Abstract: A device for manufacturing a three-dimensional shaped object includes a table on which a layer of granulated powder is stacked, a layer formation portion that forms the granulated powder on the table into a layer having a predetermined thickness, a compression unit configured to compress a first region in the layer, a processing unit that processes the formation region of the three-dimensional shaped object in the layer, and a control unit that controls the compression unit to form the first region in which the granulated powder are crushed, and the second region in which the granulated powder are not crushed.

Abstract: An additive repair device for internal threads is provided. The device includes a moving assembly, a rotating assembly, a speed regulation assembly, a gear assembly, an additive assembly, and a connecting assembly. The moving assembly includes a drive part and a linear movement mechanism. The additive assembly is connected to the linear movement mechanism through the connecting assembly. One end, which is far away from the drive part, of the linear movement mechanism is connected to an input end of the speed regulation assembly through the gear assembly. The rotating assembly includes a clutch mechanism and a clamping mechanism. The clutch mechanism includes a clutch outer gear and a clutch inner gear. The clutch outer gear is arranged at an output end of the speed regulation assembly. The clamping mechanism is fixed to one end, which is far away from the speed regulation assembly, of the clutch inner gear.

Abstract: Devices, systems, methods, and kits of parts for monitoring operation of an electron beam additive manufacturing systems are disclosed. A monitoring system includes one or more measuring devices positioned on the at least one wall in the interior of a build chamber of the additive manufacturing system. Each one of the one or more measuring devices includes a piezoelectric crystal. The monitoring system further includes an analysis component communicatively coupled to the one or more measuring devices. The analysis component is programmed to receive information pertaining to a frequency of oscillation of the piezoelectric crystal. A collection of material on the one or more measuring devices during formation of an article within the build chamber causes a change to the frequency of oscillation of the piezoelectric crystal that is detectable by the analysis component and usable to determine a potential build anomaly of the article.

Abstract: Systems and methods for three-dimensional printing using microwave assisted deposition are disclosed herein. An example device includes a reservoir of carbonaceous nanocomposite thermoset, a microwave resonance cavity that cures the carbonaceous nanocomposite thermoset, and a sensor to measure the extrusion temperature of the resin when curing the carbonaceous nanocomposite thermoset at the point of deposition during extrusion-based 3D printing.

Abstract: Systems, devices, and methods for additive manufacturing are provided that allow for components being manufactured to be assessed during the printing process. As a result, changes to a print plan can be considered, made, and implemented during the printing process. More particularly, in exemplary embodiments, a spectrometer is operated while a component is being printed to measure one or more parameters associated with one or more layers of the component being printed. The measured parameter(s) are then relied upon to determine if any changes are needed to the way printing is occurring, and if such changes are desirable, the system is able to implement such changes during the printing process. By way of non-limiting examples, printed material in one or more layers may be reheated to alter the printed component, such as to remove defects identified by the spectrometer data.

Abstract: Methods and systems for additive manufacturing are provided. An exemplary method includes calculating a slice area distribution of a desired 3D design including slice areas of slices of the desired design, wherein the slices have an initial slice area differential. The method further includes obtaining a slice area distribution of a sacrificial 3D design comprising slice areas of slices of the sacrificial design. The method includes planning a 3D layout of the desired and sacrificial design, wherein at each respective parallel plane in the layout a total slice area includes a respective slice area of the desired design and a respective slice area of the sacrificial design, and wherein the layout has a total slice area differential that is less than the initial slice area differential. Also, the method includes generating instructions for printing slices of the desired design and the sacrificial design according to the layout.

Abstract: An apparatus for additively manufacturing three-dimensional objects may include at least one calibration unit, at least one irradiation device, and a determination device. The least one calibration unit may include at least one calibration region arranged in the beam guiding plane, and the at least one calibration region may include a plurality of sub-regions differing in respect of at least one optical property. The at least one irradiation device may be configured to guide a plurality of energy beams across the at least one calibration region comprising the plurality of sub-regions, and a plurality of calibration signals may be generated by the plurality of sub-regions being irradiated with the plurality of energy beams. The determination device may be configured to determine the plurality of calibration signals and to determine a calibration status of the irradiation device based at least in part on the determined plurality of calibration signals.

Abstract: A method is provided for smoothing a surface region of a component consisting of an electrically conductive material. The surface region of the component is coated inside a vacuum chamber, by focused electron beam(s) with a first surface energy, which brings about melting of the component material within the surface region. Before melting, the surface region is passed over at least twice by the electron beam, each time with a different focal length of the electron beam. A second surface energy is set for the electron beam, such that no melting of the component material is brought about in the surface region. Data is recorded by a number of sensors arranged inside the vacuum chamber. An actual value for the roughness is compared to a set point value. If the actual value has not reached the set point value, a value for the first surface energy is determined via comparison.

Abstract: A method for continuously applying hardbanding to an oil and gas tubular or building up a worn oil and gas tubular that includes low heat input welding without compromising the mechanical properties of the tubular. The method includes preparation of the surface of the oil and gas tubular and applying a consumable wire to the surface. The consumable wire may be hardbanding or buildup material with a hardness that is similar to the hardness of the oil and gas tubular.

Abstract: There is described a modular welding device having a welding torch assembly defining a welding axis and having a welding torch rotatable about the welding axis. The welding device further includes a drive assembly releasably attachable to the welding torch assembly and operable to linearly translate the welding torch assembly along an axis of translation. When the drive assembly is attached to the welding torch assembly in a first orientation relative to the welding torch assembly, the drive assembly is detachable from the welding torch assembly and re-attachable to the welding torch assembly so as to be disposed in a second orientation relative to the welding torch assembly.

Abstract: Thermally configurable structural elements (e.g., aircraft components such as an aircraft winglet spar) capable of assuming at least first and second structural configurations are provided whereby the structural element includes an integral actuation mechanism may be formed of sintered shape memory alloy (SMA) particles and sintered non-SMA particles formed by an additive layer manufacturing (ALM) process, such as 3D printing. The ALM process thereby provides by at least one thermally configurable region, and at least one non-thermally configurable region which is unitarily contiguous with the at least one thermally configurable region. The at least one thermally configurable region is capable of assuming at least first and second positional orientations in response to the presence or absence of a thermal input to thereby cause the structural element to assume the at least first and second structural configurations, respectively.

Abstract: Apparatuses and methods for in situ thermal treatment for PBF systems are provided. An apparatus for a PBF-based 3-D printer can include a heating element for heating a gas, wherein the heated gas is delivered via at least one port of the 3-D printer to conduct heat treatment on a build piece during printing. A method for thermal treatment in a PBF-based 3-D printer can include heating a gas and delivering it via at least one port of the 3-D printer arranged proximate a build piece to conduct heat treatment during printing. An apparatus for a PBF-based 3-D printer can include a temperature-regulating element for changing a temperature of a gas, at least one channel for delivering the gas to a plurality of ports, and a controller for determining gas temperatures and durations of application of the gas via different ones of the plurality of the ports.

Abstract: An irradiation device of a lamination molding apparatus includes: at least one laser source, generating a laser beam; a first galvano scanner, scanning the laser beam; a second galvano scanner, scanning the laser beam; and an irradiation controller, controlling the laser source, the first galvano scanner, and the second galvano scanner. Irradiable ranges of the laser beams by using the first galvano scanner and the second galvano scanner respectively include an entire of a molding region. A first X-axis galvano mirror and a first Y-axis galvano mirror of the first galvano scanner and a second X-axis galvano mirror and a second Y-axis galvano mirror of the second galvano scanner are disposed to be plane-symmetric to each other.

Abstract: A suppressor having a body and a first connector half coupled to the body, wherein the first connector half includes a first component that includes at least one channel and a first surface; and wherein the body provides a second surface, wherein a gap between the first surface and the second surface defines at least one track; wherein the gun includes a second connector half comprising at least one protrusion, wherein the protrusion and channel have corresponding shapes that allow the protrusion to be inserted through the channel and into alignment with the track, wherein the first component may be rotated with respect to the protrusion and the body to bring the protrusion out of alignment with the channel so that the first and second surfaces clamp the protrusion to thereby secure the first connector half and second connector half with respect to each other.

Abstract: A system and method of monitoring a powder-bed additive manufacturing process is provided where a layer of additive powder is fused using an energy source and electromagnetic emission signals are measured by a melt pool monitoring system to monitor the print process. The measured emission signals are analyzed to identify outlier emissions and clusters of outliers are identified by assessing the spatial proximity of the outlier emissions, e.g., using clustering algorithms, spatial control charts, etc. An alert may be provided or a process adjustment may be made when a cluster is identified or when a magnitude of a cluster exceeds a predetermined cluster threshold.

Abstract: A fabrication table includes a separable portion and a supporter. The separable portion is formed of a heat-resistant member on which a three-dimensional fabricated object is to be placed. The supporter is formed of a rigid material and configured to support the separable portion.

Abstract: A method of additive manufacturing can include forming a machine part having a first portion formed from a cast iron material; forming a second portion adjacent the first portion formed of a combination of the cast iron material and a different material; and forming a third portion adjacent the second portion formed of only the different material, wherein the third portion is located at a predetermined critical area of the machine part.

Abstract: Devices, systems, methods, and kits of parts for monitoring operation of an electron beam additive manufacturing systems are disclosed. A monitoring system includes one or more measuring devices positioned on the at least one wall in the interior of a build chamber of the additive manufacturing system. Each one of the one or more measuring devices includes a piezoelectric crystal. The monitoring system further includes an analysis component communicatively coupled to the one or more measuring devices. The analysis component is programmed to receive information pertaining to a frequency of oscillation of the piezoelectric crystal. A collection of material on the one or more measuring devices during formation of an article within the build chamber causes a change to the frequency of oscillation of the piezoelectric crystal that is detectable by the analysis component and usable to determine a potential build anomaly of the article.

Abstract: Joining methods and corresponding structures are disclosed. In some instances, a method for joining two or more components may include generating a shockwave in a first component to form a jet of a material of the first component directed towards a second component. The jet may penetrate the second component to connect the first component with the second component. Articles of pre-joined and joined components are also described.

Abstract: A method and apparatus for identifying porosity in a structure made by an additive manufacturing process in which a laser is scanned across layers of material to form the structure. Pyrometry data comprising images of the layers acquired during additive manufacturing of the structure is received. The pyrometry data is used to generate temperature data comprising estimated temperatures of points in the layers in the images of the layers. The temperature data is used to identify shapes fit to high temperature areas in the images of the layers. Conditions of the shapes fit to the high temperature areas in the images of the layers are identified. Outlier shapes are identified in the shapes fit to the high temperature areas in the images of the layers using the conditions of the shapes.

Abstract: Examples of a system for additive manufacturing are described. The system comprises a powder reservoir for storing the metal powder operatively coupled to a working chamber that includes a powder feeder with a housing that defines an inner cavity with an inlet and a number of nozzles in communication with the inner cavity of the powder feeder defining an outlet of the feeder. The number of nozzles are positioned around a center axis of a generated energy beam. A powder feeder's driver is configured to drive flow of the powder through the nozzles directly into a beam path such that an exact amount of the powder is placed into the beam path to be melted or sintered onto a powder bed.

Abstract: In a method of applying a weld to a target surface, a guide rail arrangement is attached to the target, the guide rail arrangement including at least one guide rail. A weld head carriage having a carriage housing, a rail follower assembly, and a sonotrode is movably mounted to the guide rail arrangement so that the follower assembly engages each guide rail for movement there-along. The weld head carriage is positioned adjacent the target surface, feedstock material is deposited onto the target surface, and the sonotrode is extended to engage the deposited feedstock material and apply a welding force to the feedstock material and the target. Relative movement between the carriage and the guide rail arrangement is initiated and ultrasonic vibrations are conducted into the feedstock material and the target, thereby welding the feedstock material to the target surface.

Abstract: A method of printing a hollow part with a robotic additive manufacturing system includes extruding thermoplastic material onto a build platform movable in at least two degrees of freedom in a helical pattern along a continuous 3D tool path with an extruder mounted on a robotic arm, to thereby print a hollow member having a length and a diameter. The method includes orienting the hollow member during printing by moving the build platform based on a geometry of the hollow member wherein the movement of the build platform and the movement of the robotic arm are synchronized to print the part without support structures.

Abstract: A steel track chain component, such as a track bushing, may be formed with a carburized portion, a hardface portion, and a core portion. The core portion may be softer than the carburized portion, which in turn, may be softer than the hardface portion. This configuration of the various portions of the component may allow for relatively high wear resistance of the component, as well as toughness. The core portion may be mostly ferrite crystal structure, while the carburized portion and the hardface portions may include martensitic and/or austenitic crystal structure. The carburized portion may be formed by carburizing the track chain component in a heated and carbon rich environment. The hardface portion may be formed by welding a hardface alloy over at least a portion of the carburized portion.

Abstract: A system and method of monitoring a powder-bed additive manufacturing process is provided where a layer of additive powder is fused using an energy source and electromagnetic emission signals are measured by a melt pool monitoring system to monitor the print process. The measured emission signals are analyzed to identify outlier emissions and clusters of outliers are identified by assessing the spatial proximity of the outlier emissions, e.g., using clustering algorithms, spatial control charts, etc. An alert may be provided or a process adjustment may be made when a cluster is identified or when a magnitude of a cluster exceeds a predetermined cluster threshold.

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 reworking or repairing a component includes removing a casting defect from a component manufactured of a non-fusion weldable base alloy to form a cavity that results in a through hole; sealing the through hole with a backing; and at least partially filling the cavity with a multiple of layers of a multiple of laser powder deposition spots, each of the multiple of laser powder deposition spots formed of a filler alloy, a first layer of the multiple of layers includes a perimeter of the multiple of laser powder deposition spots that overlap a wall of the cavity and the backing.

Abstract: Systems, devices, and methods for additive manufacturing are provided that allow for components being manufactured to be assessed during the printing process. As a result, changes to a print plan can be considered, made, and implemented during the printing process. More particularly, in exemplary embodiments, a spectrometer is operated while a component is being printed to measure one or more parameters associated with one or more layers of the component being printed. The measured parameter(s) are then relied upon to determine if any changes are needed to the way printing is occurring, and if such changes are desirable, the system is able to implement such changes during the printing process. By way of non-limiting examples, printed material in one or more layers may be reheated to alter the printed component, such as to remove defects identified by the spectrometer data.

Abstract: A multiple axis robotic additive manufacturing system includes a robotic arm movable in six degrees of freedom. The system includes a build platform movable in at least two degrees of freedom and independent of the movement of the robotic arm to position the part being built to counteract effects of gravity based upon part geometry. The system includes an extruder mounted at an end of the robotic arm. The extruder is configured to extrude at least part material with a plurality of flow rates, wherein movement of the robotic arm and the build platform are synchronized with the flow rate of the extruded material to build the 3D part.

Abstract: A support assembly includes a part and a tension support rod. The part is additively manufactured on a base plate and includes a series of stacked layers of material fused together. The tension support rod is attached to the base plate at a first attachment location and is attached to the part at a second attachment location. At least one of the first attachment location or the second attachment location comprises a pivot joint to enable movement of the tension support rod at the pivot joint.

Abstract: An apparatus for fabricating a three-dimensional object from a representation of the object stored in memory. The apparatus includes an outer drum supported for rotation and an inner drum positioned within the outer drum and supported for rotation therewith. A powder receiving chamber is defined between the outer drum and the inner drum. A build platform is supported for linear movement within the powder receiving chamber from a first position adjacent a first end of the drums to a second position within the powder receiving chamber. The build platform is rotationally fixed relative to at least one of the inner or outer drums such that the build platform rotates with the drums. At least one directed energy source is positioned above the build platform and is configured to apply directed energy to at least a portion of the powder receiving chamber.

Abstract: Methods and systems for fabricating a component by consolidating a particulate include a build platform configured to receive a particulate, a particulate dispenser configured to deposit the particulate on the build platform, and at least one print head including at least one jet. The at least one print head is configured to dispense a binder through the at least one jet onto the particulate to consolidate at least a portion of the particulate and form a component. The methods and systems also include at least one actuator assembly configured to rotate at least one of the at least one print head and the build platform about a rotation axis extending through the build platform and move at least one of the at least one print head and the build platform in a build direction perpendicular to the build platform as part of a helical build process for the component.

Abstract: The invention relates to an additive production method involving the production of a layer of geometrically compact particles, having the following steps: a) providing a particle layer depositing arrangement, comprising a first and a second semi-chamber, wherein a partition separates the first semi-chamber from the second semi-chamber, and the partition is permeable for a dispersion medium and impermeable for particles dispersed in the dispersion medium; b) providing a particle dispersion comprising the dispersion medium and particles dispersed therein in the first semi-chamber, the particle dispersion being distributed substantially homogenously in the first semi-chamber; c) generating a pressure gradient between the first and the second semi-chamber such that the pressure gradient in the first semi-chamber causes a particle dispersion flow directed towards the partition; and d) depositing a particle aggregate material comprising geometrically compact particles on the partition by transporting a dispersion a

Abstract: A direct metal laser melting (DMLM) system includes a rotatable base, and a build plate mounted on and supported by the rotatable base, where the build plate includes a build surface. The DMLM system also includes a first actuator assembly, a first powder dispenser disposed proximate the build plate and configured to deposit a weldable powder on the build surface of the build plate. In addition, the DMLM system includes a first powder spreader disposed proximate the build plate and configured to spread the weldable powder deposited on the build surface of the build plate, and a first laser scanner supported by the first actuator assembly in a position relative to the build plate, such that at least a portion of the build surface is within a field of view of the first laser scanner. The first laser scanner is configured to selectively weld the weldable powder. The first laser scanner is further configured to translate axially relative to the build surface on the first actuator assembly.

Abstract: An additive manufacturing system includes a build plate; a deposition system operable to dispense material as a melt pool to grow a workpiece on the build plate; a sensor system operable to determine a temperature of the workpiece being grown on the build plate adjacent to the melt pool; and a heater system operable to selectively heat the workpiece between the melt pool and the build plate.

Abstract: According to one embodiment, a disk device includes a disk-shaped recording medium, a head which processes data on the recording medium, and a housing accommodating the recording medium and the head. The housing includes a base with a side wall, and a cover having a welded portion welded to the side wall by laser welding. The welded portion includes a first welded portion welded to a first region of the side wall and having weld beads with a first shape, and a second welded portion welded to a second region of the side wall and having welded beads with a second shape different from the first shape.

Abstract: Provided is a three-dimensional laminating and shaping apparatus 100 including a column unit 200 that is configured to output an electron beam EB and deflect the electron beam EB toward the front surface of a powder layer 32, an electron detector 72 that is configured to detect electrons that may be emitted in a predetermined direction from the front surface of the powder layer 32 when the powder layer 32 is irradiated with the electron beam EB, a melting judging unit 410 that is configured to generate a melting signal based on the strength of the detection signal from the electron detector 72, and a deflection controller 420 that is configured to receive the melting signal to determine the condition of the irradiation the electron beam.

Abstract: An additive manufacturing system including a build plate and at least two powder reservoirs. The at least two powder reservoirs including a first powder reservoir configured to store a first powder and deposit the first powder onto the build plate, wherein the first powder reservoir is configured to move relative to the build plate, and a second powder reservoir configured to store a second powder and deposit the second powder onto the build plate, wherein the second powder reservoir is configured to move relative to the build plate. The first powder has at least one predetermined characteristic that is different than that of the second powder.

Abstract: The present disclosure provides three-dimensional (3D) printing methods, apparatuses, systems and/or software to form one or more three-dimensional objects, some of which may be complex. The three-dimensional objects may be formed by three-dimensional printing using one or more methodologies. In some embodiments, the three-dimensional object may comprise an overhang portion, such as a cavity ceiling, with diminished deformation and/or auxiliary support structures.

Abstract: The temperature of a molten pool is measured based on an image captured by an infrared camera or the like. A three-dimensional laminating and shaping apparatus include a material ejector that ejects a material of a three-dimensional laminated and shaped object. The three-dimensional laminating and shaping apparatus includes a light beam irradiator that irradiates the ejected material with a light beam. The three-dimensional laminating and shaping apparatus includes an image capturer that captures a molten pool of the material formed by irradiating the ejected material with the light beam. The three-dimensional laminating and shaping apparatus includes a temperature deriving unit that derives a temperature of the molten pool based on a luminance of an image of the molten pool captured by the image capturer.

Abstract: An additive manufacturing system including a build plate and a powder spreading unit having a plurality of recoater blades configured to spread powder onto the build plate. The powder spreading unit including a base member, and the plurality of recoater blades is coupled to the base member and configured to spread powder onto the build plate.

Abstract: An additive manufacturing system including a build plate, at least one recoater blade configured to spread powder onto the build plate, and at least one vibration mechanism coupled to one or more of the build plate and the at least one recoater blade. A controller coupled to the at least one vibration mechanism is configured to control actuation of the at least one vibration mechanism so that vibratory pulses are induced within the powder to effect compaction of the powder on the build plate.

Abstract: A method for producing a layered object includes irradiating a surface layer of the object with an energy beam to create an interaction zone on the surface layer. The method also includes providing relative motion between the energy beam and the surface layer so as to control the interaction between the energy beam and the surface layer. The method also includes introducing feedstock into the interaction zone so that the feedstock melts and forms a hot solidified surface after leaving the interaction zone. The method also includes applying mechanical energy to the hot solidified surface.

Abstract: An additive manufacturing system including a build plate, and at least one powder reservoir configured to store and deposit powder onto the build plate, the at least one powder reservoir including a powder dispensing aperture having a variable size. The powder dispensing unit includes a base member, and the least one powder reservoir coupled to the base member.

Abstract: The invention relates to additive manufacturing field and laser shock peening (LSP) field, in particular to a combined apparatus for layer-by-layer interactive additive manufacturing with laser thermal/mechanical effects. In the apparatus, a LSP module and a SLM module operate in alternate so as to perform LSP for the formed part in the forming process of the formed part, and thereby a better strengthening effect of the formed part is achieved. The invention effectively overcomes the challenges of “shape control” against deformation and cracking of the formed parts incurred by internal stress and “property control” against poor fatigue property of the formed parts incurred by metallurgical defects during additive manufacturing, improves fatigue strength and mechanical properties of the faulted parts, and realizes high-efficiency and high-quality holistic processing of the formed parts.

Abstract: A method is described for manufacturing a three-dimensional product, in particular a hydraulic element, the method encompassing at least the following method steps: Providing a first section of the product to be manufactured, which includes at least one first connection point for a second section of the product to be manufactured; and producing the second section by an additive manufacture in which the at least one first connection point of the first section is used as a substrate for the additive manufacture of the second section.

Abstract: An additive manufacturing system includes at least one imaging device configured to direct electromagnetic radiation towards a build layer of a component positioned within a powder bed of the additive manufacturing system. The additive manufacturing system also includes at least one detector configured to detect the electromagnetic radiation that reflects from the build layer.

Abstract: An additive manufacturing apparatus and corresponding method for building an object by layerwise consolidation of material wherein the apparatus includes a build enclosure containing a build support for supporting the object during the build, a material source for providing material to selected locations for consolidation, a radiation device for generating and directing radiation to consolidate the material at the selected locations and an acoustic sensing system. The acoustic sensing system may be arranged to detect acoustic signals generated in the build enclosure by consolidation of the material with the radiation. The acoustic sensing system may be a passive acoustic sensing system arranged to detect acoustic signals generated in the build enclosure that are indicative of at least one condition of the building process and/or the object.

Abstract: A component is produced in layers by laser melting. A molten pool is created in a bed of powder by a working laser beam. Further auxiliary laser beams are set to a power density that merely slows down the cooling of the material in one zone, but do not cause any renewed melting. In this way, the cooling rate of the microstructure can be set so that an advantageous structural formation develops. This allows for example the mechanical properties of the component produced to be advantageously improved without downstream heat treatments.

Abstract: A robot includes a first member, a second member provided to be capable of turning with respect to the first member, and a gear device configured to transmit a driving force from one side to the other side of the first member and the second member. The gear device includes internal teeth and external teeth provided halfway in a transmission path of the driving force and configured to mesh with each other and lubricant disposed between the internal teeth and the external teeth. An average grain size of a constituent material of the external teeth is smaller than an average grain size of a constituent material of the internal teeth.