Abstract: A method for additive manufacturing an object is disclosed. The method includes, for a first portion of the object to be built in a first overlapping field region of a plurality of melting beams of a metal powder AM system, sequentially forming each layer of the first portion by: forming only a border section of the first portion of the object using a first melting beam of the plurality of melting beams in the first overlapping field region; and forming an internal section of the first portion of the object within the border section using at least one second, different melting beam from the first melting beam in the first overlapping field region. An entirety of an internal edge of the border section of the first portion of the object is overlapped with an entirety of an external edge of the internal section of the first portion of the object.

Abstract: An additive manufacturing apparatus includes an energy beam source adapted to emit an energy beam, and a component building area including a base extendable between and vertically movable relative to opposed walls. The component building area includes a platform supported by the base and extendable between the walls, the platform having a layer onto which powdered material is applied, the powdered material being melted or sintered by the energy beam to form a component. The component building area includes an articulation device for rotating the platform about a horizontal axis, and a powder recovery arrangement. The apparatus includes subsequent to formation of the component, the articulation device rotating the platform about the horizontal axis for collecting loose powder by the powder recovery arrangement by virtue of gravity.

Abstract: Build plates for additive manufacturing systems are disclosed. The build plates of the additive manufacturing systems may include a body including a build surface, and a bottom surface positioned opposite the build surface. The build plates may also include a first conduit formed through the body and extending between the build surface and the bottom surface. The first conduit may be configured to be in fluid communication with a first aperture formed through a surface of a first component that may be built on the build surface of the body of the build plates.

Abstract: A component includes a body, and an interface in the body defining a first and second portion of the body made by different melting beam sources of a multiple melting beam source additive manufacturing system during a single build. The component also includes a channel extending through the body. The channel includes an interface-distant area on opposing sides of the interface, each interface-distant area having a first width. The channel also includes an enlarged width area fluidly communicative with the interface-distant areas and spanning the interface, the enlarged width area having a second width larger than the first width. Any misalignment of the melting beams at the interface is addressed by the enlarged width area, eliminating the problem of reduced cooling fluid flow in the channel.

Abstract: A method for using a build plate including a reusable supporting platform for additive manufacturing of a component is disclosed. The method may include additive manufacturing the reusable supporting platform on a top surface of a base of the build plate, and additive manufacturing a first component on the second surface of the reusable supporting platform. The method may also include separating the first component from the build plate at the second surface of the reusable supporting platform, thereby exposing a new surface of the body of the reusable supporting platform. Additionally, the method may include additive manufacturing at least a second component on the new surface of the reusable supporting platform. The reusable supporting platform may include a body including a first surface coupled to the top surface of the base of the build plate, and a second surface configured to support a component to be formed by additive manufacturing and for separation of the component from the build plate.

Abstract: A method for additive manufacturing an object is disclosed. The method includes, for a first portion of the object to be built in a first overlapping field region of a plurality of melting beams of a metal powder AM system, sequentially forming each layer of the first portion by: forming only a border section of the first portion of the object using a first melting beam of the plurality of melting beams in the first overlapping field region; and forming an internal section of the first portion of the object within the border section using at least one second, different melting beam from the first melting beam in the first overlapping field region. An entirety of an internal edge of the border section of the first portion of the object is overlapped with an entirety of an external edge of the internal section of the first portion of the object.

Abstract: Various embodiments include approaches for controlling an additive manufacturing (AM) process. In some cases, an AM system includes: a process chamber for additively manufacturing a component, the process chamber at least partially housing a plurality of distinct melting beam scanners, each of the distinct melting beam scanners configured to emit a melting beam, wherein each of the distinct melting beam scanners is independently physically movable within a corresponding region of the process chamber; and a control system coupled with the plurality of distinct melting beam scanners, the control system configured to control movement of at least one of the plurality of distinct melting beam scanners within the corresponding region based upon a geometry of the component.

Abstract: A method for additive manufacturing an object is disclosed. The method includes, for a first portion of the object to be built in a first overlapping field region of a plurality of melting beams of a metal powder AM system, sequentially forming each layer of the first portion by: forming only a border section of the first portion of the object using a first melting beam of the plurality of melting beams in the first overlapping field region; and forming an internal section of the first portion of the object within the border section using at least one second, different melting beam from the first melting beam in the first overlapping field region. An entirety of an internal edge of the border section of the first portion of the object is overlapped with an entirety of an external edge of the internal section of the first portion of the object.

Abstract: An additively manufactured (AM) structure includes a removal plane extending therein defining an object thereabove. The AM structure also includes at least one datum structure coupled relative to the AM structure. Each datum structure includes a vertical reference plane for guiding a cutting element to remove the object from a remaining portion of the AM structure through the removal plane. The vertical reference plane is horizontally coplanar with the removal plane of the AM structure. The datum structures allow for accurate object cuts regardless of whether an AM build platform is horizontal or non-planar.

Abstract: An additive manufacturing apparatus includes an energy beam source adapted to emit an energy beam, and a component building area including a base extendable between and vertically movable relative to opposed walls. The component building area includes a platform supported by the base and extendable between the walls, the platform having a layer onto which powdered material is applied, the powdered material being melted or sintered by the energy beam to form a component. The component building area includes an articulation device for rotating the platform about a horizontal axis, and a powder recovery arrangement. The apparatus includes subsequent to formation of the component, the articulation device rotating the platform about the horizontal axis for collecting loose powder by the powder recovery arrangement by virtue of gravity.

Abstract: An additively manufactured (AM) structure includes a removal plane extending therein defining an object thereabove. The AM structure also includes at least one datum structure coupled relative to the AM structure. Each datum structure includes a vertical reference plane for guiding a cutting element to remove the object from a remaining portion of the AM structure through the removal plane. The vertical reference plane is horizontally coplanar with the removal plane of the AM structure. The datum structures allow for accurate object cuts regardless of whether an AM build platform is horizontal or non-planar.

Abstract: A component includes a body, and an interface in the body defining a first and second portion of the body made by different melting beam sources of a multiple melting beam source additive manufacturing system during a single build. The component also includes a channel extending through the body. The channel includes an interface-distant area on opposing sides of the interface, each interface-distant area having a first width. The channel also includes an enlarged width area fluidly communicative with the interface-distant areas and spanning the interface, the enlarged width area having a second width larger than the first width. Any misalignment of the melting beams at the interface is addressed by the enlarged width area, eliminating the problem of reduced cooling fluid flow in the channel.

Abstract: Build plates for additive manufacturing systems are disclosed. The build plates of the additive manufacturing systems may include a body including a build surface, and a bottom surface positioned opposite the build surface. The build plates may also include a first conduit formed through the body and extending between the build surface and the bottom surface. The first conduit may be configured to be in fluid communication with a first aperture formed through a surface of a first component that may be built on the build surface of the body of the build plates.

Abstract: Various embodiments include approaches for controlling an additive manufacturing (AM) process. In some cases, an AM system includes: a process chamber for additively manufacturing a component, the process chamber at least partially housing a plurality of distinct melting beam scanners, each of the distinct melting beam scanners configured to emit a melting beam, wherein each of the distinct melting beam scanners is independently physically movable within a corresponding region of the process chamber; and a control system coupled with the plurality of distinct melting beam scanners, the control system configured to control movement of at least one of the plurality of distinct melting beam scanners within the corresponding region based upon a geometry of the component.

Abstract: A method for additive manufacturing an object is disclosed. The method includes, for a first portion of the object to be built in a first overlapping field region of a plurality of melting beams of a metal powder AM system, sequentially forming each layer of the first portion by: forming only a border section of the first portion of the object using a first melting beam of the plurality of melting beams in the first overlapping field region; and forming an internal section of the first portion of the object within the border section using at least one second, different melting beam from the first melting beam in the first overlapping field region. An entirety of an internal edge of the border section of the first portion of the object is overlapped with an entirety of an external edge of the internal section of the first portion of the object.

Abstract: A method for using a build plate including a reusable supporting platform for additive manufacturing of a component is disclosed. The method may include additive manufacturing the reusable supporting platform on a top surface of a base of the build plate, and additive manufacturing a first component on the second surface of the reusable supporting platform. The method may also include separating the first component from the build plate at the second surface of the reusable supporting platform, thereby exposing a new surface of the body of the reusable supporting platform. Additionally, the method may include additive manufacturing at least a second component on the new surface of the reusable supporting platform. The reusable supporting platform may include a body including a first surface coupled to the top surface of the base of the build plate, and a second surface configured to support a component to be formed by additive manufacturing and for separation of the component from the build plate.

Abstract: Supports for additive manufacturing systems are disclosed. The supports positioned on a build plate of the additive manufacturing systems may include a build surface, a side surface positioned adjacent the build surface, and an outlet opening formed through the build surface. The outlet opening may be configured to be in fluid communication with an aperture formed through a surface of a component built above the build surface. The support may also include an inlet opening formed through one of the build surface or the side surface, and a conduit fluidly coupling the outlet opening and the inlet opening.

Abstract: A component is disclosed, the component comprising a first material and a second material, wherein a second member made from the second material is embraced by a first member made from the first material. Further, a method is disclosed for manufacturing said component, the method comprising applying an additive manufacturing process, building up a first member from a first material by the additive manufacturing process, and adding a second member made from a second material during the additive manufacturing process and adding further first material to the first member thus embracing the second member.