Abstract: Disclosed embodiments relate to additive manufacturing systems. In some embodiments, an additive manufacturing system includes a fixed build plate, and a build volume extends above the fixed build plate. A boundary of the build volume may be defined by a powder containing shroud that is vertically displaceable relative to the fixed build plate. A powder deposition system is configured to deposit a powder layer along an upper surface of the build volume and the powder deposition is vertically displaceable relative to the fixed build plate. An optics assembly configured to direct laser energy from one or more laser energy sources towards the build volume, and exposure of the powder layer to the laser energy melts at least a portion of the powder layer. In some embodiments, the build plate may be supported by support columns configured to maintain the build plate in a level orientation throughout a build process.

Abstract: Laser control systems and related methods for controlling arrays of lasers are disclosed. A laser control system may include a first controller configured to generate a trigger signal based on a position of a laser array, and a second controller configured to send a firing signal to one or more lasers of the laser array upon receiving the trigger signal. The one or more lasers may be selected based on a desired pattern of laser energy to be formed at a particular position of the laser array.

Abstract: The present invention relates to processes that may be used singly or in combination to prevent lithium (or alkali metal) plating or dendrite buildup on bare substrate areas or edges of electrode rolls during alkaliation of a battery or electrochemical cell anode composed of a conductive substrate and coatings, in which the electrode rolls may be coated on one or both sides and may have exposed substrate on edges, or on continuous or discontinuous portions of either or both substrate surfaces.

Abstract: Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be used to deposit a material layer onto a build surface of an additive manufacturing system. In some instances, the recoater assembly may include a powder entrainment system that trails behind a recoater blade of the recoater assembly relative to a direction of motion of the recoater blade across a build surface of the additive manufacturing system. The powder entrainment system may generate a flow of fluid across a portion of the build surface behind the recoater blade that at least temporarily entrains powder above a threshold height from the build surface to mitigate, or prevent, the formation of defects on the build surface with heights greater than the threshold height.

Abstract: Aspects described herein relate to additive manufacturing systems and related methods. In some embodiments, an additive manufacturing system includes a laser array position detector to determine a position and/or orientation of laser energy pixels in a laser array. The laser array position detector may include an aperture and an optical sensor positioned within the aperture to detect laser energy from a laser energy pixel when the laser array is scanned across the aperture.

Abstract: Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be adjustable along multiple degrees of freedom relative to a build surface, which may allow for adjustment of a spacing between the recoater assembly and the build surface and/or an orientation of the recoater assembly relative to an orientation of the build surface. In some embodiments, the recoater assembly may be supported by four support columns extending above the build surface, and attachments between the recoater assembly and the support columns may be independently adjustable to adjust the recoater relative to the build surface.

Abstract: Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be adjustable along multiple degrees of freedom relative to a build surface, which may allow for adjustment of a spacing between the recoater assembly and the build surface and/or an orientation of the recoater assembly relative to an orientation of the build surface. In some embodiments, the recoater assembly may be supported by four support columns extending above the build surface, and attachments between the recoater assembly and the support columns may be independently adjustable to adjust the recoater relative to the build surface.

Abstract: An additive manufacturing system may include a build surface, one or more laser energy sources, and an optics assembly. Exposure of a layer of material on the build surface to laser energy from the optics assembly melts at least a portion of the layer of material. A gas flow head is coupled to the optics assembly and defines a partially enclosed volume between the optics assembly and the build surface. The gas flow head includes a gas inflow through which a supply gas flows into the gas flow head, a gas outflow through which a return gas flows out of the gas flow head, and an aperture arranged to permit transmission of the laser energy through the gas flow head to the build surface. The supply gas and return gas define a gas flow profile within the gas flow head.

Abstract: Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be used to deposit a material layer onto a build surface of an additive manufacturing system. In some instances, the recoater assembly may include a powder entrainment system that trails behind a recoater blade of the recoater assembly relative to a direction of motion of the recoater blade across a build surface of the additive manufacturing system. The powder entrainment system may generate a flow of fluid across a portion of the build surface behind the recoater blade that at least temporarily entrains powder above a threshold height from the build surface to mitigate, or prevent, the formation of defects on the build surface with heights greater than the threshold height.

Abstract: The present invention relates to a method for combining anode pre-lithiation, limited-voltage formation cycles, and accelerating aging via heated storage to maximize specific capacity, volumetric capacity density and capacity retention of a lithium-ion electrochemical cell.

Abstract: The present invention relates to a method for lithiation of an intercalation-based anode or a non-reactive plating-capable foil or a reactive alloy capable anode, whereby utilization of said lithiated intercalation-based anode or a plating-capable foil or reactive alloy capable anode in a rechargeable battery or electrochemical cell results in an increased amount of lithium available for cycling, and an improved reversible capacity during charge and discharge.

Abstract: Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be used to deposit a material layer onto a build surface of an additive manufacturing system. In some instances, the recoater assembly may include a powder entrainment system that trails behind a recoater blade of the recoater assembly relative to a direction of motion of the recoater blade across a build surface of the additive manufacturing system. The powder entrainment system may generate a flow of fluid across a portion of the build surface behind the recoater blade that at least temporarily entrains powder above a threshold height from the build surface to mitigate, or prevent, the formation of defects on the build surface with heights greater than the threshold height.

Abstract: An additive manufacturing system may include a build surface, one or more laser energy sources, and an optics assembly. Exposure of a layer of material on the build surface to laser energy from the optics assembly melts at least a portion of the layer of material. A gas flow head is coupled to the optics assembly and defines a partially enclosed volume between the optics assembly and the build surface. The gas flow head includes a gas inflow through which a supply gas flows into the gas flow head, a gas outflow through which a return gas flows out of the gas flow head, and an aperture arranged to permit transmission of the laser energy through the gas flow head to the build surface. The supply gas and return gas define a gas flow profile within the gas flow head.

Abstract: An additive manufacturing system includes a build surface, one or more laser energy sources, and an optics assembly. Exposure of a layer of material on the build surface to laser energy from the optics assembly melts at least a portion of the layer of material. A gas flow head is coupled to the optics assembly and defines a partially enclosed volume between the optics assembly and the build surface. The gas flow head includes a gas inflow through which a supply gas flows into the gas flow head, a gas outflow through which a return gas flows out of the gas flow head, and an aperture arranged to permit transmission of the laser energy through the gas flow head to the build surface. The supply gas and return gas define a gas flow profile within the gas flow head.

Abstract: Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be adjustable along multiple degrees of freedom relative to a build surface, which may allow for adjustment of a spacing between the recoater assembly and the build surface and/or an orientation of the recoater assembly relative to an orientation of the build surface. In some embodiments, the recoater assembly may be supported by four support columns extending above the build surface, and attachments between the recoater assembly and the support columns may be independently adjustable to adjust the recoater relative to the build surface.

Abstract: Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be used to deposit a material layer onto a build surface of an additive manufacturing system. In some instances, the recoater assembly may include a powder entrainment system that trails behind a recoater blade of the recoater assembly relative to a direction of motion of the recoater blade across a build surface of the additive manufacturing system. The powder entrainment system may generate a flow of fluid across a portion of the build surface behind the recoater blade that at least temporarily entrains powder above a threshold height from the build surface to mitigate, or prevent, the formation of defects on the build surface with heights greater than the threshold height.

Abstract: Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be adjustable along multiple degrees of freedom relative to a build surface, which may allow for adjustment of a spacing between the recoater assembly and the build surface and/or an orientation of the recoater assembly relative to an orientation of the build surface. In some embodiments, the recoater assembly may be supported by four support columns extending above the build surface, and attachments between the recoater assembly and the support columns may be independently adjustable to adjust the recoater relative to the build surface.

Abstract: Build plate assemblies and their methods of use for an additive manufacturing system are disclosed. In some embodiments, a build plate assembly may include a build plate with a build surface and one or more recesses formed in the build plate. One or more inserts may be inserted into the corresponding one or more recesses of the build plate such that a portion of the one or more inserts are accessible through one or more corresponding openings formed in the build surface associated with the recesses.

Abstract: The present invention relates to processes that may be used singly or in combination to prevent lithium (or alkali metal) plating or dendrite buildup on bare substrate areas or edges of electrode rolls during alkaliation of a battery or electrochemical cell anode composed of a conductive substrate and coatings, in which the electrode rolls may be coated on one or both sides and may have exposed substrate on edges, or on continuous or discontinuous portions of either or both substrate surfaces.

Abstract: Systems and methods for additive manufacturing are described. In some embodiments, a method of controlling the one or more laser energy sources of an additive manufacturing system may be based at least in part on a scan angle and/or desired energy density. Systems and methods for controlling melt pool spacing are also described.