Abstract: A system and a method for the rapid manufacturing of objects by direct metal deposition are disclosed. The system and method include an oscillating nozzle suspended by a gantry system or a robotic arm over a workpiece build. In some embodiments, the workpiece build is supported by a rotary stage, while in other embodiments the workpiece build is stationary. In embodiments including a rotary stage, the oscillating nozzle oscillates back and forth along the X-axis, and/or rotates clockwise and counter-clockwise about the Y-axis, as the rotary stage rotates about the Z-axis, resulting in a sinusoidal toolpath. In embodiments lacking a rotary stage, the oscillating nozzle is continuously rotated about the Z-axis by the gantry system or the robot arm. The sinusoidal toolpath results in a sinusoidal deposition track, which is particularly useful for building walled structures having rotational symmetry, including conical structures.

Abstract: An assembly for rapid manufacturing of symmetrical objects by direct metal deposition is disclosed. A rotary stage provides rotational movement to an object supported by the stage around a central stage axis. Nozzles are spaced above the rotary stage for performing direct metal deposition for building an object supported by the stage. Each nozzle is independently moveable along a horizontal axis and independently pivotable, and combined, moveable along a vertical axis for providing symmetrical movement corresponding to a symmetrical deposition configuration of the object while the object is rotated around the central stage axis.

Abstract: An improved laser weld process control system and method are provided. The system and method include a machine vision camera to detect a deviation between a pre-programmed laser beam toolpath and a gap centerpoint between first and second parts being welded together. The first and second parts are secured to a rotatable fixture, and the system and method cause the rotatable fixture to rotate through a corrective angle to bring the gap centerpoint into alignment with the laser beam toolpath, optionally in real time during the application of laser beam energy. The system and method can also correct for a vertical misalignment of the laser focal point due to rotation of the fixture by adjusting the vertical separation of the laser unit relative to the fixture.

Abstract: An assembly for measuring metal powder material mass flow rate during direct metal deposition is disclosed. A detection strip is placed in the gas-blown metal powder material flow path. The detection strip is fixed in one end and suspended at the other end. The flowing metal powder material particles induce displacement to the detection strip. A displacement measurement sensor measures the amount of displacement of the detection strip. The amount of displacement of the detection strip gives relationship to the amount of the metal powder material flowing in the metal powder material flow path. Preferably, the detection strip and the sensor are enclosed in a housing with a metal powder material inlet port and metal powder material outlet port and includes internal features for smooth travel of metal powder material particles.

Abstract: An assembly for rapid manufacturing of symmetrical objects by direct metal deposition is disclosed. A rotary stage provides rotational movement to an object supported by the stage around a central stage axis. Nozzles are spaced above the rotary stage for performing direct metal deposition for building an object supported by the stage. Each nozzle is independently moveable along a horizontal axis and independently pivotable, and combined, moveable along a vertical axis for providing symmetrical movement corresponding to a symmetrical deposition configuration of the object while the object is rotated around the central stage axis.

Abstract: In a direct metal deposition system which builds up a metallic overlay on a substrate by moving the substrate relative to a laser in a metallic powder feed, the laser power is adjusted for successive layers by sensing the weld pool in a plurality of selected points in each layer and adjusting the power during successive layers to maintain a weld pool that corresponds to those achieved during deposition of a lower optimal layer. This compensates for heating of the substrate resulting from the deposition which tends to increase the pool size or temperature in the higher layers.

Abstract: New tool paths are automatically created for rapid prototyping and additive manufacturing processes, facilitating the fabrication of new or repaired parts with superior geometries and/or compositional characteristics. The profile of a source part is imaged from camera picture and point wise offset adjustments. Part profile and process points are automatically generated without teaching by an operator. In the preferred embodiment, point-by-point process variable settings (i.e., laser power, speed and powder flow) are coupled to a closed-loop, direct-metal deposition (DMD) process to fabricate or repair production components using a tool path derived from the profile of the source part. The preferred method includes the steps of detecting the edge of the source part; generating a point-to-point database of the source part based upon the detected edge; and assigning one or more process parameters associated with the additive manufacturing process used to fabricate or repair the production part.

Abstract: In a direct metal deposition system which builds up a metallic overlay on a substrate by moving the substrate relative to a laser in a metallic powder feed, the laser power is adjusted for successive layers by sensing the weld pool in a plurality of selected points in each layer and adjusting the power during successive layers to maintain a weld pool that corresponds to those achieved during deposition of a lower optimal layer. This compensates for heating of the substrate resulting from the deposition which tends to increase the pool size or temperature in the higher layers.