Abstract: Embodiments of the present disclosure are directed to additive manufacturing apparatuses, cleaning stations incorporated therein, and methods of cleaning using the cleaning stations.

Abstract: An additive manufacturing apparatus includes a process chamber having a length, a support extending along the length of the process chamber, a printing assembly, a vision system configured to image a dispensed binder pattern, and an electronic control unit communicatively coupled to the printing assembly, the first actuator, and the vision system. The electronic control unit is configured to cause the printing assembly to traverse the build zone in a forward or reverse direction while dispensing binder according to a programmed deposition pattern, receive image data from the vision system of the dispensed binder pattern resulting from the programmed deposition pattern, analyze the image data to determine whether there is an anomaly in the dispensed binder pattern, and in response to determining the anomaly in the dispensed binder pattern, adjust the programmed deposition pattern for a subsequent traversal of the printing assembly over the build zone to address the anomaly.

Abstract: In embodiments, an additive manufacturing apparatus comprises a chassis assembly and a skin at least partially covering the chassis assembly. The chassis assembly comprises a lower chassis section secured to a low voltage chassis section; an upper environmental chassis section secured to and extending over the low voltage chassis section and the lower chassis section; a high voltage chassis section secured to the upper environmental chassis section and the lower chassis section; and a build receptacle carriage adjustably coupled to the lower chassis section. The skin comprises first and second doors providing access to the low voltage chassis section and the high voltage chassis section; a rear panel providing access to the upper environmental chassis section; a top panel covering a top of the upper environmental chassis section; and at least one hinged door providing access to the lower chassis section.

Abstract: According to various embodiments, an additive manufacturing apparatus comprises a process chamber surrounding a print head, a recoat head, and a linear motion stage to which the print head and the recoat head are coupled. The print head and recoat head operate within the process chamber to build a three-dimensional object by depositing a build material and a binder material. The additive manufacturing apparatus further comprises a condenser system fluidly coupled to the process chamber to receive a gas stream with a first vapor content from the process chamber and provide the gas stream with a second vapor content to the process chamber. The second vapor content is less than the first vapor content. Additionally, the additive manufacturing apparatus comprises a blower fluidly coupled to the process chamber and the condenser to flow the gas stream through a closed loop comprising the blower, the process chamber, and the condenser.

Abstract: A system (100) includes a build area positioned along a working surface (102), a supply receptacle (110) spaced apart from the build area and defining one or more supply receptacle sidewalls and an upwardly-facing receptacle opening (114), a dosing hopper (240) positioned above and in selective communication with the supply receptacle, where the dosing hopper is structurally configured to deliver build material to an interior space (116), and a conveyance hopper (260) in communication with the dosing hopper (240).

Abstract: Embodiments of the present disclosure are directed to additive manufacturing apparatuses, cleaning stations incorporated therein, and methods of cleaning using the cleaning stations.

Abstract: Systems and methods for machining openings of a component are provided. In one exemplary aspect, a laser system includes features for machining an opening into a component, such as a cooling hole for a CMC component of a gas turbine engine. The component can be oriented in a first position and lasered while oriented in the first position to form a portion of the opening. The component is then oriented to a second position and lasered while oriented in the second position to form another portion of the opening. The component is alternated between the first and second positions until the predetermined geometry of the opening is formed. The component is oriented in the first and second positions such that the laser beam can machine the component without clipping areas that are not desired to be machined.

Abstract: Additive manufacturing apparatuses, components of additive manufacturing apparatuses, and methods of using such manufacturing apparatuses and components are disclosed. An additive manufacturing apparatus may include a recoat head for distributing build material in a build area, a print head for depositing material in the build area, one or more actuators for moving the recoat head and the print head relative to the build area, and a cleaning station for cleaning the print head.

Abstract: Additive manufacturing apparatuses are disclosed. In one embodiment, an additive manufacturing apparatus may comprise a support chassis including a print bay, a build bay, and a material supply bay. Each bay may comprise an upper compartment and a lower compartment. A working surface may separate each of the print bay, the build bay, and the material supply bay into the upper compartment and the lower compartment, wherein: the build bay may be disposed between the print bay and the material supply bay. The lower compartment of the build bay comprises bulkheads sealing the lower compartment of the build bay from the lower compartment of the print bay and the lower compartment of the material supply bay.

Abstract: Embodiments of the present disclosure are directed to additive manufacturing apparatuses, cleaning stations incorporated therein, and methods of cleaning using the cleaning stations.

Abstract: Embodiments of the present disclosure are directed to additive manufacturing apparatuses, cleaning stations incorporated therein, and methods of cleaning using the cleaning stations.

Abstract: Embodiments of the present disclosure are directed to additive manufacturing apparatuses, cleaning stations incorporated therein, and methods of cleaning using the cleaning stations.

Abstract: Embodiments of the present disclosure are directed to additive manufacturing apparatuses, cleaning stations incorporated therein, and methods of cleaning using the cleaning stations.

Abstract: Systems and methods of laser ablating a component to form a cavity are provided. In one aspect, a laser system laser ablates a component to remove a slice of material therefrom so that at least a portion of a section of the cavity is formed. With the slice of material removed, the laser system laser ablates the component along an outline of the section to remove excess sidewall material therefrom to form one or more sidewalls of the section. This removes tapering of the sidewalls. This process can be iterated to form the depth of the cavity. The laser system then laser ablates the component to remove excess end wall material therefrom to form an end wall of the cavity to a predetermined depth.

Abstract: Embodiments of the present disclosure are directed to additive manufacturing apparatuses, cleaning stations incorporated therein, and methods of cleaning using the cleaning stations.

Abstract: Systems and methods for machining openings of a component are provided. In one exemplary aspect, a laser system includes features for machining an opening into a component, such as a cooling hole for a CMC component of a gas turbine engine. The component can be oriented in a first position and lasered while oriented in the first position to form a portion of the opening. The component is then oriented to a second position and lasered while oriented in the second position to form another portion of the opening. The component is alternated between the first and second positions until the predetermined geometry of the opening is formed. The component is oriented in the first and second positions such that the laser beam can machine the component without clipping areas that are not desired to be machined.

Abstract: A gas turbine engine arcuate leaf seal assembly includes arcuate leaf seal extending radially and circumferentially between adjacent first and second turbine components. Upper and lower leaf seal portions of leaf seal are in radially spaced apart arcuate upper and lower grooves in the first and second turbine components respectively. The seal includes an arcuate body and a circumferential retention tab extending radially away from body and disposed in a notch in a wall of grooves. Seal may have a thickness between 3 mils and 35 mils and/or torsional stiffness between 0.015 and 0.15 lb/in. Turbine components may be radially adjacent turbine nozzle upper and lower components. The upper or lower component may be made of a ceramic matrix composite material. Annular cooling air plenum including flow cavities in inner support ring segments may be in lower component and in flow communication with hollow fairing airfoils.

Abstract: A gas turbine engine arcuate leaf seal assembly includes arcuate leaf seal extending radially and circumferentially between adjacent first and second turbine components. Upper and lower leaf seal portions of leaf seal are in radially spaced apart arcuate upper and lower grooves in the first and second turbine components respectfully. The seal includes an arcuate body and a circumferential retention tab extending radially away from body and disposed in a notch in a wall of grooves. Seal may have a thickness between 3 mils and 35 mils and/or torsional stiffness between 0.015 and 0.15 lb/in. Turbine components may be radially adjacent turbine nozzle upper and lower components. The upper or lower component may be made of a ceramic matrix composite material. Annular cooling air plenum including flow cavities in inner support ring segments may be in lower component and in flow communication with hollow fairing airfoils.