Abstract: A three-dimensional (3D) printing system includes a print engine and a controller. The print engine includes a motorized build platform, a coating apparatus, and a beam forming unit. The controller is configured to perform the following steps: (a) receiving a virtual 3D body, (b) processing the 3D body to define a plurality of N slices, the N slices individually representing intersections of the 3D body with the slice, (c) processing the N slices to represent solid portions of the 3D body with vectors, the vectors defining contours and hatching patterns, the vectors individually bounded by two endpoints, (d) for the individual slices, analyzing a scan speed error for one or more of the plurality of vectors, and (e) for the individual slices, moving some of the endpoints when the scan speed error exceeds a predetermined threshold to provide a speed corrected slice.

Abstract: A method for manufacturing includes operating a beam system selectively to fuse and melt a powder layer to form each layer of a 3D article. Each layer includes at least one fused solid area that defines a dimensional parameter such as a width. When the dimensional parameter is above a threshold, the beam system is operated with a first operating mode that includes separately fused contour and hatch areas. When the dimensional parameter is below the threshold, the beam system is operated with a second operating mode that includes a zig-zag pattern with no contour. This method of operation can greatly reduce a time required to fuse complex layers having many very small features.

Abstract: A three-dimensional printing system includes a motorized build platform, a material coating module, and a beam generation module. The beam generation module is configured to selectively fuse or harden material over a build plane. The build plane defines a centroid. The beam generation module includes a laser beam formation unit, a scan module, and flat field focusing component (FFFC). The scan module has a scanner optical axis that intersects the build plane at a location that is offset from the centroid. The FFFC is configured to focus the laser beam across the build plane. The FFFC includes a plurality of lenses at least one of which has an optical asymmetry relative to the scanner optical axis. The asymmetry includes one or more of a lateral offset with an offset distance D and an angular offset with an offset angle ?.

Abstract: A three-dimensional printing system includes a motorized build platform, a material coating module, and a beam generation module. The beam generation module includes a laser beam formation unit, a scan module, and flat field focusing system. The laser beam formation unit includes a laser configured to output a laser beam. The scan module is configured to receive the laser beam and to scan the laser beam over a build plane that is above the motorized build platform. The flat field focusing system is configured to focus the laser beam across the laser beam and includes an input component and an output component. The input component is configured to receive the laser beam from the beam formation unit and to pass the laser beam to the scan module. The output component is configured to receive the laser beam from the scan module and pass the laser beam to the build plane.

Abstract: A three-dimensional (3D) printing system includes a print engine and a controller. The print engine includes a motorized build platform, a coating apparatus, and a beam forming unit. The controller is configured to perform the following steps: (a) receiving a virtual 3D body, (b) processing the 3D body to define a plurality of N slices, the N slices individually representing intersections of the 3D body with the slice, (c) processing the N slices to represent solid portions of the 3D body with vectors, the vectors defining contours and hatching patterns, the vectors individually bounded by two endpoints, (d) for the individual slices, analyzing a scan speed error for one or more of the plurality of vectors, and (e) for the individual slices, moving some of the endpoints when the scan speed error exceeds a predetermined threshold to provide a speed corrected slice.

Abstract: A method of manufacturing a three-dimensional article includes: (1) Loading a metal platen into a build chamber, the metal platen defines an upper surface; (2) Performing concurrent processes including operating a movement mechanism to vertically translate the platen, operating a laser system to impinge a radiation beam upon the upper surface of the platen, and receiving a signal from an acoustic sensor that is positioned within the build chamber; (3) Analyzing the signal including determining a height of optimal laser convergence for the platen; and (4) Based upon the analysis, adjusting the laser convergence height to a build plane height.

Abstract: A manufacturing system for fabricating a three-dimensional article includes a housing, a sensor within the housing, a coater, a removable powder module (RPM) with a platen, a laser system, and a controller. A method of operating the manufacturing system includes installing the RPM into the housing, forming pillars onto the platen, positioning the top surfaces of the pillars a distance D below a build plane, installing a calibration plate onto the top surfaces of the pillars, and then calibrating the laser system using the sensor. The sensor can include one or more of an optical sensor and an acoustic sensor.

Abstract: An apparatus for layered manufacture of a three-dimensional product includes a build chamber having a window, a build platform within the build chamber, a calibration device that is physically separated from the build chamber, an optical system including a beam source and a scanning apparatus, and a mobile base. The mobile base is configured to position the scanning apparatus at two spaced part positions including a (1) production position and a (2) calibration position. At the production position the scanning apparatus is configured to receive an energy beam from the beam source and to reflect and scan the energy beam through the window and to a build surface over the build platform to create a layer of the three-dimensional product. At the calibration position the scanning apparatus is configured to reflect the energy beam to the calibration device but not through the window.

Abstract: A system (100) and method for monitoring a recoating mechanism (415A, 415B) in an additive manufacturing environment is provided. Various embodiments involve the use of a control computer (102a-102d) to receive data based on a thermal image of a recoating mechanism (415A, 415B) from an imaging device (436) configured to capture thermal image. The control computer (102a-102d) further determines a value of a property of the thermal image, wherein the property is related to an amount of powder in the recoating mechanism. The control computer (102a-102d) further determines at least one of if the value indicates an error related to the amount of powder in the recoating mechanism (415A, 415B), and an action to take with respect to the recoating mechanism (415A, 415B) that is based on the value.

Abstract: A three dimensional printing system includes a laser system, a beam splitter, a pinhole, a sensor, and a controller. The laser system emits a light beam of varying diameter carrying at least 100 watts of optical power along an optical path. The laser has an imaging plane along the optical path which can be coincident or close to a focal plane at which the beam has a minimum diameter. The beam splitter is positioned along the optical path to receive the beam and to transmit most of the optical power and to reflect remaining optical power. The pinhole is positioned along the optical path at the imaging plane to receive the reflected beam having a minimal diameter. The controller is configured to analyze a signal from the sensor to determine intensity and distribution parameters for the light beam.

Abstract: A manufacturing system for fabricating a three-dimensional article includes a housing, a sensor within the housing, a coater, a removable powder module (RPM) with a platen, a laser system, and a controller. A method of operating the manufacturing system includes installing the RPM into the housing, forming pillars onto the platen, positioning the top surfaces of the pillars a distance D below a build plane, installing a calibration plate onto the top surfaces of the pillars, and then calibrating the laser system using the sensor. The sensor can include one or more of an optical sensor and an acoustic sensor.

Abstract: A method of manufacturing a three-dimensional article includes: (1) Loading a metal platen into a build chamber, the metal platen defines an upper surface; (2) Performing concurrent processes including operating a movement mechanism to vertically translate the platen, operating a laser system to impinge a radiation beam upon the upper surface of the platen, and receiving a signal from an acoustic sensor that is positioned within the build chamber; (3) Analyzing the signal including determining a height of optimal laser convergence for the platen; and (4) Based upon the analysis, adjusting the laser convergence height to a build plane height.

Abstract: A three-dimensional printing system for manufacturing a three-dimensional article includes a build chamber, a carrier plate, a vertical positioning apparatus, a laser system, a sensor, a powder dispenser, and a controller. The carrier plate defines a receptacle and an alignment target. The receptacle is for receiving and aligning a prefabricated body. The alignment target is in precise lateral alignment with respect to the receptacle. The controller is configured to: (1) operate the laser system to generate and scan a radiation beam over an upper surface of the carrier plate; (2) concurrent with scanning the radiation beam, receive a signal from the sensor; (3) analyze the signal to align the radiation beam to the prefabricated body; and (4) operate the vertical positioning apparatus, the laser system, and the powder dispenser to selectively form layers of metal over the prefabricated body to complete manufacture of the three-dimensional article.

Abstract: A three dimensional printing system includes a laser system, a beam splitter, a pinhole, a sensor, and a controller. The laser system emits a light beam of varying diameter carrying at least 100 watts of optical power along an optical path. The laser has an imaging plane along the optical path which can be coincident or close to a focal plane at which the beam has a minimum diameter. The beam splitter is positioned along the optical path to receive the beam and to transmit most of the optical power and to reflect remaining optical power. The pinhole is positioned along the optical path at the imaging plane to receive the reflected beam having a minimal diameter. The controller is configured to analyze a signal from the sensor to determine intensity and distribution parameters for the light beam.

Abstract: The invention relates to an apparatus for layered manufacture of a three-dimensional product, in particular for application of an additive manufacturing technique such as selective laser melting. This apparatus has a build chamber in which said product is constructed and an optical system that extends outside of the build chamber. The optical system has at least a beam source to generate an energy beam and contains corresponding scanning means to move this beam. Here, a control unit is provided that controls the scanning means to move the beam so that it strikes a selected position. The wall of the build chamber features a closed window that is transparent for the beam so that it passes through the window and enters the build chamber.

Abstract: Embodiments set forth in this application relate to systems and methods by which parts produced by additive manufacturing can be reliably assessed for conformity to a known master model which has quality conforming to the desired specifications. These systems and methods involve recording a thermal history of the manufacturing process of each part. The recorded thermal history is then compared to the previously-recorded thermal history of the master model. Significant deviations in thermal history are indicative of irregularities in the manufacturing build, and the part quality may then be assessed in view of those irregularities.

Abstract: A system and method for calibrating a laser scanning system is provided. Various embodiments involve the use of a calibration plate with reference markings which is positioned to receive a directed beam in a set of known laser scanner positions. The directed beam forms a laser spot on the calibration plate, and the laser spot is captured using an image acquisition assembly such as a digital camera along with a motorized mount. The movement of the image acquisition assembly may be coordinated with the movement of the laser scanner to track the laser spot across the plate. After photographing various positions, actual laser spot coordinates are deduced from their position relative to the known positions of the reference markings.

Abstract: A system (100) and method for monitoring a recoating mechanism (415A, 415B) in an additive manufacturing environment is provided. Various embodiments involve the use of a control computer (102a-102d) to receive data based on a thermal image of a recoating mechanism (415A, 415B) from an imaging device (436) configured to capture thermal image. The control computer (102a-102d) further determines a value of a property of the thermal image, wherein the property is related to an amount of powder in the recoating mechanism. The control computer (102a-102d) further determines at least one of if the value indicates an error related to the amount of powder in the recoating mechanism (415A, 415B), and an action to take with respect to the recoating mechanism (415A, 415B) that is based on the value.

Abstract: Methods and apparatuses for using multiple beam spot widths in order to obtain improved performance in optical additive manufacturing techniques are disclosed. In some embodiments, an optical additive manufacturing apparatus for manufacturing an object, comprises a scanner configured to direct a beam emitted by an emitter towards an object layer and a control module in data communication with the scanner. The control module may be configured to: calculate a plurality of hatch vectors; select two or more of the plurality hatch vectors to be compared; compare the two or more selected hatch vectors to a first combination parameter; and calculate a first new hatch vector based on the two or more selected hatch vectors.

Abstract: A system and method for calibrating a laser scanning system is provided. Various embodiments involve the use of a calibration plate with reference markings which is positioned to receive a directed beam in a set of known laser scanner positions. The directed beam forms a laser spot on the calibration plate, and the laser spot is captured using an image acquisition assembly such as a digital camera along with a motorized mount. The movement of the image acquisition assembly may be coordinated with the movement of the laser scanner to track the laser spot across the plate. After photographing various positions, actual laser spot coordinates are deduced from their position relative to the known positions of the reference markings.