Abstract: A powder bed fusion system includes a powder bed including a build surface and a vacuum system. The vacuum system includes a collection device positioned over the build surface. The collection device includes a body, a pathway defined in the body, wherein the pathway ends in a passageway opening, and a particle retainer connected to the body near the passageway opening. A method of forming a component includes forming a layer of unfused metal powder on a powder bed with a recoater, introducing gas to the powder bed and applying a vacuum with a collection device, fusing a portion of the layer of unfused metal powder on the powder bed with a heat source to form a component layer and generating contaminants, collecting the contaminants from the powder bed with the gas and the vacuum applied by the collection device.

Abstract: A system and method for additive manufacturing are provided. The system includes a structure defining a chamber for manufacturing parts via additive manufacturing. A powder metal applicator is configured to deposit layers of powder metal material to build a part on a build platform. A laser source is configured to direct one or more laser beams onto each layer of powder metal material to fuse the powder metal material, wherein metal condensate is created by the laser beam(s) contacting the powder metal material. An element spaced apart from the layers of powder material has a temperature different than the chamber temperature, so that the element is configured to attract or repel the metal condensate by virtue of the temperature differential between the element and the chamber. The method includes using the element having the different temperature to attract or repel the metal condensate within the chamber.

Abstract: A post-build powder removal system includes a work bed, a platform wall having at least one powder evacuation port, and an evacuation port sealing system operable for selectively closing and opening the powder evacuation port. The platform wall cooperates with the work bed to define a powder chamber. The evacuation port sealing system includes an external sleeve slidingly fitted onto the exterior surface of the platform wall such that the external sleeve is slideable in a first direction closing the at least one powder evacuation port and slideable in an opposite second direction opening the at least one powder evacuation port.

Abstract: A configurable build volume system for a powder bed fusion manufacturing process includes a chamber wall defining a chamber, the chamber wall extending in the X-, Y-, and Z-axis directions, a plurality of build platforms enclosed within the chamber, a plurality of adjustment mechanisms coupled to the plurality of build platforms such that each build platform is coupled to a separate adjustment mechanism, a sensor mounted within the chamber and configured to capture data regarding a Z-axis position of each of the plurality of build platforms, and a controller in electronic communication with the plurality of adjustment mechanisms and the sensor. The controller receives the Z-axis position data and generates a plurality of control signals to adjust a Z-axis position of each of the plurality of build platforms and each of the plurality of build platforms is actively and independently controlled by the controller.

Abstract: A powder bed fusion system includes a powder bed including a build surface and a vacuum system. The vacuum system includes a collection device positioned over the build surface. The collection device includes a body, a pathway defined in the body, wherein the pathway ends in a passageway opening, and a particle retainer connected to the body near the passageway opening. A method of forming a component includes forming a layer of unfused metal powder on a powder bed with a recoater, introducing gas to the powder bed and applying a vacuum with a collection device, fusing a portion of the layer of unfused metal powder on the powder bed with a heat source to form a component layer and generating contaminants, collecting the contaminants from the powder bed with the gas and the vacuum applied by the collection device.

Abstract: A post-build powder removal system includes a work bed, a platform wall having at least one powder evacuation port, and an evacuation port sealing system operable for selectively closing and opening the powder evacuation port. The platform wall cooperates with the work bed to define a powder chamber. The evacuation port sealing system includes an external sleeve slidingly fitted onto the exterior surface of the platform wall such that the external sleeve is slideable in a first direction closing the at least one powder evacuation port and slideable in an opposite second direction opening the at least one powder evacuation port.

Abstract: A system and method for additive manufacturing are provided. The system includes a structure defining a chamber for manufacturing parts via additive manufacturing. A powder metal applicator is configured to deposit layers of powder metal material to build a part on a build platform. A laser source is configured to direct one or more laser beams onto each layer of powder metal material to fuse the powder metal material, wherein metal condensate is created by the laser beam(s) contacting the powder metal material. An element spaced apart from the layers of powder material has a temperature different than the chamber temperature, so that the element is configured to attract or repel the metal condensate by virtue of the temperature differential between the element and the chamber. The method includes using the element having the different temperature to attract or repel the metal condensate within the chamber.

Abstract: A connecting rod comprises a shaft connecting a first end including a first bore with a second end including a second bore. Methods for forming and assembling a connecting rod and crankshaft assembly include fabricating the second end of the connecting rod via additive manufacturing such that the second end comprises a first and second weakened regions on opposing sides of the second bore, and breaking the second end of the connecting rod at the first and second weakened regions to form a connecting rod assembly comprising a second end base and a second end cap, wherein the base comprises a first fracture face and a second fracture face which each respectively correspond to a first fracture face and a second fracture face of the cap. The methods can further include mating the base and the cap such that a crankpin of a crankshaft is disposed within the second bore.

Abstract: A configurable build volume system for a powder bed fusion manufacturing process includes a chamber wall defining a chamber, the chamber wall extending in the X-, Y-, and Z-axis directions, a plurality of build platforms enclosed within the chamber, a plurality of adjustment mechanisms coupled to the plurality of build platforms such that each build platform is coupled to a separate adjustment mechanism, a sensor mounted within the chamber and configured to capture data regarding a Z-axis position of each of the plurality of build platforms, and a controller in electronic communication with the plurality of adjustment mechanisms and the sensor. The controller receives the Z-axis position data and generates a plurality of control signals to adjust a Z-axis position of each of the plurality of build platforms and each of the plurality of build platforms is actively and independently controlled by the controller.

Abstract: A connecting rod comprises a shaft connecting a first end including a first bore with a second end including a second bore. Methods for forming and assembling a connecting rod and crankshaft assembly include fabricating the second end of the connecting rod via additive manufacturing such that the second end comprises a first and second weakened regions on opposing sides of the second bore, and breaking the second end of the connecting rod at the first and second weakened regions to form a connecting rod assembly comprising a second end base and a second end cap, wherein the base comprises a first fracture face and a second fracture face which each respectively correspond to a first fracture face and a second fracture face of the cap. The methods can further include mating the base and the cap such that a crankpin of a crankshaft is disposed within the second bore.