Aspects of the present disclosure relate generally to preparing models of three-dimensional structures. In particular, a model of a three-dimensional structure constructed of porous geometries is prepared. A component file including a porous CAD volume having a boundary is prepared. A space including the porous CAD volume is populated with unit cells. The unit cells are populated with porous geometries having a plurality of struts having nodes on each end. The space is populated with at least one elongated fixation element extending beyond the boundary to produce an interlocking feature enabling assembly or engagement with a mating structure.

This invention effectively prevents charge-up of an unsintered region. A three-dimensional laminating and shaping apparatus includes a linear funnel for recoating the material of a three-dimensional laminated and shaped object onto a shaping surface on which the three-dimensional laminated and shaped object is to be shaped. The three-dimensional laminating and shaping apparatus also includes an electron gun for generating an electron beam. The three-dimensional laminating and shaping apparatus further includes a charge shield for shielding the material recoated on the shaping surface when irradiating the material with the electron beam. In addition, the apparatus includes a vertical driving mechanism for vertically moving the charge shield.

Disclosed are designs, methods and systems for manufacturing implants, implant components, features of implant components, and/or related tools using solid freeform fabrication or additive metals technologies.

This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensor; determining an area of the build plane traversed during the scans; determining a thermal energy density for the area of the build plane traversed by the scans based upon the amount of energy radiated and the area of the build plane traversed by the scans; mapping the thermal energy density to one or more location of the build plane; determining that the thermal energy density is characterized by a density outside a range of density values; and thereafter, adjusting subsequent scans of the energy source across or proximate the one or more locations of the build plane.

A turbocharger wheel (4) and shaft (1) assembly exhibits a frustoconical geometry of welding zone contact surfaces extending to the outer circumference of the shaft (1). This frustoconical geometry not only allows continuous centering of the parts (1, 4) during joining, it also eliminates the problem of stress propagation along a plane. The location of the electron beam is shifted so that only the radially outer segment of the frustoconical contact surface is joined by welding, leaving a radially inner unmelted and unfused zone for maintaining firm contact of the oblique surfaces.

A method for hardfacing a metal article is disclosed including applying a first pass of a metal composition to a surface of the metal article along a first application path, applying a second pass of the metal composition to the surface along a second application path, and applying a third pass of the metal composition to the surface along a third application path between the first application path and the second application path. The first pass and the second pass form a hardfacing perimeter, and the third pass fills in the hardfacing perimeter.

A component includes an additively manufactured component with an internal passage; and an additively manufactured elongated member within the internal passage. A method of additively manufacturing a component including additively manufacturing a component with an internal passage; and additively manufacturing an elongated member within the internal passage concurrent with additively manufacturing the component.

In metal powder processing equipment where metal powder is sequentially laminated on a table inside a chamber and laser beam melting or electron beam melting, and shaping by a cutting tool subsequent to the melting are performed, unmolded powder remaining at the time of the melting and cut powder generated by the cutting can be scattered by generating air flow with respect to the cutting tool from either side of a main shaft or a tool holder. As a result, life of the cutting tool is prolonged and quality of a cut surface can be improved.

Various embodiments include approaches for controlling an additive manufacturing (AM) process. In some cases, an AM system includes: a process chamber for additively manufacturing a component, the process chamber at least partially housing a plurality of distinct melting beam scanners, each of the distinct melting beam scanners configured to emit a melting beam, wherein each of the distinct melting beam scanners is independently physically movable within a corresponding region of the process chamber; and a control system coupled with the plurality of distinct melting beam scanners, the control system configured to control movement of at least one of the plurality of distinct melting beam scanners within the corresponding region based upon a geometry of the component.

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved structure formation, part creation and manipulation, use of multiple additive manufacturing systems, and high throughput manufacturing methods suitable for automated or semi-automated factories are also disclosed.