Systems and methods for additive manufacturing are generally described. In some embodiments, an additive manufacturing system may include at least one mechanical fixture in the form of a resilient member for accurately biasing one or more optical fibers into alignment features (e.g., grooves formed in a fiber holder) to maintain a desired position and/or orientation of the fiber without the use of adhesives. In some embodiments, the additive manufacturing system may include magnetic elements configured to facilitate precise and accurate assembly of one or more housing elements without significant manual alignment. In some embodiments, the additive manufacturing system may include an active cooling system including channels to direct cooling fluid through the system to absorb thermal energy and reduce the risk of localized hot spots. The cooling system may direct cooling fluid flow in one or more directions along the axial dimension of the one or more optical fibers.
Additive manufacturing systems and related methods are disclosed. In some embodiments, a first motion stage may be used to move a recoater and an optics assembly. The optics assembly may be configured to direct laser energy from one or more laser energy sources towards a build plate. The recoater may be configured to form a layer of precursor material on the build plate. In some embodiments, a secondary housing formed of a composite material may be used.
The techniques described herein relate to controlling a geometry of melt pools in additive manufacturing systems. An example method comprises directing laser energy from laser energy source(s) through an optics assembly and toward a build surface; melting at least a portion of a layer of material on the build surface due to exposure of the portion to the laser energy; and controlling a geometry of melt pools at end portions of scanning trajectories followed by the laser energy source(s), a first scanning trajectory of the scanning trajectories including one or more first scans in a first scanning orientation and a second scanning trajectory of the scanning trajectories including one or more second scans in a. second scanning orientation. Controlling the geometry of melt pools comprises controlling parameter(s) of the laser energy source(s) at end portions of the first scan(s) and at end portions of the second scan(s).
Systems and methods involved in additive manufacturing are disclosed. Calibrating one or more optical cameras of an additive manufacturing system includes controlling one or more laser energy sources to form a design on a surface. The design is a two-dimensional array of elements, at least two elements of the array differing in shape and/or orientation from each other. The method also includes obtaining one or more images of the design based on using the one or more cameras, and analyzing the one or more images by implementing one or more algorithms to determine or update parameters for each of the one or more cameras. The parameters of each of the one or more cameras include extrinsic parameters relating a printer coordinate system of the one or more laser energy sources and an image coordinate system of the camera, intrinsic parameters controlling image distortion resulting from lens properties, or both.
Systems and methods for supporting a plurality of cables of an additive manufacturing system. A cable carrier having first and second ends may be configured to support the plurality of cables within a channel of the cable carrier. The cable carrier may be pivotably supported via a first and second coupling engageable with the first and second ends, respectively. The first and second couplings may be attached to first and second components of an additive manufacturing system, respectively. The couplings may be configured to permit rotation of the first and second ends of the cable carrier in response to movement of the second end and/or the second component in a direction transverse to a plane in which the cable carrier lies.
B22F 12/00 - Apparatus or devices specially adapted for additive manufacturingAuxiliary means for additive manufacturingCombinations of additive manufacturing apparatus or devices with other processing apparatus or devices
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
6.
METHOD AND APPARATUS FOR POWDER MATERIAL HANDLING IN ADDITIVE MANUFACTURING
System and method for dispensing powder material for an additive manufacturing system. A preload container can be configured to hold a predetermined amount of powder material, and move the powder material from a powder supply to a powder recoater. The preload container may be configured to hold an amount of powder suitable for forming multiple powder layers on a build surface and may be configured to rapidly deliver the powder material to a powder recoater, e.g., in less than 10 seconds. The powder material in the preload container and/or the powder supply may be maintained in an isolated environment, e.g., during transfer of powder material from the powder supply to the preload container. A seal may have a movable portion configured to interface between the powder supply and a recoater hopper.
Systems and methods for providing a component to and/or removing a component from a printer enclosure of an additive manufacturing system. A chamber may be configured to removably receive and hold a component such as a build volume having a build surface on which a manufactured part is to be formed. One or more portions of the chamber may interact with the component to define a sealed internal space that may be isolated from an external environment and/or purged with inert gas. The chamber and component may be moved independent of a printer enclosure while the sealed internal space is isolated, and the chamber and printer enclosure may sealingly engage for transfer of the component from the chamber into and/or out of the printer enclosure.
B22F 12/00 - Apparatus or devices specially adapted for additive manufacturingAuxiliary means for additive manufacturingCombinations of additive manufacturing apparatus or devices with other processing apparatus or devices
B22F 10/32 - Process control of the atmosphere, e.g. composition or pressure in a building chamber
B22F 12/88 - Handling of additively manufactured products, e.g. by robots
Systems and methods for providing gas flow characteristics for gas heads for additive manufacturing. A gas head may have a tubular arrangement with proximal and distal openings to allow flow through the gas head from the distal to proximal opening. A gas head may draw gas including process ejecta into and through the gas head in two different directions, which may be along corresponding scan directions and transverse to a plane of a proximal opening or proximal edge of the gas head. A gas head may include an inlet at a bottom wall of the gas head to receive process ejecta between the bottom wall and a build surface and/or to influence movement of process ejecta in the gas head interior volume. Various levels of gas flow may be provided for exhaust ports of a gas head and/or for different gas heads by operating one or more flow control valves.
Systems and methods for additive manufacturing are generally provided. The systems and methods provided herein may allow one or more build surfaces to be aligned with a formation plane and locked into a desired pose. Such systems and methods may have advantages for parallelized additive manufacturing and/or for additive manufacturing of features on parts manufactured without additive manufacturing.
System and method for dispensing powder material for an additive manufacturing system. A hopper can include a spline configured for rotation to dispense powder material from an exit opening of the hopper. A shield can be provided for one or both ends of the spline to help control powder movement at an interface with the spline, e.g., so powder that passes the interface is trapped in a space. An auger can be provided in a hopper and configured for moving powder in the hopper in two opposed directions in response to rotation of the auger in a single direction. A common drive can be used to move both an auger and spline. One or more load cells can be provided to determine a mass of powder delivered to and/or dispensed from the hopper.
A system may include a build plate aligned with a build plate plane and at least one build plate actuator operatively coupled to the build plate and configured to change a pose of the build plate plane. The build plate may be configured to receive a layer of material. One or more distance sensors may be configured to obtain build plate distance information including a relative distance between a reference frame of an optics assembly and the build plate and/or the build surface of the layer of material. At least one processor may be configured to receive the build plate and/or build surface distance information from the one or more distance sensors, and command the at least one build plate actuator to adjust the pose of the build plate plane based at least partly on the build plate and/or build surface distance information.
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/194 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control during lay-up
A mounting system for a build plate of an additive manufacturing system includes a build plate, a build plate support structure, and at least one clamp assembly. The build plate has a build surface and a coupling surface opposite the build surface. The build plate support structure is in supportive contact with the coupling surface of the build plate, and the build plate support structure supports the build plate during an additive manufacturing process. Each clamp assembly has a coupling member extending between the build plate support structure and the build plate, and each coupling member engages with the coupling surface of the build plate. Each clamp assembly resiliently biases the build plate towards the build plate support structure when the coupling member is engaged with the build plate.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
Systems and methods for additive manufacturing are generally described. In some embodiments, an additive manufacturing system may include an optical sensing system. The optical sensing system may include a housing with an inlet to a chamber configured to receive a laser energy beam emitted from a laser energy source, an optics module, an optical interferometer, and a photosensitive sensor array. In some embodiments, the optical sensing system may include a gas inlet configured to direct a flow of gas from a gas source into the chamber such that a pressure within the chamber is greater than a pressure in an environment surrounding the chamber, thereby pushing contaminants away from the chamber. In some embodiments, the optical sensing system may include one or more transparent debris barriers disposed along an optical path of the laser energy beam.
The techniques described herein relate to build plan generation for additive manufacturing (AM) systems. An example method for determining a configuration of an AM system comprises slicing a three-dimensional model of a part to be fabricated by the AM system into at least one layer including a first layer, determining a surrounding volume ratio of a first volume of fused material surrounding one or more voxels and a total volume surrounding the one or more voxels for respective features of the first layer including a first feature, identifying at least one portion of the first feature as a first subregion of the first layer based on determining that a surrounding volume ratio of the at least one portion satisfies a threshold, mapping at least the surrounding volume ratio to one or more configuration parameters of the AM system, and fabricating the first subregion using the one or more configuration parameters.
Disclosed embodiments are generally related to recoater assemblies for additive manufacturing systems. In some embodiments, a recoater blade may include a plurality of flexible portions that are configured to deflect relative to one another when moved over and past a defect on a build surface. In other embodiments, a recoater assembly may include compliant attachments that exhibit compliances that increase in an outward direction relative to a central portion of a body of the recoater assembly. In still other embodiments, a pair of scoops may be disposed on opposing end portions of a recoater blade and/or recoater assembly to help guide and collect excess powder dispensed onto a build surface.
Disclosed embodiments are generally related to recoater assemblies for additive manufacturing systems. In some embodiments, a recoater blade may include a plurality of flexible portions that are configured to deflect relative to one another when moved over and past a defect on a build surface. In other embodiments, a recoater assembly may include compliant attachments that exhibit compliances that increase in an outward direction relative to a central portion of a body of the recoater assembly. In still other embodiments, a pair of scoops may be disposed on opposing end portions of a recoater blade and/or recoater assembly to help guide and collect excess powder dispensed onto a build surface.
Systems and methods involved in additive manufacturing are disclosed. One or more optical fibers optically couple one or more laser energy sources and an optics assembly. One or more photosensitive detectors are arranged along a length of the one or more optical fibers between an output of the one or more laser energy sources and an input of the optics assembly. Each photosensitive detector among the one or more photosensitive detectors is in a contact-less arrangement with one or more of the two or more optical fibers. Each photosensitive detector among the one or more photosensitive detectors detects fiber fuse-generated propagation of plasma through the one or more optical fibers. The system also includes one or more processors arranged to receive signals from the one or more photosensitive detectors and to control operation of the one or more laser energy sources based at least in part on the signals.
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/268 - Arrangements for irradiation using laser beamsArrangements for irradiation using electron beams [EB]
Methods for registering one or more laser energy pixels on a build surface to at least one laser energy source of the plurality of laser energy sources and/or determining an operating state of the at least one laser energy source are described. In some embodiments, a photosensitive detector may capture at least one image of the build surface with one or more laser energy pixels formed thereon. A reference frame of the photosensitive detector may be registered with a reference frame of the one or more laser energy pixels based at least in part on an identified location of the one or more laser energy pixels within the at least one image. This may include using a characteristic spatial frequency of the laser energy pixels within the at least one image. In some embodiments, at least one image including a weld pattern of a part being formed may be compared to an expected weld pattern to determine an operating state of the at least one laser energy source during operation.
Methods for registering one or more laser energy pixels on a build surface to at least one laser energy source of the plurality of laser energy sources and/or determining an operating state of the at least one laser energy source are described. In some embodiments, a photosensitive detector may capture at least one image of the build surface with one or more laser energy pixels formed thereon. A reference frame of the photosensitive detector may be registered with a reference frame of the one or more laser energy pixels based at least in part on an identified location of the one or more laser energy pixels within the at least one image. This may include using a characteristic spatial frequency of the laser energy pixels within the at least one image. In some embodiments, at least one image including a weld pattern of a part being formed may be compared to an expected weld pattern to determine an operating state of the at least one laser energy source during operation.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
Fiber optic laser energy paths including photonic lanterns for use in additive manufacturing systems are disclosed. According to some embodiments, a plurality of photonic lanterns are configured to combine laser energy from a plurality of laser energy sources. According to other embodiments, a first plurality of photonic lanterns may combine laser energy from a plurality of laser energy sources and a second plurality of photonic lanterns may furcate the combined laser energy and direct the furcated laser energy to form a plurality of laser energy pixels on a build surface. Laser energy paths including photonic lanterns my provide enhanced control and redundancy within an additive manufacturing system. The disclosure may apply to laser paths for all types of additive manufacturing systems. Some disclosed embodiments are directed to powder bed fusion additive manufacturing systems including a plurality of laser power sources.
Systems and methods for monitoring light emitted from a build surface as well as other sources during an additive manufacturing process are disclosed. Systems and methods for monitoring laser energy directed towards a build surface during an additive manufacturing process are also disclosed.
A method for monitoring an additive manufacturing process comprises directing laser energy from one or more laser energy sources onto a build surface, emitting and/or reflecting light from the build surface including a plurality of wavelengths of light, and splitting the emitted light into at least a first range of wavelengths of light and a second range of wavelengths of light different from the first range of wavelengths of light. The method may further comprise sensing the first range of wavelengths of light with a first photosensitive detector and sensing the second range of wavelengths of light with a second photosensitive detector.
Disclosed embodiments relate to additive manufacturing systems. In some embodiments, an additive manufacturing system includes a fixed build plate, and a build volume extends above the fixed build plate. A boundary of the build volume may be defined by a powder containing shroud that is vertically displaceable relative to the fixed build plate. A powder deposition system is configured to deposit a powder layer along an upper surface of the build volume and the powder deposition is vertically displaceable relative to the fixed build plate. An optics assembly configured to direct laser energy from one or more laser energy sources towards the build volume, and exposure of the powder layer to the laser energy melts at least a portion of the powder layer. In some embodiments, the build plate may be supported by support columns configured to maintain the build plate in a level orientation throughout a build process.
B23K 26/064 - Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
B22F 10/368 - Temperature or temperature gradient, e.g. temperature of the melt pool
B22F 10/40 - Structures for supporting workpieces or articles during manufacture and removed afterwards
B22F 12/00 - Apparatus or devices specially adapted for additive manufacturingAuxiliary means for additive manufacturingCombinations of additive manufacturing apparatus or devices with other processing apparatus or devices
B22F 12/17 - Auxiliary heating means to heat the build chamber or platform
Disclosed embodiments relate to additive manufacturing systems. In some embodiments, an additive manufacturing system may include a plurality of laser energy sources, an optics assembly configured to direct laser energy onto a build surface, and an optical fiber connector positioned between the plurality of laser energy sources and the optics assembly. A first plurality of optical fibers may extend between the plurality of laser energy sources and the optical fiber connector, and a second plurality of optical fibers may extend between the optical fiber connector and the optics assembly. Each optical fiber of the first plurality of optical fibers may be coupled to a corresponding optical fiber of the second plurality of optical fibers within the optical fiber connector.
A hopper for dispensing powder material for an additive manufacturing system includes a gate that is movable along a first direction to open and close a discharge slot and which is pivotable about a pivot axis transverse to the first direction. The first direction can be a horizontal direction and the pivot axis can be parallel to a vertical direction. The gate can have a portion that contacts the hopper, e.g., at a surface including the discharge slot, and is elastically deformed with movement from the open to the closed position.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/255 - Enclosures for the building material, e.g. powder containers
An additive manufacturing system has a build surface supporting a precursor material to be fused by incident light energy. The system includes an optics assembly to direct the incident light energy along a beam path in a first direction toward the build surface, and an energy management system. The energy management system includes a beam block disposed along the beam path. The beam block has an aperture allowing the incident light energy to pass through the beam block in the first direction. The beam block also has a surface to absorb or deflect, away from the beam path, light energy traveling in a second direction different from the first direction. The energy management system also includes a heat sink to receive heat energy from at least a portion of the light energy traveling in the second direction.
B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
Systems and methods for predicting weld and/or part defects during additive manufacturing process are disclosed. Additionally, systems and methods related to controlling an additive manufacturing process using predicted weld and/or build defects are disclosed.
B23K 31/12 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to investigating the properties, e.g. the weldability, of materials
An additive manufacturing system includes a build surface, one or more laser energy sources, and an optics assembly movable relative to the build surface. The optics assembly directs laser energy from the one or more laser energy sources toward the build surface to fuse a portion of a precursor material on the build surface. A gas head is operatively coupled to the optics assembly and movable relative to the build surface. The gas head entrains emitted materials released during fusion of the precursor material. The system also includes a gas head cleaning device having a scraper to remove debris from a surface of the gas head.
A support for a build table for use with an additive manufacturing system. Two or more actuators may be coupled to the build table and configured to move the build table in a Z direction, e.g., for deposition of multiple precursor material layers, and rotate the build table about axes parallel to a build surface, e.g., to level the build surface. Couplings for one or more actuator may provide pivotal movement about at least two orthogonal axes and linear movement along only one direction parallel to the build surface.
B22F 12/00 - Apparatus or devices specially adapted for additive manufacturingAuxiliary means for additive manufacturingCombinations of additive manufacturing apparatus or devices with other processing apparatus or devices
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
30.
CONTROL OF ADDITIVE MANUFACTURING SYSTEMS INCLUDING MULTIPLE LASER ENERGY SOURCES
Additive manufacturing systems and methods related to the selection and use of groups of laser pixels from an array of laser pixels including a plurality of laser pixels are disclosed. According to some embodiments a plurality of laser pixels may be divided into one or more groups of laser pixels based on one or more process parameters and/or based on the identification of failed laser pixels. The groups may be include fewer laser pixels than the overall array of laser pixels. In some embodiments, an additive manufacturing system may switch between laser pixel groups during a manufacturing process to provide redundancy and/or to enable continued operation of the system even when laser pixel failures occur.
An additive manufacturing system has an optics assembly to direct laser energy toward a build surface to fuse a portion of a precursor material on the build surface. An optics shield of the additive manufacturing system has a debris shield including an optical window. The optical window permits laser energy to pass through the debris shield and prevents fusion products released during fusion of the precursor material from contacting a portion of the optics assembly. The optics shield has a gas flow passage between the optical window and the build surface. The gas flow passage directs a flow of gas away from the optical window to resist movement of the fusion products through the gas flow passage toward the debris shield.
B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
Additive manufacturing systems and their methods of use are disclosed. According to some embodiments, a delivery portion of small optical fiber is optically coupled to a large optical fiber by an adiabatic fiber taper. In some instances, an additional reducing taper may be included between the small optical fiber and the adiabatic fiber taper. Increasing the transverse dimension and therefore the cross sectional area of the optical fiber path may reduce the power and/or energy density near the termination of the laser path. Decreased power and/or energy density may provide increased life, reliability, and contamination tolerance of the optic fibers, termination surfaces, and other components located along an optical path connected to a laser energy source.
B28B 1/00 - Producing shaped articles from the material
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/268 - Arrangements for irradiation using laser beamsArrangements for irradiation using electron beams [EB]
A hopper for dispensing powder material for an additive manufacturing system includes a gate that is movable along a first direction to open and close a discharge slot and which is pivotable about a pivot axis transverse to the first direction. The first direction can be a horizontal direction and the pivot axis can be parallel to a vertical direction. The gate can have a portion that contacts the hopper, e.g., at a surface including the discharge slot, and is elastically deformed with movement from the open to the closed position.
An additive manufacturing system has a build surface supporting a precursor material to be fused by incident light energy. The system includes an optics assembly to direct the incident light energy along a beam path in a first direction toward the build surface, and an energy management system. The energy management system includes a beam block disposed along the beam path. The beam block has an aperture allowing the incident light energy to pass through the beam block in the first direction. The beam block also has a surface to absorb or deflect, away from the beam path, light energy traveling in a second direction different from the first direction. The energy management system also includes a heat sink to receive heat energy from at least a portion of the light energy traveling in the second direction.
B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
G02B 7/00 - Mountings, adjusting means, or light-tight connections, for optical elements
B29C 64/268 - Arrangements for irradiation using laser beamsArrangements for irradiation using electron beams [EB]
G02B 26/08 - Optical devices or arrangements for the control of light using movable or deformable optical elements for controlling the direction of light
An additive manufacturing system includes a build surface, one or more laser energy sources, and an optics assembly movable relative to the build surface. The optics assembly directs laser energy from the one or more laser energy sources toward the build surface to fuse a portion of a precursor material on the build surface. A gas head is operatively coupled to the optics assembly and movable relative to the build surface. The gas head entrains emitted materials released during fusion of the precursor material. The system also includes a gas head cleaning device having a scraper to remove debris from a surface of the gas head.
B08B 1/16 - Rigid blades, e.g. scrapersFlexible blades, e.g. wipers
B08B 5/02 - Cleaning by the force of jets, e.g. blowing-out cavities
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
Additive manufacturing systems and their methods of use are disclosed. According to some embodiments, a delivery portion of small optical fiber is optically coupled to a large optical fiber by an adiabatic fiber taper. In some instances, an additional reducing taper may be included between the small optical fiber and the adiabatic fiber taper. Increasing the transverse dimension and therefore the cross sectional area of the optical fiber path may reduce the power and/or energy density near the termination of the laser path. Decreased power and/or energy density may provide increased life, reliability, and contamination tolerance of the optic fibers, termination surfaces, and other components located along an optical path connected to a laser energy source.
Additive manufacturing systems and methods related to the selection and use of groups of laser pixels from an array of laser pixels including a plurality of laser pixels are disclosed. According to some embodiments a plurality of laser pixels may be divided into one or more groups of laser pixels based on one or more process parameters and/or based on the identification of failed laser pixels. The groups may be include fewer laser pixels than the overall array of laser pixels. In some embodiments, an additive manufacturing system may switch between laser pixel groups during a manufacturing process to provide redundancy and/or to enable continued operation of the system even when laser pixel failures occur.
In some embodiments, systems and methods are related to identifying recoating defects based at least in part on imaged light intensities are disclosed. In other embodiments, systems and methods for predicting the formation of part defects during an additive manufacturing process based at least in part on information related to the presence of recoating defects are disclosed.
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
B22F 12/90 - Means for process control, e.g. cameras or sensors
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/268 - Arrangements for irradiation using laser beamsArrangements for irradiation using electron beams [EB]
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
39.
METHOD AND APPARATUS FOR BUILD SURFACE SUPPORT IN ADDITIVE MANUFACTURING SYSTEM
A support for a build table for use with an additive manufacturing system. Two or more actuators may be coupled to the build table and configured to move the build table in a Z direction, e.g., for deposition of multiple precursor material layers, and rotate the build table about axes parallel to a build surface, e.g., to level the build surface. Couplings for one or more actuator may provide pivotal movement about at least two orthogonal axes and linear movement along only one direction parallel to the build surface.
B29C 64/232 - Driving means for motion along the axis orthogonal to the plane of a layer
B29C 64/188 - Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
40.
METHOD AND APPARATUS FOR OFFSETTING REFLECTED LIGHT ENERGY IN ADDITIVE MANUFACTURING SYSTEM
Light energy directed toward a build surface can be deflected by a deflection optical element at a location and at an angle suitable to offset light energy reflected by a melt pool at the build surface from the location. The reflected light energy can be offset a distance to prevent the reflected light energy from traveling a coincident path of incident light energy and to cause the reflected light energy to be received by a light absorbing element.
In some embodiments, systems and methods are related to identifying recoating defects based at least in part on imaged light intensities are disclosed. In other embodiments, systems and methods for predicting the formation of part defects during an additive manufacturing process based at least in part on information related to the presence of recoating defects are disclosed.
Additive manufacturing systems and related methods directed to load balancing and power optimization for one or more additive manufacturing systems are disclosed. In some embodiments this may include load balancing and power optimization of a plurality of simultaneously running additive manufacturing processes. In some embodiments, one or more additive manufacturing systems may utilize coordinated timing of energy sources, such as laser energy sources, to reduce a maximum combined power during operation of these systems. In other embodiments, the orientations of parts being manufactured may be selected to reduce a maximum energy consumption per layer and/or a variation of energy consumption between layers during additive manufacturing of the parts. The disclosed part orientation and system timing coordination may either be used individually or in combination with one another.
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/268 - Arrangements for irradiation using laser beamsArrangements for irradiation using electron beams [EB]
An electrostatic recoater having an electrode and dielectric shield mounted to a lower surface of the electrode. The dielectric shield and electrode can be movable relative to each other at an interface and/or the dielectric shield may be removably mounted to the electrode.
Light energy directed toward a build surface can be deflected by a deflection optical element at a location and at an angle suitable to offset light energy reflected by a melt pool at the build surface from the location. The reflected light energy can be offset a distance to prevent the reflected light energy from traveling a coincident path of incident light energy and to cause the reflected light energy to be received by a light absorbing element.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/268 - Arrangements for irradiation using laser beamsArrangements for irradiation using electron beams [EB]
45.
SYSTEMS AND METHODS FOR PREDICTING PART DEFECTS DURING ADDITIVE MANUFACTURING
Systems and methods for predicting weld and/or part defects during additive manufacturing process are disclosed. Additionally, systems and methods related to controlling an additive manufacturing process using predicted weld and/or build defects are disclosed.
An electrostatic recoater having an electrode and dielectric shield mounted to a lower surface of the electrode. The dielectric shield and electrode can be movable relative to each other at an interface and/or the dielectric shield nay be removably mounted to the electrode. For example, systems that use laser energy to melt metal-based precursor material create significant heat at the build surface that may not quickly dissipate. Thus, when a recoater moves over the build surface to smooth a layer of precursor material, the recoater may be exposed to relatively high temperatures. The high temperature environment and/or high electric field requirements for electrostatic recoaters can expose a recoater to extreme conditions that can cause a recoater to fail, e.g., due to thermal stresses.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
An additive manufacturing system has an optics assembly to direct laser energy toward a build surface to fuse a portion of a precursor material on the build surface. An optics shield of the additive manufacturing system has a. debris shield including an optical window. The optical window permits laser energy to pass through the debris shield and prevents fusion products released during fusion of the precursor material from contacting a portion of the optics assembly. The optics shield has a. gas flow passage between the optical window and the build surface. The gas flow passage directs a flow of gas away from the optical window to resist movement of the fusion products through the gas flow passage toward the debris shield.
B08B 5/02 - Cleaning by the force of jets, e.g. blowing-out cavities
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
Laser control systems and related methods for controlling arrays of lasers are disclosed. A laser control system may include a first controller configured to generate a trigger signal based on a position of a laser array, and a second controller configured to send a firing signal to one or more lasers of the laser array upon receiving the trigger signal. The one or more lasers may be selected based on a desired pattern of laser energy to be formed at a particular position of the laser array.
Systems and methods for additive manufacturing are generally disclosed. Additive manufacturing may be performed in a continuous manner and/or semi-continuous manner by transporting one or more build plates relative to printheads that comprise a plurality of energy source arrays and/or binderjet arrays that may be selectively activated to form a desired pattern in a material layer disposed on the one or more build plates.
Systems and methods for additive manufacturing are generally disclosed. Additive manufacturing may be performed in a continuous manner and/or semi-continuous manner by transporting one or more build plates relative to a plurality of printheads that comprise a plurality of energy source arrays and/or binderjet arrays that may be selectively activated to form a desired pattern in a material layer disposed on the one or more build plates. The plurality of energy source arrays may be disposed in a plurality of optical assemblies.
Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be adjustable along multiple degrees of freedom relative to a build surface, which may allow for adjustment of a spacing between the recoater assembly and the build surface and/or an orientation of the recoater assembly relative to an orientation of the build surface. In some embodiments, the recoater assembly may be supported by four support columns extending above the build surface, and attachments between the recoater assembly and the support columns may be independently adjustable to adjust the recoater relative to the build surface.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/371 - Conditioning of environment using an environment other than air, e.g. inert gas
An additive manufacturing system may include a build surface and an optics assembly movable relative to the build surface. The optics assembly may direct laser energy from one or more laser energy sources toward the build surface to melt a portion of the build surface. The system may further comprise a gas flow head operatively coupled to the optics assembly and moveable relative to the build surface. The gas flow head may define a partially enclosed volume between the optics assembly and the build surface. The gas flow head may generate a non-uniform flow of gas through the gas flow head in a direction that is opposite a direction of motion of the optics assembly. A velocity of the gas flow may be sufficient to entrain particles ejected from the melted portion of the layer of material in order to remove the ejected particles from the partially enclosed volume.
An additive manufacturing system may include a build surface and an optics assembly movable relative to the build surface. The optics assembly may direct laser energy from one or more laser energy sources toward the build surface to melt a portion of the build surface. The system may further comprise a gas flow head operatively coupled to the optics assembly and moveable relative to the build surface. The gas flow head may define a partially enclosed volume between the optics assembly and the build surface. The gas flow head may generate a non-uniform flow of gas through the gas flow head in a direction that is opposite a direction of motion of the optics assembly. A velocity of the gas flow may be sufficient to entrain particles ejected from the melted portion of the layer of material in order to remove the ejected particles from the partially enclosed volume.
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
An additive manufacturing system may include a build surface, one or more laser energy sources, and an optics assembly. Exposure of a layer of material on the build surface to laser energy from the optics assembly melts at least a portion of the layer of material. A gas flow head is coupled to the optics assembly and defines a partially enclosed volume between the optics assembly and the build surface. The gas flow head includes a gas inflow through which a supply gas flows into the gas flow head, a gas outflow through which a return gas flows out of the gas flow head, and an aperture arranged to permit transmission of the laser energy through the gas flow head to the build surface. The supply gas and return gas define a gas flow profile within the gas flow head.
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B23K 26/064 - Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms
B23K 26/14 - Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beamNozzles therefor
B23K 26/142 - Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beamNozzles therefor for the removal of by-products
B23K 26/082 - Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
55.
OPTICAL FIBER MODULES FOR ADDITIVE MANUFACTURING SYSTEMS
Systems and methods for additive manufacturing are generally described. In some embodiments, an additive manufacturing system may include at least one mechanical fixture in the form of a resilient member for accurately positioning one or more optical fibers without the use of adhesives. The resilient member may, in some embodiments, bias each optical fiber (or similarly, an endcap coupled to a distal end of an optical fiber) against an alignment fixture to maintain a desired position and/or orientation of the fiber or endcap. In some embodiments, an additive manufacturing system may include at least one stray light baffle for reducing the amount of stray light within the optical system.
Systems and methods for additive manufacturing are generally described. In some embodiments, an additive manufacturing system may include at least one mechanical fixture in the form of a resilient member for accurately positioning one or more optical fibers without the use of adhesives. The resilient member may, in some embodiments, bias each optical fiber (or similarly, an endcap coupled to a distal end of an optical fiber) against an alignment fixture to maintain a desired position and/or orientation of the fiber or endcap. In some embodiments, an additive manufacturing system may include at least one stray light baffle for reducing the amount of stray light within the optical system.
Methods and apparatuses for additive manufacturing are described. A method for additive manufacturing may include exposing a layer of material on a build surface to one or more projections of laser energy including at least one line laser having a substantially linear shape. The intensity of the line laser may be modulated so as to cause fusion of the layer of material according to a desired pattern as the one or more projections of laser energy are scanned across the build surface.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B22F 3/16 - Both compacting and sintering in successive or repeated steps
B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be used to deposit a material layer onto a build surface of an additive manufacturing system. In some instances, the recoater assembly may include a powder entrainment system that trails behind a recoater blade of the recoater assembly relative to a direction of motion of the recoater blade across a build surface of the additive manufacturing system. The powder entrainment system may generate a flow of fluid across a portion of the build surface behind the recoater blade that at least temporarily entrains powder above a threshold height from the build surface to mitigate, or prevent, the formation of defects on the build surface with heights greater than the threshold height.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
Systems and methods for additive manufacturing are generally described. According to certain aspects, endcaps optically coupled to optical fibers of additive manufacturing systems are provided. In some aspects, methods for reducing a power area density of laser energy within an endcap are provided. The endcaps described herein may be used to at least partially mitigate thermal cycling that may result from the transmission of laser energy through interfaces of an additive manufacturing system.
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
60.
OPTICAL FIBERS INCLUDING ENDCAPS FOR USE IN ADDITIVE MANUFACTURING
Systems and methods for additive manufacturing are generally described. According to certain aspects, endcaps optically coupled to optical fibers of additive manufacturing systems are provided. In some aspects, methods for reducing a power area density of laser energy within an endcap are provided. The endcaps described herein may be used to at least partially mitigate thermal cycling that may result from the transmission of laser energy through interfaces of an additive manufacturing system.
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
B23K 26/06 - Shaping the laser beam, e.g. by masks or multi-focusing
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/268 - Arrangements for irradiation using laser beamsArrangements for irradiation using electron beams [EB]
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
B22F 12/41 - Radiation means characterised by the type, e.g. laser or electron beam
B23K 26/064 - Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms
B29C 64/20 - Apparatus for additive manufacturingDetails thereof or accessories therefor
61.
ADDITIVE MANUFACTURING SYSTEMS AND RELATED METHODS UTILIZING RISLEY PRISM BEAM STEERING
Additive manufacturing systems and related methods are disclosed. In some embodiments, an additive manufacturing system includes a build surface, one or more laser energy sources configured to emit laser energy, an optical phased array operatively coupled to the one or more laser energy sources, and a Risley prism assembly comprising a plurality of wedge prisms. The optical phased array includes one or more phase shifters operatively coupled to the one or more laser energy sources and configured to control a phase of the laser energy. The optical phased array is configured to direct the laser energy towards the Risley prism assembly, and the Risley prism assembly is configured to direct the laser energy towards the build surface.
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B22F 12/90 - Means for process control, e.g. cameras or sensors
B22F 10/366 - Scanning parameters, e.g. hatch distance or scanning strategy
G02B 26/08 - Optical devices or arrangements for the control of light using movable or deformable optical elements for controlling the direction of light
G02F 1/295 - Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulatingNon-linear optics for the control of the position or the direction of light beams, i.e. deflection in an optical waveguide structure
62.
ADDITIVE MANUFACTURING SYSTEMS AND RELATED METHODS UTILIZING RISLEY PRISM BEAM STEERING
Additive manufacturing systems and related methods are disclosed. In some embodiments, an additive manufacturing system includes a build surface, one or more laser energy sources configured to emit laser energy, an optical phased array operatively coupled to the one or more laser energy sources, and a Risley prism assembly comprising a plurality of wedge prisms. The optical phased array includes one or more phase shifters operatively coupled to the one or more laser energy sources and configured to control a phase of the laser energy. The optical phased array is configured to direct the laser energy towards the Risley prism assembly, and the Risley prism assembly is configured to direct the laser energy towards the build surface.
Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be adjustable along multiple degrees of freedom relative to a build surface, which may allow for adjustment of a spacing between the recoater assembly and the build surface and/or an orientation of the recoater assembly relative to an orientation of the build surface. In some embodiments, the recoater assembly may be supported by four support columns extending above the build surface, and attachments between the recoater assembly and the support columns may be independently adjustable to adjust the recoater relative to the build surface.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be used to deposit a material layer onto a build surface of an additive manufacturing system. In some instances, the recoater assembly may include a powder entrainment system that trails behind a recoater blade of the recoater assembly relative to a direction of motion of the recoater blade across a build surface of the additive manufacturing system. The powder entrainment system may generate a flow of fluid across a portion of the build surface behind the recoater blade that at least temporarily entrains powder above a threshold height from the build surface to mitigate, or prevent, the formation of defects on the build surface with heights greater than the threshold height.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be used to deposit a material layer onto a build surface of an additive manufacturing system. In some instances, the recoater assembly may include a powder entrainment system that trails behind a recoater blade of the recoater assembly relative to a direction of motion of the recoater blade across a build surface of the additive manufacturing system. The powder entrainment system may generate a flow of fluid across a portion of the build surface behind the recoater blade that at least temporarily entrains powder above a threshold height from the build surface to mitigate, or prevent, the formation of defects on the build surface with heights greater than the threshold height.
Optics assemblies and their methods of use in additive manufacturing systems are described. In some embodiments, an additive manufacturing system may include a build surface, a plurality of laser energy sources configured to produce a plurality of laser spots on the build surface, and an optics assembly configured to independently control a size of each of the plurality of laser spots and a spacing between the plurality of laser spots on the build surface. The optics assembly may include a plurality of lens arrays, where the plurality of lens arrays is configured to adjust a size of each of the plurality of laser spots on the build surface, and at least one lens. The at least one lens may also be configured to adjust a spacing between the plurality of laser spots on the build surface.
B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
B22F 12/00 - Apparatus or devices specially adapted for additive manufacturingAuxiliary means for additive manufacturingCombinations of additive manufacturing apparatus or devices with other processing apparatus or devices
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
Optics assemblies and their methods of use in additive manufacturing systems are described. In some embodiments, an additive manufacturing system may include a build surface, a plurality of laser energy sources configured to produce a plurality of laser spots on the build surface, and an optics assembly configured to independently control a size of each of the plurality of laser spots and a spacing between the plurality of laser spots on the build surface. The optics assembly may include a plurality of lens arrays, where the plurality of lens arrays is configured to adjust a size of each of the plurality of laser spots on the build surface, and at least one lens. The at least one lens may also be configured to adjust a spacing between the plurality of laser spots on the build surface.
Build plate assemblies and their methods of use for an additive manufacturing system are disclosed. In some embodiments, a build plate assembly may include a build plate with a build surface and one or more recesses formed in the build plate. One or more inserts may be inserted into the corresponding one or more recesses of the build plate such that a portion of the one or more inserts are accessible through one or more corresponding openings formed in the build surface associated with the recesses.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B23K 26/34 - Laser welding for purposes other than joining
B23K 37/04 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work
Build plate assemblies and their methods of use for an additive manufacturing system are disclosed. In some embodiments, a build plate assembly may include a build plate with a build surface and one or more recesses formed in the build plate. One or more inserts may be inserted into the corresponding one or more recesses of the build plate such that a portion of the one or more inserts are accessible through one or more corresponding openings formed in the build surface associated with the recesses.
Systems and methods for additive manufacturing are described. In some embodiments, a method of controlling the one or more laser energy sources of an additive manufacturing system may be based at least in part on a scan angle and/or desired energy density. Systems and methods for controlling melt pool spacing are also described.
Systems and methods for additive manufacturing are described. In some embodiments, a method of controlling the one or more laser energy sources of an additive manufacturing system may be based at least in part on a scan angle and/or desired energy density. Systems and methods for controlling melt pool spacing are also described.
Systems and methods for additive manufacturing are described. In some embodiments, a method of controlling a weld height in an additive manufacturing process includes determining a desired melt pool width based, at least in part, on a desired weld height; selectively activating one or more laser energy sources based, at least in part, on the desired melt pool width; and melting a portion of a layer of material on a build surface via exposure to laser energy from the one or more activated laser energy sources to form a melt pool on the build surface having the desired melt pool width. Systems and methods to the use of staggered laser energy sources are also described.
Systems and methods for additive manufacturing are described. In some embodiments, a method of controlling a weld height in an additive manufacturing process includes determining a desired melt pool width based, at least in part, on a desired weld height; selectively activating one or more laser energy sources based, at least in part, on the desired melt pool width; and melting a portion of a layer of material on a build surface via exposure to laser energy from the one or more activated laser energy sources to form a melt pool on the build surface having the desired melt pool width. Systems and methods to the use of staggered laser energy sources are also described.
B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
74.
ADDITIVE MANUFACTURING SYSTEMS AND RELATED METHODS UTILIZING OPTICAL PHASED ARRAY BEAM STEERING
Methods and systems for additive manufacturing are described. In one embodiment, laser energy is emitted from one or more laser energy sources, and a phase of the laser energy emitted by each of the laser energy sources is controlled to at least partially control a position of one or more laser beams directed towards a build surface. In some embodiments an optical phased array (OPA) is used to at least partially control the position and/or shape of the one or more laser beams on the build surface. Additionally, in some embodiments one or more mirror galvanometers and/or a moveable portion of a system may be used in coordination with one or more OPA assemblies.
G02F 1/29 - Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulatingNon-linear optics for the control of the position or the direction of light beams, i.e. deflection
75.
ADDITIVE MANUFACTURING SYSTEMS AND RELATED METHODS UTILIZING OPTICAL PHASED ARRAY BEAM STEERING
Methods and systems for additive manufacturing are described. In one embodiment, laser energy is emitted from one or more laser energy sources, and a phase of the laser energy emitted by each of the laser energy sources is controlled to at least partially control a position of one or more laser beams directed towards a build surface. In some embodiments an optical phased array (OPA) is used to at least partially control the position and/or shape of the one or more laser beams on the build surface. Additionally, in some embodiments one or more mirror galvanometers and/or a moveable portion of a system may be used in coordination with one or more OPA assemblies.
B23K 26/04 - Automatically aligning, aiming or focusing the laser beam, e.g. using the back-scattered light
B23K 26/06 - Shaping the laser beam, e.g. by masks or multi-focusing
B23K 26/082 - Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
B23K 26/144 - Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beamNozzles therefor the fluid stream containing particles, e.g. powder
Methods and apparatuses for additive manufacturing are described. A method for additive manufacturing may include exposing a layer of material on a build surface to one or more projections of laser energy including at least one line laser having a substantially linear shape. The intensity of the line laser may be modulated so as to cause fusion of the layer of material according to a desired pattern as the one or more projections of laser energy are scanned across the build surface.
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/268 - Arrangements for irradiation using laser beamsArrangements for irradiation using electron beams [EB]
B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
B23K 26/34 - Laser welding for purposes other than joining
Aspects described herein relate to additive manufacturing systems and related methods. An additive manufacturing system may include two or more laser energy sources and associated optical fibers. An optics assembly may be constructed and arranged to form a rectangular laser energy pixel associated with each laser energy source. Each pixel may have a substantially uniform power density, and the pixels may be arranged to form a linear array of laser energy pixels on a build surface with no spacing between the pixels. Exposure of a portion of a layer of material on the build surface to the linear array of laser energy pixels may melt the portion of the layer.
B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
B22F 10/36 - Process control of energy beam parameters
B22F 12/00 - Apparatus or devices specially adapted for additive manufacturingAuxiliary means for additive manufacturingCombinations of additive manufacturing apparatus or devices with other processing apparatus or devices
B22F 12/41 - Radiation means characterised by the type, e.g. laser or electron beam
Aspects described herein relate to additive manufacturing systems and related methods. In some embodiments, an additive manufacturing system includes a laser array position detector to determine a position and/or orientation of laser energy pixels in a laser array. The laser array position detector may include an aperture and an optical sensor positioned within the aperture to detect laser energy from a laser energy pixel when the laser array is scanned across the aperture.
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/268 - Arrangements for irradiation using laser beamsArrangements for irradiation using electron beams [EB]
B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
Aspects described herein relate to additive manufacturing systems and related methods. In some embodiments, an additive manufacturing system includes a laser array position detector to determine a position and/or orientation of laser energy pixels in a laser array. The laser array position detector may include an aperture and an optical sensor positioned within the aperture to detect laser energy from a laser energy pixel when the laser array is scanned across the aperture.
B29C 64/282 - Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED] of the same type, e.g. using different energy levels
B29C 64/277 - Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
B29C 64/386 - Data acquisition or data processing for additive manufacturing
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B23K 26/082 - Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be adjustable along multiple degrees of freedom relative to a build surface, which may allow for adjustment of a spacing between the recoater assembly and the build surface and/or an orientation of the recoater assembly relative to an orientation of the build surface. In some embodiments, the recoater assembly may be supported by four support columns extending above the build surface, and attachments between the recoater assembly and the support columns may be independently adjustable to adjust the recoater relative to the build surface.
Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be adjustable along multiple degrees of freedom relative to a build surface, which may allow for adjustment of a spacing between the recoater assembly and the build surface and/or an orientation of the recoater assembly relative to an orientation of the build surface. In some embodiments, the recoater assembly may be supported by four support columns extending above the build surface, and attachments between the recoater assembly and the support columns may be independently adjustable to adjust the recoater relative to the build surface.
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be adjustable along multiple degrees of freedom relative to a build surface, which may allow for adjustment of a spacing between the recoater assembly and the build surface and/or an orientation of the recoater assembly relative to an orientation of the build surface. In some embodiments, the recoater assembly may be supported by four support columns extending above the build surface, and attachments between the recoater assembly and the support columns may be independently adjustable to adjust the recoater relative to the build surface.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
83.
Optical fiber connector for additive manufacturing system
Disclosed embodiments relate to additive manufacturing systems. In some embodiments, an additive manufacturing system may include a plurality of laser energy sources, an optics assembly configured to direct laser energy onto a build surface, and an optical fiber connector positioned between the plurality of laser energy sources and the optics assembly. A first plurality of optical fibers may extend between the plurality of laser energy sources and the optical fiber connector, and a second plurality of optical fibers may extend between the optical fiber connector and the optics assembly. Each optical fiber of the first plurality of optical fibers may be coupled to a corresponding optical fiber of the second plurality of optical fibers within the optical fiber connector.
Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be adjustable along multiple degrees of freedom relative to a build surface, which may allow for adjustment of a spacing between the recoater assembly and the build surface and/or an orientation of the recoater assembly relative to an orientation of the build surface. In some embodiments, the recoater assembly may be supported by four support columns extending above the build surface, and attachments between the recoater assembly and the support columns may be independently adjustable to adjust the recoater relative to the build surface.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be adjustable along multiple degrees of freedom relative to a build surface, which may allow for adjustment of a spacing between the recoater assembly and the build surface and/or an orientation of the recoater assembly relative to an orientation of the build surface. In some embodiments, the recoater assembly may be supported by four support columns extending above the build surface, and attachments between the recoater assembly and the support columns may be independently adjustable to adjust the recoater relative to the build surface.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/20 - Apparatus for additive manufacturingDetails thereof or accessories therefor
Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be adjustable along multiple degrees of freedom relative to a build surface, which may allow for adjustment of a spacing between the recoater assembly and the build surface and/or an orientation of the recoater assembly relative to an orientation of the build surface. In some embodiments, the recoater assembly may be supported by four support columns extending above the build surface, and attachments between the recoater assembly and the support columns may be independently adjustable to adjust the recoater relative to the build surface.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
87.
OPTICAL FIBER CONNECTOR FOR ADDITIVE MANUFACTURING SYSTEM
Disclosed embodiments relate to additive manufacturing systems. In some embodiments, an additive manufacturing system may include a plurality of laser energy sources, an optics assembly configured to direct laser energy onto a build surface, and an optical fiber connector positioned between the plurality of laser energy sources and the optics assembly. A first plurality of optical fibers may extend between the plurality of laser energy sources and the optical fiber connector, and a second plurality of optical fibers may extend between the optical fiber connector and the optics assembly. Each optical fiber of the first plurality of optical fibers may be coupled to a corresponding optical fiber of the second plurality of optical fibers within the optical fiber connector.
Laser control systems and related methods for controlling arrays of lasers are disclosed. A laser control system may include a first controller configured to generate a trigger signal based on a position of a laser array, and a second controller configured to send a firing signal to one or more lasers of the laser array upon receiving the trigger signal. The one or more lasers may be selected based on a desired pattern of laser energy to be formed at a particular position of the laser array.
Laser control systems and related methods for controlling arrays of lasers are disclosed. A laser control system may include a first controller configured to generate a trigger signal based on a position of a laser array, and a second controller configured to send a firing signal to one or more lasers of the laser array upon receiving the trigger signal. The one or more lasers may be selected based on a desired pattern of laser energy to be formed at a particular position of the laser array.
Disclosed embodiments relate to additive manufacturing systems. In some embodiments, an additive manufacturing system includes a fixed build plate, and a build volume extends above the fixed build plate. A boundary of the build volume may be defined by a powder containing shroud that is vertically displaceable relative to the fixed build plate. A powder deposition system is configured to deposit a powder layer along an upper surface of the build volume and the powder deposition is vertically displaceable relative to the fixed build plate. An optics assembly configured to direct laser energy from one or more laser energy sources towards the build volume, and exposure of the powder layer to the laser energy melts at least a portion of the powder layer. In some embodiments, the build plate may be supported by support columns configured to maintain the build plate in a level orientation throughout a build process.
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
B22F 10/368 - Temperature or temperature gradient, e.g. temperature of the melt pool
B22F 12/00 - Apparatus or devices specially adapted for additive manufacturingAuxiliary means for additive manufacturingCombinations of additive manufacturing apparatus or devices with other processing apparatus or devices
B22F 12/17 - Auxiliary heating means to heat the build chamber or platform
Disclosed embodiments relate to additive manufacturing systems. In some embodiments, an additive manufacturing system includes a fixed build plate, and a build volume extends above the fixed build plate. A boundary of the build volume may be defined by a powder containing shroud that is vertically displaceable relative to the fixed build plate. A powder deposition system is configured to deposit a powder layer along an upper surface of the build volume and the powder deposition is vertically displaceable relative to the fixed build plate. An optics assembly configured to direct laser energy from one or more laser energy sources towards the build volume, and exposure of the powder layer to the laser energy melts at least a portion of the powder layer. In some embodiments, the build plate may be supported by support columns configured to maintain the build plate in a level orientation throughout a build process.
B22F 7/02 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite layers
B23K 13/01 - Welding by high-frequency current heating by induction heating
An additive manufacturing system may include a build surface, one or more laser energy sources, and an optics assembly. Exposure of a layer of material on the build surface to laser energy from the optics assembly melts at least a portion of the layer of material. A gas flow head is coupled to the optics assembly and defines a partially enclosed volume between the optics assembly and the build surface. The gas flow head includes a gas inflow through which a supply gas flows into the gas flow head, a gas outflow through which a return gas flows out of the gas flow head, and an aperture arranged to permit transmission of the laser energy through the gas flow head to the build surface. The supply gas and return gas define a gas flow profile within the gas flow head.
A23G 1/18 - Apparatus for conditioning chocolate masses for moulding
A23G 1/50 - Cocoa products, e.g. chocolateSubstitutes therefor characterised by shape, structure or physical form, e.g. products with an inedible support
An additive manufacturing system includes a build surface, one or more laser energy sources, and an optics assembly. Exposure of a layer of material on the build surface to laser energy from the optics assembly melts at least a portion of the layer of material. A gas flow head is coupled to the optics assembly and defines a partially enclosed volume between the optics assembly and the build surface. The gas flow head includes a gas inflow through which a supply gas flows into the gas flow head, a gas outflow through which a return gas flows out of the gas flow head, and an aperture arranged to permit transmission of the laser energy through the gas flow head to the build surface. The supply gas and return gas define a gas flow profile within the gas flow head.
B33Y 30/00 - Apparatus for additive manufacturingDetails thereof or accessories therefor
B23K 26/064 - Shaping the laser beam, e.g. by masks or multi-focusing by means of optical elements, e.g. lenses, mirrors or prisms
B23K 26/14 - Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beamNozzles therefor
B23K 26/142 - Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beamNozzles therefor for the removal of by-products
B23K 26/082 - Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
Aspects described herein relate to additive manufacturing systems and related methods. An additive manufacturing system may include two or more laser energy sources and associated optical fibers. An optics assembly may be constructed and arranged to form a rectangular laser energy pixel associated with each laser energy source. Each pixel may have a substantially uniform power density, and the pixels may be arranged to form a linear array of laser energy pixels on a build surface with no spacing between the pixels. Exposure of a portion of a layer of material on the build surface to the linear array of laser energy pixels may melt the portion of the layer.
Aspects described herein relate to additive manufacturing systems and related methods. An additive manufacturing system may include two or more laser energy sources and associated optical fibers. An optics assembly may be constructed and arranged to form a rectangular laser energy pixel associated with each laser energy source. Each pixel may have a substantially uniform power density, and the pixels may be arranged to form a linear array of laser energy pixels on a build surface with no spacing between the pixels. Exposure of a portion of a layer of material on the build surface to the linear array of laser energy pixels may melt the portion of the layer.
Methods and apparatuses for additive manufacturing are described. A method for additive manufacturing may include exposing a layer of material on a build surface to one or more projections of laser energy including at least one line laser having a substantially linear shape. The intensity of the line laser may be modulated so as to cause fusion of the layer of material according to a desired pattern as the one or more projections of laser energy are scanned across the build surface.
B22F 3/105 - Sintering only by using electric current, laser radiation or plasma
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
Methods and apparatuses for additive manufacturing are described. A method for additive manufacturing may include exposing a layer of material on a build surface to one or more projections of laser energy including at least one line laser having a substantially linear shape. The intensity of the line laser may be modulated so as to cause fusion of the layer of material according to a desired pattern as the one or more projections of laser energy are scanned across the build surface.
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