Abstract: A method of forming an article in a layer wise manufacturing process from a computer software file representing the article includes dividing the file into sub files in dependence of the size or other characteristics of features of the article to be created, applying a process characteristic selected independence on a characteristic feature to each sub file and manufacturing the article in accordance with the subfiles.

Abstract: A selective laser sintering apparatus is adapted contain or receive a build frame and comprises a cap assembly which includes a removable plate assembly having at least one gas inlet formed therein. The removable plate assembly sealingly covers the build frame. The cap assembly further comprises at least one gas line fluidly connectable to the gas inlet via a gas port to deliver inert gas to the interior of the build frame. The plate assembly comprises upper and lower plates defining a spacing therebetween. A seal extends around a periphery of the upper and lower plates and is sandwiched therebetween to enclose the spacing. The lower plate has a plurality of gas inlets formed therein which are in fluid communication with the spacing such that inert gas may be delivered to the build volume while the cap assembly is installed thereupon.

Abstract: A method of manufacturing an article comprises providing a first sheet, wetting the first sheet with a liquid precursor to provide a first wet sheet, and irradiating the first wet sheet in a pattern corresponding to a first cross section of the article such that the liquid precursor is at least partially converted to a solid in the first cross section. A second sheet is disposed adjacent to the first sheet. The method further comprises wetting the second sheet with the liquid precursor to provide a second wet sheet, and irradiating the second wet sheet in a pattern corresponding to a second cross section of the article such that the liquid precursor is at least partially converted to a solid in the second cross section. In particular the liquid precursor may be converted to a metal, ceramic, semiconductor, semimetal, or a combination of these materials.

Abstract: Inventive machine allowing the simultaneous fabrication of several objects by a method of “rapid prototyping” type, by depositing a succession of layers of heat-fusible fluid. It chiefly comprises a crossbar (20) carrying two platforms (11) on each of which an object is fabricated by deposition. Two fixed work stations are arranged diametrically opposite each other so that the jet (12) of each of these fixed stations can perform a depositing operation at the same time as the other jet (12). After each deposit, the crossbar is rotated 180° to alternate the depositing operations of the two different materials. Particular application to prototyping jewellery models.

Abstract: A device and a method for manufacturing a three-dimensional object (3) by solidifying layers (25) of a material in powder form at those positions corresponding to the respective cross-section of the object (3) are provided. The device comprises an application device (40) for applying layers of the material in powder form (47) in the building area (5), which can be moved over the building area (5). The application device (40) is formed to have a first longitudinal wall (41a) and a second longitudinal wall (41b) that are connected to one another via two side walls. The application device (40) is provided with a fluidization device for homogenizing the material in powder form (47). This fluidization device comprises at least one hollow body having escape openings in its walls, through which escape opening a gas can flow from the hollow body into the material in powder form (47).

Abstract: A process of fabricating aerospace parts using selective laser sintering is provided, wherein the process generally comprises the steps of preparing a powder nylon material, loading the powder nylon material into a laser sintering machine, warming up the powder nylon material according to build warm-up parameters, building the part according to build parameters and part parameters, and cooling down the part according to build cool-down parameters. As a result, parts are produced that are directly used in aerospace structures, which meet the stringent performance requirements of aerospace applications, rather than as rapid prototypes as with conventional selective laser sintering processes. Additionally, specific designs for aerospace parts such as ducts, panels, and shrouds are provided that are produced by the selective laser sintering process.

Abstract: The invention relates to a method producing parts using laser sintering wherein a fusible powder is exposed to a plurality of laser scans at controlled energy levels and for time periods to melt and densify the powder and in the substantial absence of particle bonding outside the fusion boundary. Strength is improved up to 100% compared to previous methods. An example includes a relatively high energy initial scan to melt the powder followed by lower energy scans controlled to densify the melt and separated in time to dissipate heat to the surrounding part cake. The rate and extent to which the powder particles are fused together can be controlled so that each successive scan can be used to fuse the particles together in discreet incremental steps. As a result, the final dimensions of the part and its density and mechanical properties can be improved compared to conventional methods and part growth avoided.

Abstract: Solid free form fabrication techniques such as fused deposition modeling and three-dimensional printing are used to create a shell or die used in the manufacture of a dental restoration. Three-dimensional printing includes ink-jet printing a binder into selected areas of sequentially deposited layers of powder. Each layer is created by spreading a thin layer of powder over the surface of a powder bed. Instructions for each layer may be derived directly from a CAD representation of the restoration. The area to be printed is obtained by computing the area of intersection between the desired plane and the CAD representation of the object. All the layers required for an aesthetically sound shell can be deposited concurrently slice after slice and sintered/cured simultaneously.

Abstract: A method of shaping a green body provides a shaped green body comprised of a plurality of sinterable particles and an organic binder. Such a method includes: (1) molding a mixture of sinterable particles and organic binder into the shape of an initial green body or intermediate, wherein the sinterable particles include at least one of metal particles or ceramic particles; and (2) shaping the green body intermediate with at least one of a stream of energy or a stream of matter, wherein the shaping yields a green body having a desired shape. The shaped green body can be sintered in order to provide a hardened body having substantially the shape of the shaped green body.

Abstract: A device for manufacturing a three-dimensional product, which device comprises a work table on which said three-dimensional product is to be built, a powder dispenser which is arranged to lay down a thin layer of powder on the work table for the formation of a powder bed, a ray gun for giving off energy to the powder whereby fusion of the powder takes place, members for controlling of the beam released by the ray gun across said powder bed for the formation of a cross section of said three-dimensional product through fusion of parts of said powder bed, and a controlling computer in which information about successive cross sections of the three-dimensional product is stored, which cross sections build the three-dimensional product, the controlling computer intended to control said members for guiding the ray gun across the powder bed according to a running schedule forming a cross section of said three-dimensional body, whereby said three-dimensional product is formed by successive fusion of successively forme

Abstract: A light beam is irradiated to sinter powder layers into a plurality of cured layer which are superimposed to each other to fabricate a three-dimensional object. A portion forming an outer shell of the object is given by high-density cured layers, while the other portion is given by low-density cured layers. The high-density cured layer making up at least a side of the object is composed of a high-density primary cured layer obtained by irradiation of a primary irradiation to the powder layer, and a high-density secondary layer obtained by a secondary irradiation to a supplemental powder layer supplied on the high-density primary cured layer. Thus, the high-density cured layer is given a height in level with the low-density cured layer, which assures constant height of each cured layer which is a combination of the high-density cured layer and the low-density cured layer.

Abstract: A light-activatable polymer composition and polymer composite includes a polymer binder selected from epoxy resins, silica filled epoxy, bismaleimide resins, bismaleimide triazines, fluoropolymers, polyesters, polyphenylene oxide/polyphenylene ether resins, polybutadiene/polyisoprene crosslinkable resins (and copolymers), liquid crystal polymers, polyamides, cyanate esters, or combinations thereof, the polymer binder being present in an amount from 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 96, or 97 weight-percent of the total weight of the polymer composition; a spinel crystal filler present in an amount from 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 20, 25, 30, 35, 40, 45, 50, 55 and 60 weight-percent of the total weight of the polymer composition, and methods for making same are provided.

Abstract: A self-contained parts kit is created by forming a container around parts formed using a direct manufacturing process. The formation of the container is part of the same process by which the parts are formed. The container can be formed with one or more openings by which the parts can be removed. The container can also be formed with perforations in one or more surfaces to allow the parts therein to be cleaned without removing the parts, such as by shaking or by the external application of a fluid such as pressurized air. Indicia can also be formed on the container.

Abstract: The invention is a method for controllably cooling at least a portion of a part-cake from a laser sintering system to minimize cool down time, maximize throughput, and minimize thermal gradients within the part-cake. The method generally comprises forming one or more thermal transfer channels within the part-cake. The thermal transfer channels can include ducts and cooling fins in the part-cake surrounding the formed part. The method can further comprise removing unfused powder from the ducts and introducing cooling media into the ducts. The invention also includes a part-cake having thermal transfer channels formed therein and a laser sintering apparatus comprising a part-cake containing cylinder having permanent fittings therein for receiving terminal portions of thermal transfer channels formed in the part-cake.

Abstract: A stereolithography apparatus having a resin vat with resupply containers in one-way flow communication and a leveling container in two-way flow communication, an automatic offload cart to remove and replace build support platforms, an elevator assembly for supporting and releasably retaining a build platform removably attached to the stereolithography apparatus frame such that elevator forks supporting the build platform can be released into the vat and removed from the stereolithography apparatus with the vat, and a recoater assembly and recoater blade for mapping the resin surface in the vat and applying a fresh coating of resin to a cross-section being built in the vat.

Abstract: The present invention provides a method of manufacturing a porous chemical mechanical polishing pad comprising focusing a laser beam from a laser into a sintering nozzle and injecting the fluidized thermoplastic particles into the sintering nozzle via an injection port. The method further provides sintering the thermoplastic particles with the laser beam and selectively depositing the sintered thermoplastic particles onto a table to form the polishing pad.

Abstract: Methods and systems for controlling and adjusting heat distribution over a part bed are disclosed. In one embodiment, a technique for providing a calibrated heat distribution over a part bed includes determining the temperature distribution within a part bed, generating a zone heat distribution for a plurality of heat zones from the temperature distribution, analyzing the zone heat distribution to create an adjustment command to calibrate a heater for providing a substantially consistent temperature distribution within the part bed, and adjusting the heater based on the adjustment command.

Abstract: A method of assembling a first part and a second part. The method includes the step of integrally forming an attachment device and a first part. For example, the attachment device may be a nut plate operative to retain a nut therein, and the first part may be an air duct. The nut plate and the air duct may be integrally formed via selective laser sintering or stereo lithography such that the nut plate is an integral feature of the air duct. A nut may be retained in the nut plate, and a mating bolt may engage the nut to attach the air duct (i.e., the first part) to the second part.

Abstract: The present invention provides selectively laser sintered porous polymeric articles and methods of making and using the same. In one embodiment, a method of the present invention comprises providing a first layer of particles of a first polymeric material, heating selected locations of the first layer to sinter particles of the first polymeric material to form a three-dimensional article, the three-dimensional article having a porosity of at least about 30 percent.

Abstract: Apparatus for producing an object by sequentially forming thin layers of a construction material one on top of the other responsive to data defining the object, the apparatus comprising: a plurality of printing heads each having a surface formed with a plurality of output orifices and controllable to dispense the construction material through each orifice independently of the other orifices; a shuttle to which the printing heads are mounted; a support surface; and a controller adapted to control the shuttle to move back and forth over the support surface and as the shuttle moves to control the printing heads to dispense the construction material through each of their respective orifices responsive to the data to form a first layer on the support surface and thereafter, sequentially the other layers; wherein each printing head is dismountable from the shuttle and replaceable independently of the other printing heads.

Abstract: A method for producing an artificial bone precursor is disclosed. The method comprises: extracting a part corresponding to a cancellous bone and/or a cortical bone from digitalized three-dimensional image data of a living bone, followed by setting a center line on the part; drawing a beam or a wall having a uniform diameter or thickness along the center line to form artificial bone image data; and stacking a sintered layer by laser-sintering a powder of titanium and the like based on the artificial bone image data. The precursor is suitable for an artificial bone having excellent osteoconductivity and osteoinductivity.

Abstract: A method is provided, by which a three-dimensional object is manufactured by a subsequent solidification of layers of a building material in powder form at the positions in the respective layer that corresponds to the cross-section of the object by means of the action of a laser or another energy source, wherein as building material in powder form a material is used which contains the old powder that has remained as unsolidified powder in the manufacturing of one or more previously formed objects and a proportion of new powder that has not been used before in any manufacturing process, characterized in that the building material in powder form is mechanically consolidated when a layer is applied.

Abstract: This invention relates to a device and procedure for the production of a work piece with exact geometry and high surface quality, a form tool in particular. Preferably, the work piece is constructed using a process wherein powder coatings are applied one on top of each other, by means of compaction, said process being computer-controlled. After the powder has been compacted, the surfaces thereof are finely machined in a mechanical manner. During the entire machining process, the work piece to be produced is surrounded with powdery source material.

Abstract: The invention relates to a die consisting of PCBN or a CBN composite material. To fix the die in a tool holder, said die comprises a clamping depression. The die is suitable for machining metals.

Abstract: Apparatuses and methods are described for supplying powder for solid free-form fabrication from a powder supply reservoir (2) that is movable from a servicing position to a dispensing position. The powder supply reservoir may be supported by a horizontally retractable support arm (4). It may also be supported by a support pivot (22), and the support pivot may comprise a horizontally retractable support arm. These features add the convenience of permitting the powder supply reservoir to be serviced outside of a housing that encloses the solid free-form fabrication apparatus during the article-building operation.

Abstract: Systems and methods are disclosed for a platform to form a three-dimensional article from successively selectively solidified layers of a liquid medium which is solidifiable by application thereto of a prescribed energy. The platform can be coated or uncoated. The platform can have an array of openings therethrough. Upon completion, the article can be removed from the platform using a punch having a plurality of projections adapted to engage openings in the platform. Alternatively, a tool can be used to push articles from the platform.

Abstract: A solid imaging apparatus and method employing a radiation transparent build material carrier and a build material dispensing system that accurately controls the thickness of the transferred layer of solidifiable liquid build material to the radiation transparent build material carrier to achieve high resolution imaging in three-dimensional objects built using an electro-optical radiation source.

Abstract: A honeycomb filter includes a pillar-shaped honeycomb structure integrally formed, first and second lamination members, a metal casing containing the honeycomb structure and the lamination member, and first and second end members connected to first and second end portions of the casing, respectively to secure the honeycomb structure and the lamination member. The honeycomb structure includes a wall portion defining through holes which extend substantially along a longitudinal direction of the honeycomb structure, each of the through holes being sealed at either one end portion. Each of the lamination members has aligned through holes extending substantially along the longitudinal direction. The honeycomb structure and lamination members include inorganic fibers oriented substantially perpendicular to the longitudinal direction.

Abstract: A sinter powder containing a polyamide and metal soaps, in particular particles of a salt of an alkanemonocarboxylic acid. A process for laser sintering, and to moldings produced from the sinter powder. The moldings formed using the powder have advantages in appearance and in surface finish when recyclability in the selective laser sintering (SLS) process is taken into account. Moldings produced from recycled sinter powder have improved mechanical properties, in particular in the modulus of elasticity and tensile strain at break.

Abstract: The invention relates to a method for making metallic and/or non-metallic products 2, in particular dental products, by freeform sintering and/or melting, in which the products 2 are fabricated layer by layer from a material 5 that is applied layer by layer by means of a computer-controlled high-energy beam 7, in particular a laser or electron beam. In order to reduce production times, beam 7 irradiates predetermined positions P1 to P6 of a layer of a material 5 a plurality of time, namely m times, where m is a whole integer greater than 1. Each of said positions P1 to P6 is initially heated during the first irradiation to a temperature below the melting point Tmelt of the material 5, and during the mth irradiation to a temperature above said melting point and is completely melted over the entire thickness of the layer in such a way that the material (5) fuses at said position to the layer thereunder. The invention also relates to an apparatus for performing said method.

Abstract: Gas permeable molds and mold segments having open porosity (60) are disclosed. Blind vents (56) in the mold wall's (54) outside surface (52) allow for an uninterrupted molding surface (62) while enhancing the gas permeability provided by the open porosity (60). Methods of making such gas permeable molds include forming them from sintered material. Methods also include the use of solid free-form fabrication followed by sintering. Also disclosed are unitary structures (150), for use in EPS bead molding, having a steam chest portion (152) with gas impermeable walls (156) and a mold section (154) having a gas permeable mold wall (172) having open porosity (176), and, optionally, open and/or blind vents (180, 178). Methods for making such unitary structures (150) include the use of solid free-form fabrication.

Abstract: The invention relates to a method for producing a polymeric optical waveguide-forming master plate, comprising: laying a thread which does not transmit rays used for subsequent exposure on a substrate for a master plate, applying a positive resist material onto the substrate to have a thickness such that, when parallel rays are vertically radiated onto the resist from a side opposite to a substrate side with respect to the thread and then the resist is developed, a layer made of the resist is formed at whole space where the rays have not been radiated; radiating parallel rays substantially vertically to the substrate to expose the resist to the rays; and developing the exposed resist on the substrate to form a convex portion corresponding to a shape of an optical waveguide core, to waveguide production methods using the same, and to the resultant waveguide.

Abstract: A process and a device for producing a three-dimensional object is provided, with which process or device the object is produced by layer-wise solidification of a pulverulent material by sintering of the material at the points corresponding to the cross-section of the object by means of the action of radiation energy. The process comprises the application of a layer of the pulverulent material onto a substrate or a previously sintered layer, pre-heating of the pulverulent material to a working temperature below the temperature at which the powder is sintered and sintering of the material at the points corresponding to the cross-section of the object in the layer, wherein a step of controlled heating of an applied powder layer and of determining the quantity of heat taken up by the powder per (FIG. 3) temperature interval for at least two temperature intervals is carried out.

Abstract: A device for manufacturing a three-dimensional object by a layerwise solidification of a building material in powder form at the positions in the respective layer that correspond to the object to be manufactured is provided. A work plane (4) is provided, in which successively layers of the building material in powder form, which are to be solidified, are applied and are partially solidified. An application device (5) for applying a layer of the building material in the work plane or onto a previously solidified layer of the building material has an application surface (53) facing the work plane (4). An adjustment device (59, 60, 54) is provided that is constructed such that an angle (?) between the application surface (53) and the work plane (4) is adjustable.

Abstract: Apparatus for manufacturing a three-dimensional object (3) by solidifying a powdery constituent material layer by layer at the positions corresponding to the profile of the object (3) to be manufactured in the corresponding layer, by the action of a laser or another energy source comprises a support (2) on which the object (3) is formed and an applicator (6, 7) for applying a layer of the constituent material onto the support or a layer at least partially solidified in advance. The applicator (6, 7) has a receiving device (40) for receiving a applying module such as a blade module (30). The receiving device (40) is formed in a way so that the applying module (30) can be exchangeably inserted into and removed from the receiving device (40) in a way that a predetermined position of the applying module (30) in the receiving device (40) is reproducibly determined.

Abstract: A device (1) for manufacturing a three-dimensional object by a layerwise solidification of a building material at positions in the respective layers that correspond to the object is provided. The device comprises a machine frame (2, 3, 4, 5) and a building space (10) that is positioned in the machine frame; an energy source (6) that emits a beam (9) for selectively solidifying the building material; and a ventilator (54) that generates an airflow (T) for cooling the energy source (6). There are provided connecting channels (55), which lead the airflow (T) onto a partition wall (56) that is limiting the building space (10).

Abstract: A radiant heating for heating the building material in a laser sintering device and a laser sintering device having such a radiant heating are described. The radiant heating has a sheet-like heat radiating element (113, 213, 313), which is characterized in that it is made of a material, that has a low thermal inertia with a thermal diffusivity of preferably more than 1.5·10?4 m2/s and preferably has a thickness of 2 mm or less.

Abstract: A method of forming an extrusion die comprises depositing at least one layer of a sinterable material, such as binder-free sinterable material, in a plane creating a layer of unsintered material, applying irradiation to the at least one layer of unsintered material along a pattern creating a layer of centered material, and forming the extrusion die as a single, integrally-formed piece by repeating the depositing and irradiating steps in a coordinate direction that is substantially orthogonal to the plane, wherein a new layer is superposed upon a previously sintered layer. The extrusion die formed via this method includes an inlet section having a die inlet face and a plurality of feed channels extending from the inlet face toward a honeycomb-forming section that is spaced from the inlet face and terminates in a die outlet face that includes an array of discharge channels formed from pins.

Abstract: Disclosed are methods and systems for selective inhibition of sintering in 3D fabrication. The disclosure provides methods and systems that use selective heating arrangements to selectively sinter areas during fabrication thereby reducing waste improving efficiency.

Abstract: A powder sinter layered manufacturing apparatus is provided with a first container 13 of a cylindrical shape for defining a first manufacturing region, a first manufacturing table 15 configured to move vertically along an inner wall of the first container 13, a second container 17 of the cylindrical shape for defining a second manufacturing region within the first manufacturing region, detachably fitted to the first container easily, and provided with a flange which covers an upper face located outside the second manufacturing region but inside first container 13, and a second manufacturing table 15b configured to move vertically up and down along an inner wall of the second container 17.

Abstract: A method for creating a three-dimensional solid freeform fabrication object with phase-change material includes depositing a bulk amount of phase-change material in a defined region, selectively ink-jetting an ultraviolet initiator onto a predetermined area of the phase-change material, wherein the ultraviolet initiator defines a cross-sectional area of the three-dimensional object, and exposing the ultraviolet initiator to an ultraviolet light to cause cross-linking of the defined region.

Abstract: The invention relates to a method of making a three-dimensional object, comprising the steps of: (a) forming a powder material layer (10) of inorganic material; (b) irradiating an optical beam (L) on a predetermined portion of the powder material layer (10) to form a first sintered layer (11) and integrate the first sintered layer (11) with a second sintered layer (11) just below the first sintered layer (11); (c) repeating the steps (a) and (b) to form a sintered block (B) united with a plurality of the first and second sintered layers (11), the sides of the sintered block (B) including a concave portion (g); (d) removing an excess portion (17) from a surface of the sintered block (B); and (e) repeating the steps (c) and (d) with respect to the sintered block (B) from which the excess portion (17) is removed, in order to make a target shape of a three-dimensional object united with a plurality of the sintered blocks (B).

Abstract: Disclosed are methods and systems for selective inhibition of sintering in 3D fabrication. The disclosure provides methods and systems that use selective heating arrangements to selectively sinter areas during fabrication thereby reducing waste improving efficiency.

Abstract: Process for layer-wise production of a three dimensional body (generative rapid prototyping), in particular by 3D binder printer, including a multiple succession of the steps of depositing a powder particle layer, activating in defined areas an adhesive present on the powder particles and/or in the powder particle coating, as well as adhering the powder particles to each other and to the layer thereunder, wherein the powder particle layer is electrically discharged by ionized particles and brushed flat by means of an electrically insulated blade prior to activation of the adhesive material, and the invention further concerns a device adapted for application of thin powder particle layers, including at least one ionizing device.

Abstract: Defects within structures formed by deposition processes can be relatively expensive, particularly as previously non-destructive testing was performed only once the component had been formed. By in-situ continuous or intermittent sequential non-destructive testing, early notice of defects can be provided. Such early notice may allow rejection of the part-formed component, correction of the errors causing the defect, or through an auto-correction process adjustment of the deposition devices or otherwise to improve component quality. Generally, deposition processes provide for provision of a layer of material which is consolidated in order to form an object component through use of a consolidation device. By providing a non-destructive testing device which either continuously inspects the layers of consolidated component or sequentially inspects the object component, it is possible as indicated to provide an early identification of defect problems within a formed object component.

Abstract: A selective inhibition of sintering (SIS) technique may be used to fabricate a three-dimensional (3-D) dense metal object from a binderless metal powder. Layers of metal powder are provided on a build tank. For each layer, regions of the layer are sinter-inhibited, e.g., by depositing a sinter-inhibiting material such as a ceramic slurry, a metal salt, or oxidizing metal particles in the powder using chemicals or a concentrated heat source. Each layer may be compacted before the next layer is provided. A final compact may then be sintered. Unwanted sintered sections may be removed from the compact at boundaries formed by the sinter-inhibited (unsintered) regions, and the object extracted.

Abstract: A rapid prototype tempering process comprises producing a rapid prototype part from a base material, creating voids in the rapid prototype part, and filling the voids with a filler material that changes at least one characteristic of the prototype part. The rapid prototype part may be made, for example, by stereolithography, selective laser sintering (SLS), extrusion, printhead technology, or the like. The base material is generally a brittle material and the filler material may be selected to enhance the durability of the prototype part, for example. Parts made completely from a filler material that is injected into cavities of molds made from a base material are also disclosed.

Abstract: A composition containing from 88 to 99.99% by weight of a polyamide, a compound of a polyamide and mixtures of these, and from 0.01 to 0.25% by weight of a flow aid where the drying loss from the flow aid after 5 days of conditioning at a relative humidity of 95% is less than or equal to 1%, determined by ISO 787/2.

Abstract: In order for a surface of a three-dimensional sintered object to be smoothly finished by removing unwanted portions and an excessively sintered growth formed during sintering to form sintered layers, the three-dimensional sintered object is formed by repeating successive processes of dispensing a powdery material and directing an optical sintering beam to the powdery material to form the sintered layer, until a required number of integral laminated bodies are formed. During the formation of the integral laminated bodies, trimming is applied to a first zone different from a second zone in which each laminated body is formed, to remove unwanted portions of the respective laminated body.

Abstract: An apparatus for formation of a three dimensional object comprising a sealed container; an electron beam subsystem capable of directing energy within said container; a positioning subsystem contained within said container; a wire feed subsystem contained within said container; an instrumentation subsystem electronically connected to said electron beam subsystem, positioning subsystem, and wire feed subsystem; and a power distribution subsystem electrically connected to said electron beam subsystem, positioning subsystem, wire feed subsystem, and said instrumentation subsystem.