Abstract: An additive manufacturing system includes a laser device, a build plate, a first scanning device, and an alignment system. The laser device is configured to generate a laser beam. The build plate has a position relative to the laser device. The first scanning device is configured to selectively direct the laser beam across the build plate. The laser beam generates a melt pool on the build plate. The alignment system includes a fiducial marks projector configured to project a plurality of fiducial marks across the build plate. Each fiducial mark has a location on the build plate. The alignment system also includes an optical detector configured to detect the location of each of the fiducial marks on the build plate. The alignment system is configured to detect the position of the build plate relative to the laser device.

Abstract: A method of making a component includes: depositing a metallic powder on a workplane; directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a cross-sectional layer of the component; repeating in a cycle the steps of depositing and fusing to build up the component in a layer-by layer fashion; and during the cycle of depositing and melting, using an external heat control apparatus separate from the directed energy source to maintain a predetermined temperature profile of the component, such that the resulting component has a directionally-solidified or single-crystal microstructure.

Abstract: Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Abstract: Methods and systems for fabricating a component by consolidating a particulate include a build platform configured to receive the particulate, a particulate dispenser configured to deposit the particulate onto the build platform, and a consolidation device configured to consolidate at least a portion of the particulate to form a component. The methods and systems also include a first actuator assembly configured to induce rotation of the build platform about a rotation axis at a first speed. The rotation axis extends through a center of the build platform. The methods and systems further include a second actuator assembly including an actuator and a shaft extending along the rotation axis. The actuator is configured to cause rotation of the shaft about the rotation axis at a second speed different from the first speed. The shaft is coupled to the build platform and configured to induce linear movement of the build platform along the rotation axis upon rotation of the shaft.

Abstract: Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Abstract: A method of forming a build in a powder bed includes emitting a plurality of laser beams from selected fibers of a diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build; and simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build.

Abstract: Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Abstract: A method of method of forming or repairing a superalloy article having a columnar or equiaxed or directionally solidified or amorphous or single crystal microstructure includes emitting a plurality of laser beams from selected fibers of a diode laser fiber array corresponding to a pattern of a layer of the article onto a powder bed of the superalloy to form a melt pool; and controlling a temperature gradient and a solidification velocity of the melt pool to form the columnar or single crystal microstructure.

Abstract: A call routing system for use with a wireless telephone systems is disclosed. The system, which monitors the subscriber's current physical location, determines the device to which a call should be terminated, and routes the call. The device can be any IP telephone, including a cable television system adapted to IP telephony. The system routes calls without direct subscriber actions, without a second telephone number, regardless of the time of day and day of week. Various options can also apply to a call, determined by subscriber-established preferences, when specified criteria are met, or calls can be limited to/from specified telephone numbers. The system and method uses signaling techniques that will allow routing of the call, along with any authorization or restrictions, to be done remotely from the actual switching of the call. Call events are transmitted to the call routing system while the communications path of the call is held at the switching system awaiting call routing information.

Abstract: A method of operation of a navigation system comprising: determining a geographic limitation with a control unit based on the geographic limitation associated with a traveler information included in a traveler restriction information; generating a provisional route based on a path between a start point and a destination point; determining a provisional POI based on a POI of the provisional route; determining a POI restriction based on the POI restriction associated with the provisional POI included in a rule information; determining a navigation restriction based on matching the geographic limitation and the POI restriction for presenting on a device.

Abstract: A navigation system includes: a control unit configured to: identify a route obstacle in a travel environment of a user vehicle during operation of the user vehicle in an autonomous operation mode; generate an obstacle handling assessment of whether the user vehicle is capable of navigation beyond the route obstacle in the autonomous operation mode; generate an obstacle orientation alert based on the obstacle handling assessment and an engagement state of a system user of the user vehicle; a user interface, coupled to the control unit, configured to present the obstacle orientation alert.

Abstract: Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Abstract: An additive manufacturing apparatus includes at least one build unit with a powder delivery mechanism, a powder recoating mechanism and an irradiation beam directing mechanism. The build platform is a rotating build platform or a non-rotating build platform. A gas inlet nozzle and a gas exhaust nozzle direct gas across the build site. A positioning mechanism is connected to the gas inlet nozzle and the gas exhaust nozzle, and the positioning mechanism is configured to provide independent movement of the gas inlet nozzle and the gas exhaust nozzle.

Abstract: Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Abstract: A component is fabricated in a powder bed by moving a laser array across the powder bed. The laser array includes a plurality of laser devices. The power output of each laser device of the plurality of laser devices is independently controlled. The laser array emits a plurality of energy beams from a plurality of selected laser devices of the plurality of laser devices to generate a melt pool in the powder bed. A non-uniform energy intensity profile is generated by the plurality of selected laser devices. The non-uniform energy intensity profile facilitates generating a melt pool that has a predetermined characteristic.

Abstract: A method of making a component includes depositing a metallic powder on a workplane; directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a cross-sectional layer of the component; repeating in a cycle the steps of depositing and fusing to build up the component in a layer-by layer fashion; and during the cycle of depositing and melting, using an external heat control apparatus separate from the directed energy source to maintain a predetermined temperature profile of the component, such that the resulting component has a directionally-solidified or single-crystal microstructure.

Abstract: A recoating device for an additive manufacturing system includes a plurality of recoater blades which include a first stage and a second stage. The first stage includes a plurality of rows of the plurality of recoater blades and extends in the transverse dimension. The second stage includes a plurality of recoater blades and is configured substantially similar to the first stage of the plurality of recoater blades. The second stage of recoater blades is displaced from the first stage of recoater blades in the vertical dimension.