Abstract: An additive manufacturing system having a heat source for melting powder particles in a desired shape and pattern to produce a product. A secondary heat source is used for heat treating the product to achieve heat treatment. The secondary heat source is used to peen or anneal residual stresses caused by the additive manufacturing process.

Abstract: An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved structure formation, part creation and manipulation, use of multiple additive manufacturing systems, and high throughput manufacturing methods suitable for automated or semi-automated factories are also disclosed.

Abstract: A method and an apparatus for collecting powder samples in real-time in powder bed fusion additive manufacturing may involves an ingester system for in-process collection and characterizations of powder samples. The collection may be performed periodically and uses the results of characterizations for adjustments in the powder bed fusion process. The ingester system of the present disclosure is capable of packaging powder samples collected in real-time into storage containers serving a multitude purposes of audit, process adjustments or actions.

Abstract: A system is disclosed for performing an Additive Manufacturing (AM) fabrication process on a powdered material forming a substrate. The system may make use of a diode array for generating an optical signal sufficient to melt a powdered material of the substrate. A mask may be used for preventing a first predetermined portion of the optical signal from reaching the substrate, while allowing a second predetermined portion to reach the substrate. At least one processor may be used for controlling an output of the diode array.

Abstract: The present disclosure relates to an apparatus for additively manufacturing a product in a layer-by-layer sequence, wherein the product is formed using powder particles deposited on an interface layer of a substrate. A laser generates first and second beam components, where the second beam component has a substantially higher power level and a substantially shorter duration than the first beam component. A mask is used to create a 2D optical pattern in which only select portions of the first and second beam components are allowed to irradiate the powdered particles. The first beam component heats the powder particles at least to substantially a melting point, at which point the particles begin to experience surface tension forces relative to the interface layer.

Abstract: An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved optical systems supporting beam combining, beam steering, and both patterned and unpatterned beam recycling and re-use are described.

Abstract: A system for additive manufacturing uses a pulsed laser beam with one or more low flux components on the order of kW/cm2, and one or more high flux components on the order of MW/cm2 during the duration of the pulse. The pulsed laser beam is directed onto the powder particles on the substrate thereby melting the powder particles and melting the substrate at the interface layer between the powder and the substrate such that the powder particles bond to the substrate. This is accomplished by using low power (and low cost) lasers to do the majority of the energy transfer, and using high power (and higher cost) lasers to complete the melting process, overcoming the kinetics of powder agglomeration through surface tension forces by partially melting the powder-substrate interface layer before surface tension can take effect on the molten powder particles.

Abstract: Systems and methods are disclosed for manufacturing a three dimensional (3D) part. In one implementation a system in accordance with the present disclosure may make use of an additive manufacturing (AM) subsystem for performing an AM operation to form the 3D part. The 3D part may be formed using a plurality of distinct material layers layered one on top of another. The system may also involve at least one of a laser peening (LP) subsystem and a High Velocity Laser Accelerated Deposition (HVLAD) subsystem. The LP subsystem may be used for laser peening a selected subquantity of the layers, to impart improved hardness to the selected subquantity of the layers and/or to the overall 3D part. The HVLAD subsystem may be used to bond at least one of the material layers to a previously laid down one of the material layers.

Abstract: A solid state beam routing apparatus includes a controller and a spatial angular light valve arranged to direct a two-dimensional patterned light beam through a predetermined angle in response to an applied voltage. A bed is arranged to receive the two-dimensional patterned light beam as a succession of tiles. In some embodiments, one or more solid state galvo mechanisms are used to direct the two-dimensional patterned light beams formed by the light valve to the multiple powder bed chambers.

Abstract: A method and an apparatus for additive manufacturing pertaining to high efficiency, energy beam patterning and beam steering to effectively and efficiently utilize the source energy. In one embodiment recycling and reuse of unwanted light includes a source of multiple light patterns produced by one or more light valves, with at least one of the multiple light patterns being formed from rejected patterned light. An image relay is used to direct the multiple light patterns, and a beam routing system receives the multiple light patterns and respectively directs them toward defined areas on a powder bed.

Abstract: A system is disclosed for performing an Additive Manufacturing (AM) fabrication process on a powdered material forming a substrate. The system may make use of a diode array for generating an optical signal sufficient to melt a powdered material of the substrate. A mask may be used for preventing a first predetermined portion of the optical signal from reaching the substrate, while allowing a second predetermined portion to reach the substrate. At least one processor may be used for controlling an output of the diode array.

Abstract: An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. The two-dimensional energy patterning system may be used to control a state of matter of each successive additive layer. Accordingly, the system may be used to alter the chemical bond arrangement of the material forming the various additive layers.

Abstract: An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. The two-dimensional energy patterning system may be used to control the rate of cooling experienced by each successive additive layer. Accordingly, the system may be used to heat treat the various additive layers.

Abstract: An additive manufacturing method that can use a two-dimensional energy patterning system is disclosed. Information related to a part is provided, with the information including CAD files, material type, selected additive manufacturing process type, and tolerances of selected design features. Manufacture of a part is simulated and compared to selected design tolerance. If the simulated manufactured part is outside selected design tolerances, simulation parameters can be adjusted until results indicate the simulated manufactured part is within selected design tolerances. In certain embodiments, manufacturing the part uses a real-time sensor monitoring system, along with post processing analysis of selected design features to improve simulated manufacture of the part.

Abstract: A system for melting powdered material and bonding it to the substrate below such as could be used for the additive manufacturing of a product includes a substrate, powder particles on the substrate, a pulsed laser that produces a pulsed laser beam with one or more low flux components on the order of kW/cm?2, and one or more high flux components on the order of MW/cm?2 during the duration of the pulse. The pulsed laser beam is directed onto the powder particles on the substrate thereby melting the powder particles and melting the substrate at the interface layer between the powder and the substrate such that the powder particles bond to the substrate. The laser further can be spatially patterned through the use of a mask such that portions of the laser pulse can be transmitted to the powder to be melted, and other portions can be rejected to prevent melting of the powder in desired locations.

Abstract: A laser-based additive manufacturing system tailored to be material specific based on the laser wavelength or frequency used. The system adjusts the frequency/wavelength of the laser during the process to improve coupling efficiency and/or tailor heating and cooling profiles of different materials.

Abstract: Systems provide cooling of an optic such as an optically addressed light valve such that the valve is sensitive to temperature and pressure variations and is thus temperature and pressure controlled. In the case of an optic such as an optically addressed light valve, the fluid pressure outside the valve is low enough that it does not compress the liquid crystal gap of the valve. The cooling fluid is transparent to the high powered wavelength of light used during operation such as in an additive manufacturing process.

Abstract: An additive manufacturing system having a heat source for melting powder particles in a desired shape and pattern to produce a product. A secondary heat source is used for heat treating the product to achieve heat treatment. The secondary heat source is used to peen or anneal residual stresses caused by the additive manufacturing process.

Abstract: An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved structure formation, part creation and manipulation, use of multiple additive manufacturing systems, and high throughput manufacturing methods suitable for automated or semi-automated factories are also disclosed.

Abstract: A system of 3D printing using a high temperature 3D print head that functions as a “modified ink jet” printer. The print head has the ability to print high temperature material such as metal, silicon carbide, and other high temperature material as opposed to inks or plastics. The print head is fabricated from a high temperature material to maintain structural integrity while operation at temperatures above the melting temperature for the material that is being printed.