Systems and methods for multi-materials and varying print parameters in Additive Manufacturing systems are provided. In one example, a layer including a first powder material and a second material different from the first powder material are deposited, such that at least a first portion of the first powder material is in a first area that is devoid of the second material. An energy beam is generated and applied to fuse the layer at a plurality of locations. In another example, a layer of a powder material is deposited based on a first subset of parameters. An energy beam is generated based on a second subset of the parameters, and the energy beam is applied to fuse the layer at a plurality of locations based on a third subset of the parameters. At least one of the parameters is set to have different values during a slice printing operation.

A method of providing cooling structure for a component including forming a first cavity in the component and forming a first passageway in the first cavity in fluid communication with a second cavity positioned inside the component, the second cavity in fluid communication with a cooling air source. The method includes forming a unitary insert including a first surface, a second surface, the insert having an inlet formed in the first surface and an outlet formed in the second surface. A second passageway is in fluid communication with the inlet and the outlet. The method includes positioning the insert in the first cavity into fluid communication with the first passageway, the first surface facing the first cavity; and rigidly attaching the insert in the first cavity.

Systems and methods for beam scanning for powder bed fusion (PBF) systems are provided. A PBF apparatus can include a structure that supports a layer of powder material, an energy beam source that generates an energy beam, and a deflector that applies the energy beam to fuse an area of the powder material in the layer at multiple locations, the deflector being further configured to apply the energy beam to each of the locations multiple times. A PBF apparatus can include a deflector configured to provide multiple scans to a layer powder material supported by the structure. A PBF apparatus can include a deflector that applies the energy beam to fuse an area of the powder material in the layer at multiple locations, the deflector being further configured to apply the energy beam in a raster scan.

Systems and methods for reducing charged powder particle scattering in powder-bed fusion (PBF) systems are provided. A PBF apparatus can include a structure that supports a layer of powder material having a plurality of particles of powder. For example, the structure can be a build plate, a build floor, a build piece, etc. The apparatus can also include an energy beam source that generates an energy beam and a deflector that applies the energy beam to fuse an area of the powder material in the layer. The energy beam can electrically charge the particles of powder. The apparatus can also include an electrical system that generates an electrical force between the structure and the charged particles of powder. For example, the electrical system can include a voltage source that applies a first voltage to the structure.

The present invention relates to an apparatus 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 apparatus comprising an electron beam source emanating an electron beam for fusing the powder material in a build tank, a hollow construction having an upper opening and a lower opening, means for moving the hollow construction between a first position and a second position, a synchronising unit for synchronising the movement of a powder distributor for applying the individual layers of powder material on the work table with the movement of the hollow construction so that the hollow metal construction is at the first position when fusing and/or heating the powder layer and at the second position when the powder distributor is distributing the powder material for forming the individual powder layers.

Systems and methods for control in additive manufacturing systems are provided. A powder-bed fusion apparatus can include an energy beam source that generates an energy beam and a deflector that applies the energy beam to fuse powder material to create a 3-D object based on an object model. The system can also include a characterizer that obtains information relating to fusing the powder material. The characterizer can be a sensor that measures the shape of the object, a processor that determines a physics-based model of the object, etc. The system can also include a comparator that determines a variation from the object model based on the information, and a compensator that modifies the application of energy to the powder material based on the variation. For example, applied energy can be increased in areas that require higher energy to completely fuse powder material, such areas of thicker powder layer.

Implants are formed from a multiple staged process that combines both additive and subtractive techniques. Additive techniques melt powders and fragments of a desired material, then successively layer the molten material into the desired implant shape, without compressing or remelting for homogenization of the layers, thereby producing an implant that is substantially free of pores and inclusions. Subtractive techniques refine implant surfaces to produce a bioactive roughened surface comprised of macro, micro, and nano structural features that facilitate bone growth and fusion.

Implants are formed from a multiple staged process that combines both additive and subtractive techniques. Additive techniques melt powders and fragments of a desired material, then successively layer the molten material into the desired implant shape, without compressing or remelting for homogenization of the layers, thereby producing an implant that is substantially free of pores and inclusions. Subtractive techniques refine implant surfaces to produce a bioactive roughened surface comprised of macro, micro, and nano structural features that facilitate bone growth and fusion.

Composite metallic-ceramic construction blades for gas turbine engine compressor or turbine sections. A ceramic splice component, such as a squealer or other blade tip, or leading edge, mechanically interlocks with a metallic blade body, including a superalloy blade body. Respective interlocking mechanical joint portions of the ceramic splice component and metallic blade body are subsequently held in an interlocked position by a separately applied and independent metallic retainer member. Methods for manufacture of such composite blades are also useful for repair or retrofitting of non-composite, metallic blades.

In an additive manufacturing apparatus using electron beam melting for manufacturing three-dimensional structures by laminating layers in which metal powder is selectively molten-solidified with electron beam, defect in current apparatus is to be removed such that electrons accelerated with a constant accelerating voltage are irradiated irrespective of filling rate or density of metal powder to be used for additive manufacturing. Voltage of power supply applied between a grid and an anode provided in an electron gun for generating electron beam is varied corresponding to filling rate and/or density of metal powder. With this, velocity of electron such that a position where thermal energy becomes maximum is taken as most suitable can be obtained.