Abstract: An additive manufacturing machine (900) including a build unit (904) that is supported by an overhead gantry (912) and a method for positioning the build unit (904) are provided. A positioning system (930) includes one or more position sensors (932) that are separate from the build unit (904) and are configured for obtaining positional data of the build unit (904). The positioning system (930) may continuously track the position and orientation of the build unit (904) and the additive manufacturing machine (900) may adjust the position of the build unit (904) toward a target position.

Abstract: The present disclosure generally relates to additive manufacturing systems and methods on a large-scale format. One aspect involves a build unit that can be moved around in three dimensions by a positioning system, building separate portions of a large object. The build unit has an energy directing device that directs, e.g., laser or e-beam irradiation onto a powder layer. In the case of laser irradiation, the build volume may have a gasflow device that provides laminar gas flow to a laminar flow zone above the layer of powder. This allows for efficient removal of the smoke, condensates, and other impurities produced by irradiating the powder (the “gas plume”) without excessively disturbing the powder layer. The build unit may also have a recoater that allows it to selectively deposit particular quantities of powder in specific locations over a work surface to build large, high quality, high precision objects.

Abstract: Methods are generally provided for making an object(s) from powder. In one embodiment, the method includes: (a) applying a layer of powder on a build platform; (b) irradiating at least part of a layer of powder to form a build wall defining at least one internal cavity therein; (c) moving at least one of the build platform downward or the build unit upward in a direction substantially normal to the layer of powder; and (d) repeating at least steps (a) through (c) to form the build wall. The build wall defines at least one passageway therein, and wherein the at least one passageway has an inlet and an outlet defined in the layer of powder.

Abstract: An additive manufacturing machine (910) includes a build unit (920) including a powder dispenser (906) having a hopper (904) for receiving a volume of additive powder (902). A powder supply system (1000) includes a powder supply source (940) and a conveyor (1024) for transporting dispensed additive powder (902) to the hopper (904). A supply sensing system (1060) monitors the additive powder (902) that is dispensed from the powder supply source (940) and transported to the hopper (904) and a hopper sensing system (1040) monitors the additive powder (902) within the hopper (904). Each of these systems includes one or more powder level sensors (1042, 1044, 1062), weight sensors (1050, 1064), and/or vision systems (1054, 1070) for monitoring the additive powder (902).

Abstract: A method, apparatus, and program for additive manufacturing. In one aspect, the additive manufacturing method includes irradiating a build material (416) to form a first solidified portion within a first scan region (812A) using an irradiation source (401) of a build unit (400). At least one of the build unit and a build platform may be moved to irradiate a second scan region (812B), wherein an irradiation source (401) directing mechanism is adjusted to compensate for a misalignment between the first scan region and the second scan region (640).

Abstract: An additive manufacturing apparatus is provided. The additive manufacturing apparatus may include a stabilizing system; a build platform on the stabilizing system; and a build unit positioned over the build platform, wherein the build unit comprises a powder dispenser and a recoater blade. Methods are also provided for making an object from powder.

Abstract: An additive manufacturing apparatus is provided and may include at least one build unit; a build platform; and at least one collector positioned on the apparatus such that the at least one collector contacts an outer surface of a build wall as the build wall is formed during a build. Methods are also provided for manufacturing at least one object.

Abstract: The present disclosure generally relates to methods and apparatuses (200) for additive manufacturing with improved powder (702) distribution capabilities. One aspect involves a mobile build unit (700) that can be moved around in two to three dimensions by a positioning system, to build separate portions of an object, such as a large object. The mobile build unit (700) may be used with an energy directing device (712) that directs irradiation onto a powder (702) layer. In the case of laser irradiation, the mobile build unit (700) may be used with a gasflow device (713A, 713B) that provides laminar gas flow to a laminar flow zone (714) above the layer of powder (703).

Abstract: An additive manufacturing machine (910) includes a build unit (920) comprising a powder dispenser (906) including a hopper (1004) for receiving a volume of additive powder (1006). A powder supply system (1000) includes a powder supply source (1010) for providing additive powder (1006) into the hopper (1004) during a refill process. A powder reclamation system (1002) includes a vacuum pump (1030) coupled to a vacuum duct (1034, 1036) defining a suction inlet (1040) positioned for collecting misdirected additive powder (1006) dispensed during the refill process. A return duct (1038) includes a filter mechanism (1050) may filter and return the collected additive powder (1006) back to the powder supply source (1010) for reuse.

Abstract: A scanning technique for the additive manufacturing of an object. The method comprises the irradiation a portion of a given layer of powder to form a fused region using an energy source. When forming an object layer by layer, the irradiation follows a first irradiation pattern at least partially bounded by a stripe region. When forming the first fused region using a first irradiation pattern a first series of solidification lines are formed, at angle other than 90° with respect to a substantially linear stripe region boundary. A series of second solidification lines are formed that intersecting the end of the first solidification line at a first angle other than 0° and 180° with respect to the first solidification line. A third series of solidification lines are formed that are substantially parallel to a first series of solidification lines and intersect one of the second solidification lines.

Abstract: A system and method for manufacturing and authenticating a component is provided. The method includes forming a component having an identifying region that contains two or more materials having different conductivities such that the identifying region generates an eddy current response signature that defines a component identifier of the component. The method further includes interrogating the identifying region of the surface with an eddy current probe to determine the component identifier. The component identifier may be stored in a database as a reference identifier and may be used for authenticating components.

Abstract: The present disclosure generally relates to methods of additive manufacturing with control of the energy beam incidence angle that allows for aligning the laser beam angle to directly oppose the building direction of an angled wall. The method includes building an object in an additive manufacturing powder bed where the object includes a surface that is defined by a build vector projecting outward relative to the build plate center at an angle ? relative to normal of the build plate such that 90°>?>0° and the directed energy beam forms an angle ?L2 relative to normal of the build plate such that 270°>?L2>180°, wherein ?L2??=180°±?, and ?<45°. The present methods provide finished objects having overhanging regions with more consistent surface finish and resistance to mechanical strain or stress.

Abstract: The present disclosure generally relates to additive manufacturing systems and methods on a large-scale format. One aspect involves a build unit that can be moved around in three dimensions by a positioning system, building separate portions of a large object. The build unit has an energy directing device that directs, e.g., laser or e-beam irradiation onto a powder layer. In the case of laser irradiation, the build volume may have a gasflow device that provides laminar gas flow to a laminar flow zone above the layer of powder. This allows for efficient removal of the smoke, condensates, and other impurities produced by irradiating the powder (the “gas plume”) without excessively disturbing the powder layer. The build unit may also have a recoater that allows it to selectively deposit particular quantities of powder in specific locations over a work surface to build large, high quality, high precision objects.

Abstract: The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials.

Abstract: The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials, in-process monitoring, and closed loop control.

Abstract: The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials, in-process monitoring, and closed loop control.

Abstract: The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials, in-process monitoring, and closed loop control.

Abstract: The present disclosure generally relates to methods and apparatuses for additive manufacturing using foil-based build materials. Such methods and apparatuses eliminate several drawbacks of conventional powder-based methods, including powder handling, recoater jams, and health risks. In addition, the present disclosure provides methods and apparatuses for compensation of in-process warping of build plates and foil-based build materials, in-process monitoring, and closed loop control.

Abstract: A method, apparatus, and program for calibrating an additive manufacturing apparatus. In one aspect, a method is disclosed for calibrating an additive manufacturing apparatus. The method includes forming a first solidified portion within a first scan region, wherein the solidified portion within the first scan region is formed by irradiating a build material while a build unit is in a first location. The method further includes forming a second solidified portion within a second scan region, wherein the second solidified portion within the second scan region is formed by irradiating a build material while a build unit is in a second location different from said first location. An alignment of the additive manufacturing apparatus determined based on the detected alignment of the first solidified portion and the second solidified portion.

Abstract: A method of fabricating an object by additive manufacturing is provided. The method includes measuring a build surface for building the object, determining which areas of the build surface are depressed, and initiating a build of the object at one of the depressed areas of the build surface. The initial building includes the steps of depositing a given layer of powder at the one depressed area of the build surface, fusing the given layer of powder at the one depressed area, and depositing a subsequent layer of powder at the one depressed area. The steps are repeating until the build surface is at a layer that is unified across the build surface.