Abstract: A method for additively manufacturing a component includes generating, via imaging software, a plurality of slices of a support structure of the component based on component geometry. The method also includes melting or fusing, via the additive manufacturing system, layers of material to a build platform of the component so as to form the support structure according to the plurality of slices. The support structure includes a lattice configuration having of a plurality of support members arranged together to form a plurality of cells. Further, the method includes melting or fusing, via the additive manufacturing system, a component body to the support structure. After the component body solidifies, the method includes removing all of the support structure from the component body to form the component.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize support structure in the process of building objects that may be removed by rotating the support structure to a second orientation before removal, as well as novel support structures to be used within these AM processes. The support structures are fabricated in a first orientation and then rotated to the second orientation. The support structures are removed by passing through an outlet of the object.

Abstract: A method for additively manufacturing a component includes generating, via imaging software, a plurality of slices of a support structure of the component based on component geometry. The method also includes melting or fusing, via the additive manufacturing system, layers of material to a build platform of the component so as to form the support structure according to the plurality of slices. The support structure includes a lattice configuration having of a plurality of support members arranged together to form a plurality of cells. Further, the method includes melting or fusing, via the additive manufacturing system, a component body to the support structure. After the component body solidifies, the method includes removing all of the support structure from the component body to form the component.

Abstract: A rotary actuator and a method of additively manufacturing the same are provided. The rotary actuator includes a valve housing defining a valve chamber and a shaft channel extending from the valve chamber. A valve body includes a valve shaft extending through the shaft channel and a valve head positioned within the valve chamber and defining a head width that is larger than the channel diameter to inseparably join the valve body and the valve housing. The valve head divides the valve chamber into a first chamber and a second chamber which are in fluid communication with a first port and a second port, respectively. The valve body is rotated by adjusting a fluid pressure within at least one of the first chamber and the second chamber.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize powder removal ports in the process of building objects, as well as novel support structures including powder removal ports to be used within these AM processes. The objects include walls defining regions of unfused powder. The powder removal ports include at least one tube aligned with an opening in the walls to allow removal of the powder. The methods include removing unfused powder from the enclosed space via the at least one tube.

Abstract: A valve assembly and a method of additively manufacturing the same are provided. The valve assembly includes a valve housing defining first and second mounting features, such as recessed dimples or protruding bumps, positioned on opposite sides of a substantially cylindrical channel to define a hinge axis. One or more valve flaps are positioned within the cylindrical channel, each valve flap including a hinge member extending along the hinge axis and defining two or more complementary features or coupling members for engaging either the mounting features of the valve housing or an adjacent hinge member.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize support surrounding structures in the process of building objects, as well as novel surrounding support structures to be used within these AM processes. The support structure surrounds at least a portion of the object with a continuous thickness of powder disposed between the support structure and the object, the continuous thickness of powder having a maximum thickness that does not exceed 10 mm.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize connecting support structures in the process of building objects, as well as novel connecting support structures to be used within these AM processes. The connecting support structures include two fused connections to the object and an axial direction between the fused connections, a perimeter of fused material about the axial direction, and unfused powder or air completely surrounding the perimeter of fused material.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize support structure in the process of building objects that may be removed by rotating the support structure to a second orientation before removal, as well as novel support structures to be used within these AM processes. The support structures are fabricated in a first orientation and then rotated to the second orientation. The support structures are removed by passing through an outlet of the object.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize support structure in the process of building objects that may be removed by rotating the support structure to a second orientation before removal, as well as novel support structures to be used within these AM processes. The support structures are fabricated in a first orientation and then rotated to the second orientation. The support structures are removed by passing through an outlet of the object.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize support leading edge structures in the process of building objects, as well as novel leading edge support structures to be used within these AM processes. The support structure is positioned adjacent the object between the object and a first side of the powder bed. The support structure has a shape that tapers outward in the direction from the first side to the object.

Abstract: A valve assembly and a method of additively manufacturing the same are provided. The valve assembly includes a valve housing defining first and second mounting features, such as recessed dimples or protruding bumps, positioned on opposite sides of a substantially cylindrical channel to define a hinge axis. One or more valve flaps are positioned within the cylindrical channel, each valve flap including a hinge member extending along the hinge axis and defining two or more complementary features or coupling members for engaging either the mounting features of the valve housing or an adjacent hinge member.

Abstract: A rotary actuator and a method of additively manufacturing the same are provided. The rotary actuator includes a valve housing defining a valve chamber and a shaft channel extending from the valve chamber. A valve body includes a valve shaft extending through the shaft channel and a valve head positioned within the valve chamber and defining a head width that is larger than the channel diameter to inseparably join the valve body and the valve housing. The valve head divides the valve chamber into a first chamber and a second chamber which are in fluid communication with a first port and a second port, respectively. The valve body is rotated by adjusting a fluid pressure within at least one of the first chamber and the second chamber.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize table support structures in the process of building objects, as well as novel table support structures to be used within these AM processes. The table support structures include a first leg portion extending vertically from a build platform; a platform portion including a horizontal top surface supported on the first leg portion; and a plurality of supports extending from the platform portion to a downfacing surface of the object.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize integrated ribs to support thin walled annular structures. An annular wall fabricated using AM has a thickness less than 0.022 inches across a majority of a surface of the annular wall and a plurality of ribs having a thickness greater than 0.030 inches. The annular wall has a mean thickness less than 0.100 inches. The annular wall conforms to a surface of the component and a mean distance between the annular wall and the component is less than 0.080 inches.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize powder removal ports in the process of building objects, as well as novel support structures including powder removal ports to be used within these AM processes. The objects include walls defining regions of unfused powder. The powder removal ports include at least one tube aligned with an opening in the walls to allow removal of the powder. The methods include removing unfused powder from the enclosed space via the at least one tube.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize support structure in the process of building objects that may be removed by rotating the support structure to a second orientation before removal, as well as novel support structures to be used within these AM processes. The support structures are fabricated in a first orientation and then rotated to the second orientation. The support structures are removed by passing through an outlet of the object.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize support surrounding structures in the process of building objects, as well as novel surrounding support structures to be used within these AM processes. The support structure surrounds at least a portion of the object with a continuous thickness of powder disposed between the support structure and the object, the continuous thickness of powder having a maximum thickness that does not exceed 10 mm.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize support leading edge structures in the process of building objects, as well as novel leading edge support structures to be used within these AM processes. The support structure is positioned adjacent the object between the object and a first side of the powder bed.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize connecting support structures in the process of building objects, as well as novel connecting support structures to be used within these AM processes. The connecting support structures include two fused connections to the object and an axial direction between the fused connections, a perimeter of fused material about the axial direction, and unfused powder or air completely surrounding the perimeter of fused material.