Abstract: The present disclosure generally relates to additive manufacturing systems and methods on a large-scale format. One aspect involves a method for fabricating an object. The method includes (a) irradiating a layer of powder in a build area above a build platform to form a fused region; (b) providing a subsequent layer of powder over the build area; (c) repeating steps (a) and (b) until at least a portion of the object, a support structure, and a build envelope are formed; and (d) removing the object from the build envelope and the support structure. The support structure extends from an inner surface of the build envelope to a location proximate a location of the object to be built.

Abstract: The present invention is related to additive manufacturing methods and systems using a recoater with in-situ exchangeable recoater blades. Being able to switch out recoater blades in situ, i.e. without stopping the build and opening up the build chamber, is advantageous, especially for larger, more complicated, and/or longer builds. For instance, if a recoater blade becomes damaged, a new one can be readily swapped in. Or if a different material for the object(s) is used during the build, it may be advantageous to switch in a new recoater blade that is made of the new, different material.

Abstract: The present disclosure generally relates to additive manufacturing systems and methods on a large-scale format. One aspect involves a method for fabricating an object. The method includes (a) irradiating a layer of powder in a build area above a build platform to form a fused region; (b) providing a subsequent layer of powder over the build area; (c) repeating steps (a) and (b) until at least a portion of the object, a support structure, and a build envelope are formed; and (d) removing the object from the build envelope and the support structure. The support structure extends from an inner surface of the build envelope to a location proximate a location of the object to be built.

Abstract: The present invention is related to additive manufacturing methods and systems using a recoater with in-situ exchangeable recoater blades. Being able to switch out recoater blades in situ, i.e. without stopping the build and opening up the build chamber, is advantageous, especially for larger, more complicated, and/or longer builds. For instance, if a recoater blade becomes damaged, a new one can be readily swapped in. Or if a different material for the object(s) is used during the build, it may be advantageous to switch in a new recoater blade that is made of the new, different material.