A low-cost ultrasonic system and method that can be used during powder based fusion additive manufacturing to control the microstructural features of parts built in a metallic system. The system and method include the application of laser acoustic emission technology to monitor the metallic microstructure during a build. The system and method can be built into or added onto existing laser-based powder based fusion additive manufacturing machines.

A tooling assembly for mounting a plurality of components, such as compressor blades, in a powder bed additive manufacturing machine to facilitate a repair process is provided. The tooling assembly includes component fixtures configured for receiving each of the compressor blades, a mounting plate for receiving the component fixtures, and a magnet assembly operably coupling the component fixtures to the mounting plate in a desired position and orientation to facilitate an improved printing process.

The present invention relates to a methods, computer program products, program elements, and apparatuses for forming a three-dimensional article through successively depositing individual layers of powder material that are fused together so as to form the article. The method comprising the steps of providing at least one electron beam source emitting an electron beam for at least one of heating or fusing the powder material, where the electron beam source comprises a cathode and an anode, and varying an accelerator voltage between the cathode and the anode between at least a first and second predetermined value during the forming of the three-dimensional article.

The present invention relates to a methods, computer program products, program elements, and apparatuses for forming a three-dimensional article through successively depositing individual layers of powder material that are fused together so as to form the article. The method comprising the steps of providing at least one electron beam source emitting an electron beam for at least one of heating or fusing the powder material, where the electron beam source comprises a cathode and an anode, and varying an accelerator voltage between the cathode and the anode between at least a first and second predetermined value during the forming of the three-dimensional article.

Build material application device for additively manufacturing a three-dimensional object, the build material application device comprising: at least one blade-like build material application member; at least one support unit for supporting the blade-like build material application member, wherein the support unit comprises at least two support unit members defining a receiving section for receiving a blade-like build material application member, a first support unit member is moveably supported relative to a second support unit member between a first operating position, in which a holding force is exertable or exerted on a blade-like build material application member received in the receiving section, and a second operating position, in which no holding force is exertable or exerted on a blade-like build material application member received in the receiving section.

Build material application device for additively manufacturing a three-dimensional object, the build material application device comprising: at least one blade-like build material application member; at least one support unit for supporting the blade-like build material application member, wherein the support unit comprises at least two support unit members defining a receiving section for receiving a blade-like build material application member, a first support unit member is moveably supported relative to a second support unit member between a first operating position, in which a holding force is exertable or exerted on a blade-like build material application member received in the receiving section, and a second operating position, in which no holding force is exertable or exerted on a blade-like build material application member received in the receiving section.

The devices, systems, and methods of the present disclosure are directed to powder spreading and binder distribution techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, a powder may be spread to form a layer along a volume defined by a powder box, a binder may be deposited along the layer to form a layer of a three-dimensional object, and the direction of spreading the layer and depositing the binder may be in a first direction and in a second direction, different from the first direction, thus facilitating rapid formation of the three-dimensional object with each passage of the print carriage over the volume. Powder delivery, powder spreading, thermal energy delivery, and combinations thereof, may facilitate consistently achieving quality standards as the rate of fabrication of the three-dimensional object is increased.

A compactor is disclosed for use with an additive manufacturing print head. The compactor may include a housing connectable to the additive manufacturing print head. The compactor may also include a compacting wheel, and at least one spring disposed in the housing and configured to exert an axial force on the compacting wheel. The compactor may further include a piston moveable to adjust a distance between the housing and the compacting wheel.

Disclosed herein is an additive manufacturing system that includes an energy source, a powder supply, and a build chamber. The build chamber includes a base plate and two or more variable build plates coupled to the base plate. The two or more variable build plates each have one or more adjustable features. The two or more variable build plates are configurable to position two or more parts at different heights relative to a top level of the build chamber. The additive manufacturing system also includes a control system configured to control the energy source to fuse material from the powder supply to at least one of the two or more parts while the two or more parts are respectively positioned by the two or more variable build plates at different heights relative to the top level of the build chamber.

The present disclosure relates to an apparatus for additively manufacturing a product in a layer-by-layer sequence, wherein the product is formed using powder particles deposited on an interface layer of a substrate. A laser generates first and second beam components. The second beam component has a higher power level and a shorter duration than the first beam component. A mask creates a 2D optical pattern in which only select portions of the second beam components can irradiate the powder particles. The first beam component heats the powder particles close to a melting point, where the particles experience surface tension forces relative to the interface layer. While the particles are heated, the second beam component further heats the particles and also melts the interface layer before the surface tension forces can act on and distort the particles, enabling the particles and the interface layer are able to bond together.