Abstract: In accordance with at least one aspect of this disclosure, a method can include selectively sintering at least a portion of a part and one or more indexing features onto a build plate disposed in a build area of a feedstock powder bed, determining an actual orientation of the part and the build plate relative to a recoater prior to recoating, storing the actual orientation of the part and the build plate relative to the recoater, comparing the actual orientation of the part and the build plate relative to the recoater with a predicted orientation, and recoating the build area with feedstock powder if the actual orientation of the part and the build plate relative to the recoater matches the predicted orientation to achieve a predetermined build quality for a respective layer of the part.

Abstract: A powder recoater for an additive manufacturing machine can include a body, a recoater blade extending downwardly from the body, and at least two distance probes attached to the body and configured to determine a distance to a build plate to determine if a recoater blade is parallel to the build plate and/or if a build plate is level. The at least two distance probes can be touch probes configured to determine if a build plate is contacting one or more of the probes. Any other suitable probe type is contemplated herein.

Abstract: A build piston for a powder bed fusion (PBF) additive manufacturing system is an annular build platform that includes a drive shaft, bearing sleeve, and drive shaft actuation mechanism. The end of the drive shaft is attached to the bottom center of the build platform and moves the build platform in concert with the drive shaft. The bearing sleeve ensures linear alignment of the drive shaft. The drive shaft actuation mechanism rotates the drive shaft at a continuous rate that is coupled to the drive shaft's rate of translation up and down, moving the build platform in a helical pattern.

Abstract: A build plate for a powder bed fusion (PBF) additive manufacturing system is an annular build plate that includes an inner radius wall and an outer radius wall that each extend vertically from a junction with the annular build plate to define a build area on the annular build plate. The inner radius wall and the outer radius wall each include a plurality of apertures that are configured to collect excess build powder and direct the excess build powder through the inner radius wall and outer radius wall to an excess build powder reservoir. The annular build plate is configured to be positioned on a build piston and to move in concert with the build piston, wherein the build piston is configured to rotate around a drive shaft in a continuous circular motion and to translate up and down with respect to the annular build plate.

Abstract: A powder bed fusion (PBF) additive manufacturing system includes an annular build plate including an inner radius wall and an outer radius wall, wherein the inner radius wall and the outer radius wall define a build area on the annular build plate between the inner radius wall and the outer radius wall. A build piston is configured to rotate around a drive shaft in a continuous circular motion and to translate up and down with respect to the annular build plate, wherein the annular build plate is configured to be positioned on the build piston and to move in concert with the build piston. A build powder delivery mechanism is configured to deliver build powder to the build area to form a build powder bed when the PBF additive manufacturing system is in operation. A recoater is configured to provide even distribution of the build powder in the build powder bed when the PBF additive manufacturing system is in operation.

Abstract: A powder bed fusion (PBF) additive manufacturing system includes a powder delivery mechanism configured to deliver build powder to a build area of an annular build plate to form a build powder bed while the annular build plate rotates when the PBF additive manufacturing system is in operation and a recoater configured to provide a uniform density of power packing of the build powder in the build powder bed while the annular build plate rotates when the PBF additive manufacturing system is in operation. The recoater has at least one segment positioned at an acute angle relative to an axis perpendicular to a direction of rotation of the annular build plate.

Abstract: A annular build plate for a powder bed fusion (PBF) additive manufacturing system includes an inner radius wall and an outer radius wall. The inner radius wall and the outer radius wall define a build area on the annular build plate between the inner radius wall and the outer radius wall. The annular build plate is configured to be positioned on a build piston and to move in concert with the build piston, which is configured rotate around a drive shaft in a continuous circular motion and to translate up and down with respect to the annular build plate. A method of making an annular part with a PBF additive manufacturing system includes installing in the PBF additive manufacturing system an annular build plate having an inner radius wall and an outer radius wall. Build powder is delivered, with a powder delivery mechanism, to the build area to form a build powder bed and the build powder in the build powder bed is distributed, with a recoater, to provide even distribution of the build powder.

Abstract: An annular part made with a powder bed fusion (PBF) additive manufacturing system includes a continuous, single layer of sintered and consolidated build powder that is helically overlapped on itself across an entire thickness of the part. The part has an annular cross section defined by an inner radius and an outer radius and the circumference defined by the inner radius defines an outer radius of an annulus of the part. The part can be made by installing in the PBF additive manufacturing system an annular build plate including an inner radius wall and an outer radius wall that define a build area on the annular build plate. Build powder is delivered to the build area with a powder delivery mechanism to form a build powder bed while a recoater distributes the build powder to provide even distribution of the build powder in the build powder bed. An optical array positioned over the build area directs energy onto the build powder to form a melt pool.

Abstract: A build head for a powder bed fusion (PBF) additive manufacturing system includes a powder delivery mechanism configured to deliver build powder to a build area of an annular build plate to form a build powder bed while the annular build plate rotates when the PBF additive manufacturing system is in operation. A recoater is configured to provide even distribution of the build powder in the build powder bed and an optical array is positioned over the build area on the build plate to project energy onto the build powder bed to form a melt pool in the build powder bed.

Abstract: A powder bed fusion (PBF) additive manufacturing system includes a powder delivery mechanism configured to deliver build powder to a build area of an annular build plate to form a build powder bed while the annular build plate rotates when the PBF additive manufacturing system is in operation and a recoater configured to provide a uniform density of power packing of the build powder in the build powder bed while the annular build plate rotates when the PBF additive manufacturing system is in operation. The recoater has at least one segment positioned at an acute angle relative to an axis perpendicular to a direction of rotation of the annular build plate and includes at least two regions having different mechanical properties selected to provide a desired distribution of build powder over selected portions of the powder bed.

Abstract: A core engine article includes a combustor liner defining a combustion chamber therein and a turbine nozzle. The combustor liner includes a plurality of injector ports, and the plurality of injector ports have a shape that tapers to a corner on a forward side of the injector ports. The turbine nozzle includes a plurality of airfoils. The combustor liner and turbine nozzle are integral with one another. A method of making a core engine article is also disclosed.

Abstract: An attritable engine includes an engine case, which includes an outer wall and a fuel rail integral with the outer wall. The fuel rail includes a fuel line integral with the outer wall, a fuel ring configured to receive fuel from the fuel line, and an injector throat configured to receive aerated fuel from the fuel ring. The engine case includes counter distortion webbing defining the injector throat and is integral with the fuel rail and the outer wall. The engine case includes a combustion chamber configured to receive fuel from the injector throat.

Abstract: A process for additively controlled surface features of a gas turbine engine casing. The process comprises forming the casing having an inner surface and an outer surface opposite the inner surface; forming a surface feature on the casing proximate the inner surface, wherein the surface feature comprises a structure on the inner surface configured to align or misalign with respect to a flow direction of a working fluid in a flow path of the casing.

Abstract: A rotary component may comprise a first structure configured to rotate about an axis and a second structure configured to rotate about the axis. A support structure may be coupled to the first structure at a first attachment location and to the second structure at a second attachment location. The support structure may be configured to separate from the first structure and the second structure in response to a centrifugal force generated by the first structure and the second structure rotating about the axis.

Abstract: An exhaust manifold for an additive manufacturing system includes a manifold housing, at least one baffle movable relative to the manifold housing configured to modify an exhaust flow area defined in part by the at least one baffle, and an actuator operatively connected to the at least one baffle configured to move the at least one baffle. The manifold housing defines a housing channel. The at least one baffle can be one or more moveable baffles at least partially disposed within the housing channel and configured to move relative to the housing to modify a respective exhaust flow area of a respective baffle of the one or more moveable baffles. The actuator is operatively connected to each of the one or more movable baffles and configured to move the one or more movable baffles relative to the housing.

Abstract: In accordance with at least one aspect of this disclosure, a method can include selectively sintering at least a portion of a part and one or more indexing features onto a build plate disposed in a build area of a feedstock powder bed, determining an actual orientation of the part and the build plate relative to a recoater prior to recoating, storing the actual orientation of the part and the build plate relative to the recoater, comparing the actual orientation of the part and the build plate relative to the recoater with a predicted orientation, and recoating the build area with feedstock powder if the actual orientation of the part and the build plate relative to the recoater matches the predicted orientation to achieve a predetermined build quality for a respective layer of the part.

Abstract: A method for inspecting a component made using an additive manufacturing process, the component having an internal conduit, is disclosed. In various embodiments, the method includes the steps of: attaching a fluid-blocking header to the component, the fluid-blocking header having an internal conformal surface configured to mate with an external conformal surface of the component; introducing a plugging media into the internal conduit; activating the fluid-blocking header to freeze the plugging media in a vicinity of the fluid-blocking header; pressurizing the internal conduit of the component; and analyzing a fluid flow characteristic at an outlet of the component to assess an occurrence of a blockage within the internal conduit.

Abstract: A locking module for selectively coupling a first component and a second component of a lockable device includes a housing and a magnet arranged within said housing. A locking element is movable relative to said housing between an unlocked position and a locked position. An engagement member is rotatable about an axis to selectively decouple said locking element from said magnet to move said locking element between said unlocked position and said locked position.

Abstract: An additive manufacturing device includes a build platform. A recoater is operatively connected to the build platform to move relative to the build platform to coat unfused powder onto a build on the build platform. The recoater includes a recoater mount defining a length-wise receptacle therein, and a recoater blade seated in the receptacle. A blade reel system is operatively connected to the recoater to replace the recoater blade in the receptacle during a build on the build platform.

Abstract: A core engine article includes a combustor liner defining a combustion chamber therein and a turbine nozzle. The combustor liner includes a plurality of injector ports, and the plurality of injector ports have a shape that tapers to a corner on a forward side of the injector ports. The turbine nozzle includes a plurality of airfoils. The combustor liner and turbine nozzle are integral with one another. A method of making a core engine article is also disclosed.