This disclosure concerns building of three-dimensional objects in a fluidized bed of particles. The invention uses the fluidized bed as a medium for building three-dimensional objects by joining individual particles together in a planned pattern to fabricate a product. The fluid-like properties of the fluidized bed permit movement of computer-controlled, mechanically driven probes through the fluidized medium. The probes deliver adhesives or energy to specific points in the fluidized bed. The adhesives bind the particles together. Energy delivered by the probes causes fusion and welding or chemical bonding of the particles. The invention encompasses any shape, size, or composition of particles. Particles may be joined but not limited to adhesion, welding, and chemical bonding. Auxiliary features include use of stationary or mobile forms, changing the pattern of fluidization, use of multiple probes working simultaneously, and introduction of solid objects into the build, etc., to assist in forming the product.

A method for manufacturing a dust core, includes: applying energy to a surface of a soft magnetic powder coated with an insulating body containing a compound having an aluminum-oxygen bond; exposing the soft magnetic powder to an atmosphere having a dew point of −30° C. or higher and 15° C. or lower under an atmospheric pressure; and forming a molded product by pressing the soft magnetic powder at 20 MPa or more and 400 MPa or less.

An additive manufacturing (AM) system includes a housing defining a chamber and a build platform disposed in a lower portion of the chamber. The AM system includes an upper gas inlet disposed in a side-wall and in an upper portion of the chamber and configured to supply an upper gas flow parallel to the build platform. The AM system includes a lower gas inlet in the lower portion of the chamber, wherein the lower gas inlet includes one or more pairs of dividing walls extending from the side-wall toward the build platform and configured to guide the lower gas flow at one or more flow angles with respect to the build platform. The AM system includes at least one gas delivery mechanisms to regulate flow characteristics of the upper and lower gas flows, and includes a gas outlet to discharge the upper and lower gas flows from the chamber.

An additive manufacturing (AM) system includes a housing defining a chamber and a build platform disposed in a lower portion of the chamber. The AM system includes an upper gas inlet disposed in a side-wall and in an upper portion of the chamber and configured to supply an upper gas flow parallel to the build platform. The AM system includes a lower gas inlet in the lower portion of the chamber, wherein the lower gas inlet includes one or more pairs of dividing walls extending from the side-wall toward the build platform and configured to guide the lower gas flow at one or more flow angles with respect to the build platform. The AM system includes at least one gas delivery mechanisms to regulate flow characteristics of the upper and lower gas flows, and includes a gas outlet to discharge the upper and lower gas flows from the chamber.

A method, apparatus, and program for additive manufacturing. The additive manufacturing device includes a positioning mechanism configured to provide independent movement of at least one build unit in at least two dimensions. The build unit may further include a gasflow device for providing a flow zone along a first direction with relation to the build unit. The build unit may further include a powder delivery mechanism and an irradiation beam directing unit. The irradiation bean unit may follow a first irradiation path, wherein the first irradiation path forms at least a first solidification line and at least a second solidification line formed at an angle other than 0° and 180° with respect to the first solidification line. During the formation of the first solidification line, the build unit may be positioned in a first orientation such that the first direction of the flow zone is substantially perpendicular to the first solidification line. During the formation of the second solidification line, the build unit may be positioned in a second orientation such that the flow zone along the first direction is substantially perpendicular to the second solidification line.

A method, apparatus, and program for additive manufacturing. The additive manufacturing device includes a positioning mechanism configured to provide independent movement of at least one build unit in at least two dimensions. The build unit may further include a gasflow device for providing a flow zone along a first direction with relation to the build unit. The build unit may further include a powder delivery mechanism and an irradiation beam directing unit. The irradiation bean unit may follow a first irradiation path, wherein the first irradiation path forms at least a first solidification line and at least a second solidification line formed at an angle other than 0° and 180° with respect to the first solidification line. During the formation of the first solidification line, the build unit may be positioned in a first orientation such that the first direction of the flow zone is substantially perpendicular to the first solidification line. During the formation of the second solidification line, the build unit may be positioned in a second orientation such that the flow zone along the first direction is substantially perpendicular to the second solidification line.

Disclosed is a method of generating a ceiling gas stream in the course of the generative manufacturing of a three-dimensional object in a process chamber by a layer-by-layer application and selective solidification of a building material within a build area arranged in the process chamber. The process chamber has a chamber wall having a process chamber ceiling lying above the build area. A ceiling gas stream of a process gas is passed through the process chamber which is streaming from the process chamber ceiling towards the build area in a controlled manner. In the course of this, the ceiling gas stream is supplied to the process chamber through ceiling inlets formed in the process chamber ceiling such that the ceiling gas stream is directed substantially perpendicularly to the build area downwards onto the build area as it exits the ceiling inlets.

Disclosed is a method of generating a ceiling gas stream in the course of the generative manufacturing of a three-dimensional object in a process chamber by a layer-by-layer application and selective solidification of a building material within a build area arranged in the process chamber. The process chamber has a chamber wall having a process chamber ceiling lying above the build area. A ceiling gas stream of a process gas is passed through the process chamber which is streaming from the process chamber ceiling towards the build area in a controlled manner. In the course of this, the ceiling gas stream is supplied to the process chamber through ceiling inlets formed in the process chamber ceiling such that the ceiling gas stream is directed substantially perpendicularly to the build area downwards onto the build area as it exits the ceiling inlets.

A powder cleaning system can include a fluidized bed reactor configured to retain powder and fluidize the powder to remove adsorbate and/or other contaminants from the powder, at least one inlet line, and one or more gas sources configured to be in selective fluid communication with the fluidized bed reactor via the at least one inlet line to selectively provide an inlet flow having one or more gases to the fluidized bed reactor to fluidize the powder with the one or more gases within the fluidized bed reactor. The system can include at least one outlet line in fluid communication with the fluidized bed reactor and configured to allow removal of outlet flow which comprises the adsorbate and/or other contaminants from the fluidized bed reactor.

A method of making a negative electrode material for an electrochemical cell that cycles lithium ions is provided that includes centrifugally distributing a molten precursor comprising silicon and lithium by contacting the molten precursor with a rotating surface in a centrifugal atomizing reactor. The molten precursor is solidified to form a plurality of substantially round solid electroactive particles comprising an alloy of lithium and silicon and having a D50 diameter of less than or equal to about 20 micrometers. In certain variations, the negative electroactive material particles may further have one or more coatings disposed thereon, such as a carbonaceous coating and/or an oxide-based coating.