Abstract: Embodiments of the disclosure provide a test article for additive manufacture and related methods. A test article formed may include a body having a forward face and a rearward face horizontally opposite the forward face. A first surface extending between the forward face and the rearward face of the body may include a plurality of protrusions for removable coupling of the body to a build plate. A second surface on the body may extend between the forward face and the rearward face of the body, and may include a plurality of angled flat surface portions. Each of the plurality of angled flat surface portions may have a distinct angle with respect to a horizontal plane of the body. An angular difference between each adjacent angled flat surface portion in the plurality of angled flat surface portions is substantially uniform.

Abstract: The disclosure relates to inducing compressive stress with shot peen elements in an internal opening of an additively manufactured component. Methods according to the disclosure include: receiving a component made by a metal powder additive manufacturing process, the component including a body having an external surface and an internal opening passing at least partially through the body, the internal opening including an additively manufactured shot peen element detached from a surface of the internal opening, wherein the additively manufactured shot peen element is shaped to induce a residual compressive stress upon contact with the surface of the internal opening; and vibrating the component at a selected frequency, wherein the additively manufactured shot peen element induces the compressive stress against the surface of the internal opening during the vibrating.

Abstract: Embodiments of the disclosure provide a test article for additive manufacture and related methods. A test article formed may include a body having a forward face and a rearward face horizontally opposite the forward face. A first surface extending between the forward face and the rearward face of the body may include a plurality of protrusions for removable coupling of the body to a build plate. A second surface on the body may extend between the forward face and the rearward face of the body, and may include a plurality of angled flat surface portions. Each of the plurality of angled flat surface portions may have a distinct angle with respect to a horizontal plane of the body. An angular difference between each adjacent angled flat surface portion in the plurality of angled flat surface portions is substantially uniform.

Abstract: Embodiments of the present disclosure relate to a material extraction tool, including: a body shaped to sealingly engage an aperture in a component, the aperture defining a fluid connection between a hollow interior of the component and an exterior of the component; a first passage within the body, the first passage fluidly connecting the hollow interior of the component to an air conduit outside the body, the air conduit fluidly coupled to a compressed air supply; and a second passage within the body, the second passage fluidly connecting the hollow interior of the component to an extraction conduit outside the body, the extraction conduit fluidly coupled to a material repository positioned outside the hollow interior of the component.

Abstract: The disclosure relates to inducing compressive stress with shot peen elements in an internal opening of an additively manufactured component. Methods according to the disclosure include: receiving a component made by a metal powder additive manufacturing process, the component including a body having an external surface and an internal opening passing at least partially through the body, the internal opening including an additively manufactured shot peen element detached from a surface of the internal opening, wherein the additively manufactured shot peen element is shaped to induce a residual compressive stress upon contact with the surface of the internal opening; and vibrating the component at a selected frequency, wherein the additively manufactured shot peen element induces the compressive stress against the surface of the internal opening during the vibrating.

Abstract: A test feature is disclosed that is formed during metal powder additive manufacturing of a production part. The test feature may include a metal powder sample capsule including a chamber for capturing unfused powder from the metal powder additive manufacturing, and a removable cap closing an end of the chamber. Alternatively, a test feature may include a quality control (QC) part, and at least one additional test element including a metal powder sample capsule integrally coupled to the QC part and including a chamber for capturing unfused powder from the metal powder additive manufacturing. The QC part is identical to the production part excepting the at least one test element. The QC part and the at least one test element are formed during the same metal powder additive manufacturing as the production part.

Abstract: A damaged applicator identifier system for an additive manufacturing (AM) system, and AM system including the same are disclosed. The damaged applicator identifier system may include a damaged applicator identifier determining whether the active applicator is damaged by identifying a non-planar surface in a layer of raw material on a build platform of the AM system after formation of the layer by the active applicator. A damaged applicator controller is configured to cause replacement or repair of the damaged, active applicator in response to the damaged applicator identifier identifying the damaged, active applicator.

Abstract: Various embodiments of the invention include an apparatus for removing particulates from the surface of a 3D printed workpiece. Various particular embodiments include a material removal apparatus having: an enclosure having a first inlet and a first outlet; a rotatable platform contained within the enclosure for positioning a 3D printed workpiece having particulate on a surface thereof; a pressurized fluid applicator connected to the first inlet and configured to selectively apply a pressurized fluid to the 3D printed workpiece; a vibration source configured to apply an adjustable vibratory frequency to at least one of the rotatable platform or the 3D printed workpiece; and a material reclamation unit connected to the first outlet configured to collect a material removed from the 3D printed workpiece.

Abstract: A damaged applicator identifier system for an additive manufacturing (AM) system, and AM system including the same are disclosed. The damaged applicator identifier system may include a damaged applicator identifier determining whether the active applicator is damaged by identifying a non-planar surface in a layer of raw material on a build platform of the AM system after formation of the layer by the active applicator. A damaged applicator controller is configured to cause replacement or repair of the damaged, active applicator in response to the damaged applicator identifier identifying the damaged, active applicator.

Abstract: A test feature is disclosed that is formed during metal powder additive manufacturing of a production part. The test feature may include a metal powder sample capsule including a chamber for capturing unfused powder from the metal powder additive manufacturing, and a removable cap closing an end of the chamber. Alternatively, a test feature may include a quality control (QC) part, and at least one additional test element including a metal powder sample capsule integrally coupled to the QC part and including a chamber for capturing unfused powder from the metal powder additive manufacturing. The QC part is identical to the production part excepting the at least one test element. The QC part and the at least one test element are formed during the same metal powder additive manufacturing as the production part.

Abstract: Particle detection systems are disclosed. The particle detection system may include a conduit configured to receive particles removed from a component, and at least one sensor positioned adjacent the conduit. The at least one sensor may be configured to detect a particle characteristic for the particles in the conduit removed from the component. The particle detection system may also include a particle analysis system in communication with the at least one sensor. The particle analysis system may be configured to analyze the particle characteristic for the particles in the conduit to determine if the component is substantially free of particles.

Abstract: Embodiments of the present disclosure relate to a material extraction tool, including: a body shaped to sealingly engage an aperture in a component, the aperture defining a fluid connection between a hollow interior of the component and an exterior of the component; a first passage within the body, the first passage fluidly connecting the hollow interior of the component to an air conduit outside the body, the air conduit fluidly coupled to a compressed air supply; and a second passage within the body, the second passage fluidly connecting the hollow interior of the component to an extraction conduit outside the body, the extraction conduit fluidly coupled to a material repository positioned outside the hollow interior of the component.

Abstract: Apparatuses and systems for rotatably engaging an additive manufacturing build plate are disclosed. An apparatus may include: a height adjustable platform; a rotatable member coupled to the height adjustable platform; an alignment member coupled to a first end of the rotatable member; and first and second coupling members each extending from the first radial end of the alignment member wherein the first and second coupling members are oriented substantially parallel to the rotatable member.

Abstract: Additive manufacturing systems are disclosed. The systems may include a build platform, and at least one magnet positioned adjacent the build platform. The magnet(s) may be configured to manipulate a magnetic powder material positioned on the build platform to form a pre-sintered component having a first geometry. The system may also include at least one sprayer nozzle positioned adjacent the build platform, where the at least one sprayer nozzle may be configured to coat the pre-sintered component formed from the magnetic powder material with a binder material. Additionally, the system may include a heated build chamber surrounding the build platform. The heated build chamber may be configured to heat the pre-sintered component to form a sintered component having a second geometry.

Abstract: Additive manufacturing systems are disclosed. The systems may include a build platform for a preformed component and/or a magnetic powder material, and at least one magnet positioned adjacent the build platform. The magnet(s) may be configured to manipulate the magnetic powder material to form a pre-sintered component in contact with the preformed component. The system may also include at least one sprayer nozzle positioned adjacent the build platform. The sprayer nozzle(s) may be configured to coat the pre-sintered component formed from the magnetic powder material with a binder material. Additionally, the system may include a heated build chamber substantially surrounding the build platform. The heated build chamber may be configured to heat the pre-sintered component to form a sintered portion integral with the preformed component.

Abstract: Additive manufacturing systems are disclosed. The systems may include a build platform, and at least one magnet positioned adjacent the build platform. The magnet(s) may be configured to manipulate a magnetic powder material positioned on the build platform to form a pre-sintered component having a first geometry. The system may also include at least one sprayer nozzle positioned adjacent the build platform, where the at least one sprayer nozzle may be configured to coat the pre-sintered component formed from the magnetic powder material with a binder material. Additionally, the system may include at least one radiant energy component positioned adjacent the build platform. The radiant energy component(s) may be configured to sinter the pre-sintered component to form a sintered component having a second geometry identical to the first geometry of the pre-sintered component.

Abstract: Particle detection systems are disclosed. The particle detection system may include a conduit configured to receive particles removed from a component, and at least one sensor positioned adjacent the conduit. The at least one sensor may be configured to detect a particle characteristic for the particles in the conduit removed from the component. The particle detection system may also include a particle analysis system in communication with the at least one sensor. The particle analysis system may be configured to analyze the particle characteristic for the particles in the conduit to determine if the component is substantially free of particles.

Abstract: Various embodiments of the invention include an apparatus for removing particulates from the surface of a 3D printed workpiece. Various particular embodiments include a material removal apparatus having: an enclosure having a first inlet and a first outlet; a rotatable platform contained within the enclosure for positioning a 3D printed workpiece having particulate on a surface thereof; a pressurized fluid applicator connected to the first inlet and configured to selectively apply a pressurized fluid to the 3D printed workpiece; a vibration source configured to apply an adjustable vibratory frequency to at least one of the rotatable platform or the 3D printed workpiece; and a material reclamation unit connected to the first outlet configured to collect a material removed from the 3D printed workpiece.

Abstract: A method for correction of thermal defects using tomographic scanning for additive manufacturing is provided. The method may include forming a portion of an object using an additive manufacturing system based on an intended three-dimensional (3D) model of the object that is in an additive manufacturing system format. The portion of the object is scanned using a tomographic scanner to obtain a model of the portion of the object in a tomographic scanner format. The model is converted from the tomographic scanner format into the additive manufacturing system format to obtain a converted tomographic model; and the converted tomographic model is compared to the intended 3D model to identify a defect in the portion of the object. A modified 3D model may be generated of the object correcting the intended 3D model to address the defect of the portion of the object.

Abstract: Aspects of the disclosure include apparatuses and systems for rotatably engaging an additive manufacturing build plate. An apparatus according to embodiments of the present disclosure can include: a height adjustable platform; a rotatable member coupled to the height adjustable platform; an alignment member coupled to a first end of the rotatable member; and first and second coupling members each extending from the first radial end of the alignment member wherein the first and second coupling members are oriented substantially parallel to the rotatable member.