Abstract: A method of characterizing gas flow within a housing includes: positioning one or more gas flow sensors in the housing; introducing a gas flow into the housing; using the one or more gas flow sensors to generate two or more gas flow measurements at spaced-apart locations within the housing; and recording the two or more measurements to create a gas flow map.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize thermal dissipation support structures in the process of building objects, as well as novel thermal dissipation support structures to be used within these AM processes. The thermal dissipation support structures include at least one sacrificial structure that is separated from the object by a portion of unfused powder. The sacrificial structure increases a thermal dissipation rate of at least a portion of the object such that such that thermal gradients in the object remain below a specified threshold that prevents deformation of the object.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize ghost support structure in the process of building objects, as well as novel ghost support structures to be used within these AM processes. The ghost support structures include a portion of powder that is scanned with an energy beam having insufficient power to fuse the powder. The ghost supports control timing of the additive manufacturing process and allow portions of the object to cool to a desired temperature before adjacent portions of the object are scanned.

Abstract: A method and apparatus for additive manufacturing is provided whereby a curtain of powder is provided adjacent a vertically oriented build plate, and a laser melts or sinters the powder over a region of the build plate. The curtain of powder is moved relative to the build plate to maintain the same distance between the curtain and the previously deposited layer, and the process repeated to provide a three dimensional structure on the build plate.

Abstract: This invention relates to a method for using a multivariate statistical control process to reduce the variation of an additively manufactured part or object. The invention also relates to a system and software that can be used to implement the method in additive manufacturing devices or apparatuses.

Abstract: This invention relates to a method for calibrating the delay settings of a laser or scanner head in a laser additive manufacturing process. More particularly, the invention relates to calibrating delay settings during run-ins and run-outs of a laser scanning process.

Abstract: A method for inspecting an additive manufacturing process in which a directed energy source is used to create a weld pool at an exposed build surface of a mass of powdered material, and selectively fuse the powdered material to form a workpiece. The inspection method includes: using a noncontact method to generate an acoustic wave in the build surface; using a noncontact method to measure displacement of the build surface in response to the acoustic wave; and determining at least one sub-surface material property of the workpiece by analyzing the displacement of the build surface.

Abstract: A method of characterizing gas flow within a housing includes: positioning one or more gas flow sensors in the housing; introducing a gas flow into the housing; using the one or more gas flow sensors to generate two or more gas flow measurements at spaced-apart locations within the housing; and recording the two or more measurements to create a gas flow map.

Abstract: A method of controlling an additive manufacturing process in which a directed energy source is used to selectively fuse powdered material to form a workpiece, in the presence of a gas flow, the method including: using at least one gas flow sensor to generate at least one gas flow measurement; and controlling at least one aspect of the additive manufacturing process in response to the at least one gas flow measurement.

Abstract: A method of monitoring an additive manufacturing process in which a directed energy source is used to create a weld pool at an exposed build surface of a mass of powdered material, and selectively fuse the powdered material to form a workpiece, the method including measuring acoustic energy generated by the weld pool to generate a measured acoustic profile.

Abstract: A method of monitoring an additive manufacturing process in which a layer of powdered material is deposited in a recoating process so as to define a build surface, and a directed energy source is used to create a weld pool in the build surface and selectively fuse the powdered material to form a workpiece. The method includes: measuring a vibration signal profile generated by the recoating process; and controlling at least one aspect of the additive manufacturing process in response to the measured vibration signal profile.

Abstract: A casting mold apparatus includes a unitary ceramic core including: an outer skin defining an outer surface; and an internal support structure disposed inside the outer skin, the internal support structure defining a plurality of voids configured to admit fluid to the core.

Abstract: A method of reducing surface roughness in an internal passage of a workpiece includes contacting the internal passage with a corrosive working fluid comprising water at or near supercritical conditions.