Abstract: Systems and methods additively manufacturing an object by applying heat to a first plurality of metallic particles in a powder bed using a first heat source, wherein the first heat source is one of multiple heat sources configured into an array, and the first heat source generates a first melt pool. Heat is simultaneously applied to a second plurality of metallic particles in the powder bed using a second heat source of the multiple heat sources in the array to generate a second melt pool. The first plurality of metallic particles are separated from the second plurality of metallic particles by a distance, wherein the distance and an amount of heat from each heat source is controlled to generate a combined melt pool that is larger in size and encompasses the first and second melt pools. The combined melt pool is allowed to solidify to form the object.

Abstract: A component is fabricated in an additive manufacturing process. Only a portion of a first layer of a first material is at least partially melted to define a first component layer of the component. Only a portion of the second layer of a second material is at least partially melted to define a second component layer of the component in which the entirety of the second component layer is formed simultaneously, and the second component layer is attached to the first component layer.

Abstract: Systems and methods additively manufacturing an object by applying heat to a first plurality of metallic particles in a powder bed using a first heat source, wherein the first heat source is one of multiple heat sources configured into an array, and the first heat source generates a first melt pool. Heat is simultaneously applied to a second plurality of metallic particles in the powder bed using a second heat source of the multiple heat sources in the array to generate a second melt pool. The first plurality of metallic particles are separated from the second plurality of metallic particles by a distance, wherein the distance and an amount of heat from each heat source is controlled to generate a combined melt pool that is larger in size and encompasses the first and second melt pools. The combined melt pool is allowed to solidify to form the object.

Abstract: In a method for treating carbon nanotube-based material, the carbon nanotube-based material is suspended in an oxidative atmosphere. An illumination portion is illuminated with electromagnetic radiation to heat the illumination portion, the illumination portion being out of direct contact with any supporting surface. Heat is continuously conducted away from the illumination portion to a non-illumination portion of the carbon nanotube-based material. This heating in the oxidative atmosphere causes at least partial oxidation and at least partial removal of amorphous carbon, partly ordered non-tubular carbon, and/or defective nanotubes in the carbon nanotube-based material, leaving a treated material comprising an arrangement of remaining carbon nanotubes.

Abstract: A component is fabricated in an additive manufacturing process. Only a portion of a first layer of a first material is at least partially melted to define a first component layer of the component. Only a portion of the second layer of a second material is at least partially melted to define a second component layer of the component in which the entirety of the second component layer is formed simultaneously, and the second component layer is attached to the first component layer.

Abstract: Systems and methods for multiple beam additive manufacturing use multiple beams of light (e.g., laser light) simultaneously to expose layers of powder material in selected regions until the powder material fuses to form voxels, which form build layers of a three-dimensional structure. The light may be generated from selected light sources and coupled into an array of optical fibers having output ends arranged in an optical head such that the multiple beams are directed by the optical head to different locations on each of the powder layers. The multiple beams may provide distributed exposures forming a distributed exposure pattern including beam spots that are spaced sufficiently to separate the fused regions formed by each exposure. The multiple beams may be moved using various techniques (e.g., by moving the optical head) and according to various scan patterns such that a plurality of multiple beam distributed exposures form each build layer.

Abstract: A process and apparatus are disclosed for the deposition of a layer of a first material onto a substrate of a second material. Powder particles of the first material are entrained into a carrier gas flow to form a powder beam directed to impinge on the substrate. This defines a powder beam footprint region at the substrate. The powder beam and the substrate are moved relative to each other to move the powder beam footprint relative to the substrate, thereby to deposit the layer of the first material. A laser is operated to cause direct, local heating of at least one of a forward substrate region and a powder beam footprint region. The laser beam direction is defined with reference to a plane coincident with or tangential to a surface of the substrate at the center of the laser beam footprint in terms of an elevation angle from the plane to the laser beam direction and in terms of an acute azimuthal angle from the movement direction to the laser beam direction.

Abstract: Systems and methods for multiple beam additive manufacturing use multiple beams of light (e.g., laser light) simultaneously to expose layers of powder material in selected regions until the powder material fuses to form voxels, which form build layers of a three-dimensional structure. The light may be generated from selected light sources and coupled into an array of optical fibers having output ends arranged in an optical head such that the multiple beams are directed by the optical head to different locations on each of the powder layers. The multiple beams may provide distributed exposures forming a distributed exposure pattern including beam spots that are spaced sufficiently to separate the fused regions formed by each exposure. The multiple beams may be moved using various techniques (e.g., by moving the optical head) and according to various scan patterns such that a plurality of multiple beam distributed exposures form each build layer.

Abstract: Systems and methods for multiple beam additive manufacturing use multiple beams of light (e.g., laser light) to expose layers of powder material in selected regions until the powder material fuses to form voxels, which form build layers of a three-dimensional structure. The light may be generated from selected light sources and coupled into an array of optical fibers having output ends arranged in an optical head in at least one line such that multiple beams are sequentially directed by the optical head to the same powder region providing multiple beam sequential exposures (e.g., with pre-heating, melting and controlled cool down) to fuse the powder region. The multiple sequential beams may be moved using various techniques (e.g., by moving the optical head) and according to various scan patterns such that a plurality of fused regions form each build layer.

Abstract: A process and apparatus are disclosed for the deposition of a layer of a first material onto a substrate of a second material. Powder particles of the first material are entrained into a carrier gas flow to form a powder beam directed to impinge on the substrate. This defines a powder beam footprint region at the substrate. The powder beam and the substrate are moved relative to each other to move the powder beam footprint relative to the substrate, thereby to deposit the layer of the first material. A laser is operated to cause direct, local heating of at least one of a forward substrate region and a powder beam footprint region. The laser is controlled to provide a spatial temperature distribution at the powder footprint region of the substrate in which the local temperature of the substrate is in the range 0.5Ts to less than Ts in a volume from the surface of the substrate at least up to a depth of 0.2 mm from the surface of the substrate and not more than 0.

Abstract: A process and apparatus are disclosed for the deposition of a layer of a first material onto a substrate of a second material. Powder particles of the first material are entrained into a carrier gas flow to form a powder beam directed to impinge on the substrate. This defines a powder beam footprint region at the substrate. The powder beam and the substrate are moved relative to each other to move the powder beam footprint relative to the substrate, thereby to deposit the layer of the first material. A laser is operated to cause direct, local heating of at least one of a forward substrate region and a powder beam footprint region. The laser beam direction is defined with reference to a plane coincident with or tangential to a surface of the substrate at the centre of the laser beam footprint in terms of an elevation angle from the plane to the laser beam direction and in terms of an acute azimuthal angle from the movement direction to the laser beam direction.

Abstract: An apparatus and method for monitoring light beams comprising a reflector for passing at least partially through the beam to reflect a sample of the beam and at least one sensor arranged to receive the reflected beam sample for determining a characteristic of the beam sample. The reflector may be arranged to oscillate and the sensors may he arranged at substantially forty-five or ninety degrees to the axis of the incident beam.