, the powder delivery valve may be either fully open or closed. In each embodiment, the powder delivery valve permits rapid changes in the amount of powder delivered to the nozzle.

Abstract: A system is provided for manufacturing a part. The system includes a manufacturing machine that includes at least one additive manufacturing tool. The system further includes a computer numerical control (CNC) controller operatively associated with the manufacturing machine and configured to control the at least one additive manufacturing tool based on computer aided manufacturing (CAM) instructions. The system further includes a CAM controller operatively associated with the CNC controller and configured to determine the CAM instructions based on computer aided drafting (CAD) instructions, the CAM instructions including a plurality of CAM operation control functions, each of the plurality of CAM operation control functions correlated with at least one of a plurality of CAD operation control functions of the CAD instructions.

Abstract: A method of machining a workpiece may include continuously rotating the workpiece, continuously rotating a tool having at least one cutting surface, and positioning the tool relative to the workpiece so that the at least one cutting surface engages the workpiece at a first discrete location at a periphery of the workpiece. The method may further include continuing to rotate the workpiece and the tool so that the at least one cutting surface engages a second discrete location at the periphery of the workpiece, and controlling a tool surface velocity VT relative to the workpiece surface velocity VW so that the first and second discrete locations are discontinuous. The tool may make multiple iterative passes over the workpiece to engage subsequent discrete locations, wherein the first discrete location, second discrete location, and multiple subsequent discrete locations may form a machined surface that extends continuously around the workpiece.

Abstract: A processing head assembly is provided for use with a movable tool holder of a machine tool. The processing head assembly includes an upper processing head coupled to the movable tool holder and having a body defining a socket, and a feed powder/propellant port coupled to the body and operably coupled to a feed powder/propellant supply. The processing head assembly further includes a lower processing head having a base configured to be releasably coupled to the socket, and a nozzle coupled to the base and defining a feed powder/propellant interface configured to detachably couple to the feed powder/propellant port and a nozzle exit orifice.

Abstract: A method of machining a workpiece may include continuously rotating the workpiece, continuously rotating a tool having at least one cutting surface, and positioning the tool relative to the workpiece so that the at least one cutting surface engages the workpiece at a first discrete location at a periphery of the workpiece. The method may further include continuing to rotate the workpiece and the tool so that the at least one cutting surface engages a second discrete location at the periphery of the workpiece, and controlling a tool surface velocity VT relative to the workpiece surface velocity VW so that the first and second discrete locations are discontinuous. The tool may make multiple iterative passes over the workpiece to engage subsequent discrete locations, wherein the first discrete location, second discrete location, and multiple subsequent discrete locations may form a machined surface that extends continuously around the workpiece.

Abstract: A powder delivery system for use in an additive manufacturing device includes a powder control valve configured to selectively divert at least a portion of an input fluid flow to a return line while a remainder of the input flow is delivered to a delivery nozzle. In some embodiments, the powder delivery valve may be modulated to alter the percentage of input flow diverted to the return line. Alternatively, the powder delivery valve may be either fully open or closed. In each embodiment, the powder delivery valve permits rapid changes in the amount of powder delivered to the nozzle.

Abstract: Methods and apparatus for performing additive manufacturing processes using a machine tool may include controlling an orientation of a processing head to control the tangential angle of a fabrication energy beam, a feed powder nozzle, or both. The orientation of a non-circular energy beam may be control to more evenly distribute the energy beam across a width of a tool path. Additionally or alternatively, the orientation of the feed powder nozzle may be controlled to project toward a powder target that is spaced from a beam target. The powder target may be directed to a trailing edge of a beam spot formed by the energy beam to increase the amount of powder incorporated into a melt pool formed by the energy beam. Alternatively, the powder target may be directed to a leading edge of the beam spot to provide a self-correcting feature to address thickness errors formed in previous layers of added material.

Abstract: A method of grind hardening a workpiece is provided. The method may include securing the workpiece in a workpiece retainer and a grind tool in a tool retainer, rotating the grind tool in a first angular direction at a first angular speed, controlling the workpiece and tool retainers such that the grind tool engages the workpiece, and controlling the workpiece and tool retainers such that the grind tool is guided along a grinding track of the workpiece. The grind tool may engage and/or disengage the workpiece at portions of sacrificial material disposed thereon. Coolant and cleaning nozzles may be provided and controlled such that at least a portion of the coolant from the coolant nozzle is diverted to the cleaning nozzle in a manner which reduces heat dissipation, improves thermal efficiency of the grind hardening and reduces loading of the grind tool.

Abstract: An apparatus for obtaining information about a workpiece may include a measuring device having a nozzle defining an orifice in fluid communication with a source of incompressible fluid. A fluid monitoring apparatus may monitor a parameter of the substantially incompressible fluid, and a pump may be fluidly coupled to the source and configured to supply incompressible fluid to the orifice. The pump may have a pump chamber with a first displacement setting having a first fixed volume, so that operation of the pump at a first pump speed with the pump chamber in the first displacement setting generates a first fluid flow having a substantially constant first volumetric rate. The pump may have more than one displacement setting, or the pump may be operated at different speeds to change the volumetric flow rate. The nozzle may include multiple, independent orifice sets that may be selectively provided fluid, thereby to obtain information on different parts of the workpiece with a single placement of the nozzle.

Abstract: A machine for additive manufacturing positions a film having additive material relative to a substrate. The additive material is melted onto the substrate or previously formed layers of a workpiece using a laser. The substrate/workpiece and/or the film can be positioned in multiple axes so that complex shapes can be formed without extraneous supporting structures. The film-based delivery of the additive material allows deposition in orientations other than horizontal as is required for powder-only additive manufacturing and also avoids the inconvenience of collecting and recycling unused loose powdered metal.

Abstract: Gear machining apparatus and methods are configured to produce gaps between gear teeth having portions formed by two different machining processes. A rough cutting process may be used to form a root portion of the gap, while a finish cutting process may be used to form final tooth faces. The apparatus and methods may further be configured to machine one or more gear tooth profile modifications.

Abstract: Machine tool systems and methods include methods of synchronizing cutting tools with a workpiece retainer. In some embodiments, the methods and systems provide at least two cutting tools that are synchronized to machine a common surface of a workpiece in a quick and efficient manner. A controller having a single line of code for controlling both cutting tools and the workpiece retainer may be used. The cutting tools may be synchronized such that they engage substantially opposite portions of the workpiece, thereby to reduce resulting forces in the workpiece that may tend to induce workpiece deflection and/or chatter. In other embodiments, a cutting tool is synchronized with a split workpiece holder that may be controlled to induce a compression, tension, or torsion pre-load in the workpiece.

Abstract: A cutting insert rotated about its axis may be utilized during a metalworking operation and applied against the rotating workpiece to enhance tool performance. The cutting insert is secured within a toolholder having features to secure the insert but at the same time make for efficient removal of the insert from the toolholder.

Abstract: A method of grind hardening a workpiece is provided. The method may include securing the workpiece in a workpiece retainer and a grind tool in a tool retainer, rotating the grind tool in a first angular direction at a first angular speed, controlling the workpiece and tool retainers such that the grind tool engages the workpiece, and controlling the workpiece and tool retainers such that the grind tool is guided along a grinding track of the workpiece. The grind tool may engage and/or disengage the workpiece at portions of sacrificial material disposed thereon. Coolant and cleaning nozzles may be provided and controlled such that at least a portion of the coolant from the coolant nozzle is diverted to the cleaning nozzle in a manner which reduces heat dissipation, improves thermal efficiency of the grind hardening and reduces loading of the grind tool.