Abstract: A manufacturing system includes a printer chamber having a printer bed that supports manufacturing materials and an internal heating system supported by the printer chamber. The internal heating systems is configured to direct patterned heat energy onto the printer bed and supported manufacturing materials. An external heating system is supported by or positioned near the printer chamber and configured to direct patterned heat energy onto the printer bed and any supported manufacturing materials.

Abstract: A method of additive manufacture is disclosed. The method may include providing a powder bed and directing a shaped laser beam pulse train consisting of one or more pulses and having a flux greater than 20 kW/cm2 at a defined two dimensional region of the powder bed. This minimizes adverse laser plasma effects during the process of melting and fusing powder within the defined two dimensional region.

Abstract: An RF transmitter having one or more common-gate, CG, or common-base, CB, configured output stages, and a digitally controlled current source having a plurality of unit cells connected to the output stages, each of the plurality of unit cells comprising a current source. The digitally controlled current source is configured for driving the output stages with respective driving currents originating from the associated current source in each of the plurality of unit cells, in dependence of one or more input signals. The digitally controlled current source further comprises a current diversion path in each of the plurality of unit cells for providing a diversion current to a voltage source having a voltage lower than drain/collector terminals of transistors provided in the CG/CB configured output stages.

Abstract: A method of additive manufacture is disclosed. The method may include providing a powder bed and directing a shaped laser beam pulse train consisting of one or more pulses and having a flux greater than 20 kW/cm2 at a defined two dimensional region of the powder bed. This minimizes adverse laser plasma effects during the process of melting and fusing powder within the defined two dimensional region.

Abstract: An additive manufacturing system can include at least one laser source and a speckle reduction system that receives light from the at least one laser source. The speckle reduction system provides laser light to an optical homogenizer that increases uniformity of laser light and can provide the light to an area patterning system.

Abstract: A method of additive manufacture is disclosed. The method may include providing a powder bed and directing a shaped laser beam pulse train consisting of one or more pulses and having a flux greater than 20 kW/cm2 at a defined two dimensional region of the powder bed. This minimizes adverse laser plasma effects during the process of melting and fusing powder within the defined two dimensional region.

Abstract: An additive manufacturing system includes one or more light sources and one or more light valves that can be written with two-dimensional gray scale patterns that the light valves impose on beams from the one or more light sources to obtain one or more patterned beams. The one or more patterned beams are steered to each area of a plurality of areas on a layer of powder. The two-dimensional gray scale patterns are selected to achieve desired material properties at each pixel position of the patterned beam incident on the layer of powder. The light valves may modulate one or more of amplitude, phase, or coherence. The material properties may include one or more of Young's modulus, porosity, grain size, and crystalline microstructure.

Abstract: The present disclosure relates to systems and methods for performing large area laser powder bed fusion (LBPF) to form a plurality of layers of a 3D part in a layer-by-layer fashion using meltable powder particles. In one implementation the system makes use of a first light source, which may be a diode laser subsystem, for generating a first light pulse of a first duration. The first light is used to preheat a substrate underneath a new layer of powder particles, wherein the substrate is formed from a previously fused quantity of the powder particles. A second light source, which may be a pulse laser, generates a second light pulse subsequent to the first light pulse. The second light pulse has a second duration shorter than the first duration by a factor of at least about 10, and fully melts the new layer of powder particles in addition to the substrate, to achieve a smooth printed layer. The wavelength of the first light pulse also differs from a wavelength of the second light pulse.

Abstract: A manufacturing system includes a printer chamber having a printer bed that supports manufacturing materials and an internal heating system supported by the printer chamber. The internal heating systems is configured to direct patterned heat energy onto the printer bed and supported manufacturing materials. An external heating system is supported by or positioned near the printer chamber and configured to direct patterned heat energy onto the printer bed and any supported manufacturing materials.

Abstract: A print engine of an additive manufacturing system includes a print station configured to hold a removable cartridge. A laser engine including a frame can be positioned to hold at least one removable field replaceable unit that includes at least some laser optics or patterning optics. An optical alignment system can be attached to at least one of the print station or the laser engine to align the field replaceable unit with respect to the removable cartridge.

Abstract: A cartridge for a manufacturing system includes a sealable chamber having a bed and a laser transparent window. A powder hopper can be positioned within the sealable chamber. A powder spreader is positioned within the sealable chamber for distributing powder from the powder hopper onto the bed.

Abstract: An additive manufacturing system, method of manufacturing, and fabricated part. The system uses a material joining laser system to join together foil sheets to form a metal part. The material joining laser system can be configured to join adjacent foil sheets together in a substantially uniform manner. The manufacturing system also includes a material removal system that removes material from selected locations of the foil sheets to shape the foil sheets to correspond with selective slices of the part. The material removal system can be a laser system, such as a laser system configured to remove material from a foil sheet without removing material from an underlying layer. One embodiment involves the manufacture of amorphous alloy components.

Abstract: A method of additive manufacture is disclosed. The method may include providing a powder bed and directing a shaped laser beam pulse train consisting of one or more pulses and having a flux greater than 20 kW/cm2 at a defined two dimensional region of the powder bed. This minimizes adverse laser plasma effects during the process of melting and fusing powder within the defined two dimensional region.

Abstract: A method of additive manufacture is disclosed. The method can include providing an enclosure surrounding a powder bed and having an atmosphere including helium gas. A high flux laser beam is directed at a defined two dimensional region of the powder bed. Powder is melted and fused within the defined two dimensional region, with less than 50% by weight of the powder particles being displaced into any defined two dimensional region that shares an edge or corner with the defined two dimensional region where powder melting and fusing occurs.

Abstract: A wideband, frequency agile, radio frequency digital-to-analog converter (RF-DAC) based phase modulator includes first, second, and third RF-DACs, each configured to upconvert an input I/Q digital baseband signal pair to a local oscillator (LO) frequency but with the first RF-DAC being driven by a first set of LO clocks, the second RF-DAC being driven by a second set of LO clocks that is forty-five degrees out of phase with respect to the first set of LO clocks, and the third RF-DAC being driven by a third set of LO clocks that is a further forty-five degrees out of phase with respect to the second set of LO clocks. First, second, and third upconverted analog signals produced by the first, second, and third RF-DACs are combined to reinforce the fundamental LO component while canceling 3rd-order and 5th-order LO harmonics.

Abstract: A wideband, frequency agile, radio frequency digital-to-analog converter (RF-DAC) based phase modulator includes first, second, and third RF-DACs, each configured to upconvert an input I/Q digital baseband signal pair to a local oscillator (LO) frequency but with the first RF-DAC being driven by a first set of LO clocks, the second RF-DAC being driven by a second set of LO clocks that is forty-five degrees out of phase with respect to the first set of LO clocks, and the third RF-DAC being driven by a third set of LO clocks that is a further forty-five degrees out of phase with respect to the second set of LO clocks. First, second, and third upconverted analog signals produced by the first, second, and third RF-DACs are combined to reinforce the fundamental LO component while canceling 3rd-order and 5th-order LO harmonics.

Abstract: An additive manufacturing system, method of manufacturing, and fabricated part. The system uses a material joining laser system to join together foil sheets to form a metal part. The material joining laser system can be configured to join adjacent foil sheets together in a substantially uniform manner. The manufacturing system also includes a material removal system that removes material from selected locations of the foil sheets to shape the foil sheets to correspond with selective slices of the part. The material removal system can be a laser system, such as a laser system configured to remove material from a foil sheet without removing material from an underlying layer. One embodiment involves the manufacture of amorphous alloy components.