Abstract: A method for manufacturing includes operating a beam system selectively to fuse and melt a powder layer to form each layer of a 3D article. Each layer includes at least one fused solid area that defines a dimensional parameter such as a width. When the dimensional parameter is above a threshold, the beam system is operated with a first operating mode that includes separately fused contour and hatch areas. When the dimensional parameter is below the threshold, the beam system is operated with a second operating mode that includes a zig-zag pattern with no contour. This method of operation can greatly reduce a time required to fuse complex layers having many very small features.

Abstract: A method of manufacturing a three-dimensional article is provided for a system including a powder handling module containing stored metal powder. The stored metal powder includes used metal powder that was previously part of the metal powder loaded into a print engine during a previous fabrication process. The method includes (1) loading a volume of the metal powder into an agitation device, (2) operating the agitation device until an avalanche angle of the metal powder is modified to within a specified range to provide a volume of usable metal powder, (3) loading the usable metal powder into a three-dimensional print engine, and (4) operating the print engine to fabricate a the three-dimensional article. This process improves coating quality within the print engine. Improving coating quality improves dimensional accuracy of the three-dimensional article along with reducing defects resulting from coating artifacts.

Abstract: A three-dimensional (3D) printing system for forming a 3D article includes a print engine and a controller. The print engine includes a build plate, a coater, and a plurality of beam units. The coater is configured to coat a layer of fusible powder over the build plate to span a build plane. The first beam unit is configured to generate and scan an energy beam over a first lateral region of the build plane. The second beam unit is configured to generate and scan an energy beam over a second lateral region of the build plane. The first and second lateral regions overlap over an overlap zone. In forming contours, the controller is configured to define sub-contours that connect along a seam within a layer. In the overlap zone, the sub-contours have an offset along the seam that varies from layer to layer.

Abstract: A method of manufacturing a three-dimensional article includes: (1) Loading a metal platen into a build chamber, the metal platen defines an upper surface; (2) Performing concurrent processes including operating a movement mechanism to vertically translate the platen, operating a laser system to impinge a radiation beam upon the upper surface of the platen, and receiving a signal from an acoustic sensor that is positioned within the build chamber; (3) Analyzing the signal including determining a height of optimal laser convergence for the platen; and (4) Based upon the analysis, adjusting the laser convergence height to a build plane height.

Abstract: A method of manufacturing a three-dimensional article is provided for a system including a powder handling module containing stored metal powder. The stored metal powder includes used metal powder that was previously part of the metal powder loaded into a print engine during a previous fabrication process. The method includes (1) loading a volume of the metal powder into an agitation device, (2) operating the agitation device until an avalanche angle of the metal powder is modified to within a specified range to provide a volume of usable metal powder, (3) loading the usable metal powder into a three-dimensional print engine, and (4) operating the print engine to fabricate a the three-dimensional article. This process improves coating quality within the print engine. Improving coating quality improves dimensional accuracy of the three-dimensional article along with reducing defects resulting from coating artifacts.

Abstract: A method of manufacturing a three-dimensional article includes: (1) Loading a metal platen into a build chamber, the metal platen defines an upper surface; (2) Performing concurrent processes including operating a movement mechanism to vertically translate the platen, operating a laser system to impinge a radiation beam upon the upper surface of the platen, and receiving a signal from an acoustic sensor that is positioned within the build chamber; (3) Analyzing the signal including determining a height of optimal laser convergence for the platen; and (4) Based upon the analysis, adjusting the laser convergence height to a build plane height.

Abstract: A lightweight porous material with increased strength and mechanical properties, the use and the preparation thereof.