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: 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 print engine of an additive manufacturing system includes a print station with a print bed, powder spreader, and a first and a second powder holding chamber. First and second powder nozzles are respectively connected to the first and a second powder holding chambers. At least one vibratory element is attached to at least one of the print bed, the powder spreader, the first and a second powder holding chambers, and the first and second powder nozzles. In one embodiment, a laser able to direct a two dimensional laser image against the print bed is provided. In another embodiment, size of powder held in the respective first and a second powder holding chambers is different.

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 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 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 that supports powder measurement systems includes a print bed able to hold powder of varying sizes. A laser energy patterning system is made to be directable against the print bed and a backscatter detection system is situated to evaluate scattered light distribution from powder on the print bed and determine powder size.

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: 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: Digitally controlled segmented RF power transmitter with a digital processing part (2) and an RF power amplification part (3) having a plurality of segments (122). The digital processing part (2) has a clock generation block (5) being arranged to generate n equi-phased clock signals with a 50% duty-cycle (fLO,x_50%; Cx), and a sign-bit phase mapper unit (11) being arranged to receive the n equi-phased clock signals (fLO,x_50%; Cx), and sign signals (SignI, SignQ; sign bits), and to output a set of m, m?n, phase mapped clock signals with a 50% duty-cycle (CLKy,50%; Cy) using a predetermined phase swapping scheme. Each of the plurality of segments (122) comprises logic circuitry (12) receiving the set of m phase-mapped clock signals with a 50% duty-cycle (CLKy,50%; Cy), and being arranged to provide the respective segment driving signal with a duty-cycle z of less than 50%.

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.