A computing device for controlling the operation of an additive manufacturing machine comprises a memory element and a processing element. The memory element is configured to store a three-dimensional model of a part to be manufactured, wherein the three-dimensional model defines a plurality of cross sections of the part. The processing element is in communication with the memory element. The processing element is configured to receive the three-dimensional model, determine a plurality of paths, each path including a plurality of parallel lines, determine a radiation beam power for each line, such that the radiation beam power varies non-linearly according to a length of the line, and determine a radiation beam scan speed for each line, such that the radiation beam scan speed is a function of a temperature of a material used to manufacture the part, the length of the line, and the radiation beam power for the line.

The present invention is related to additive manufacturing methods and systems using a recoater with in-situ exchangeable recoater blades. Being able to switch out recoater blades in situ, i.e. without stopping the build and opening up the build chamber, is advantageous, especially for larger, more complicated, and/or longer builds. For instance, if a recoater blade becomes damaged, a new one can be readily swapped in. Or if a different material for the object(s) is used during the build, it may be advantageous to switch in a new recoater blade that is made of the new, different material.

A computing device for controlling the operation of an additive manufacturing machine comprises a memory element and a processing element. The memory element is configured to store a three-dimensional model of a part to be manufactured, wherein the three-dimensional model defines a plurality of cross sections of the part. The processing element is in communication with the memory element. The processing element is configured to receive the three-dimensional model, determine a path across a surface of each cross section, wherein the path includes a plurality of parallel lines, calculate a power for a radiation beam to scan each of the lines, such that the power varies from line to line non-linearly according to a length of the line, and calculate a scan speed for the radiation beam for each of the lines, such that the scan speed varies line to line non-linearly according to the power of the radiation beam.

A flow-conducting component having at least one functional region for contact with a flowing medium and at least one functional region having supporting characteristics is provided. The two functional regions are produced from a material by successively solidifying layers using radiation in a manner that provides different material characteristics in the different functional regions.

A method of manufacturing and measuring the geometry of at least a part of a component, and a method of manufacturing a component, both include providing a powder layer to a melt region; selectively melting the powder layer using an energy source, the melted powder subsequently solidifying to form a solid layer; scanning the melt region, including the solid layer, using a scanning electron beam; detecting backscattered electrons resulting from the interaction of the scanning electron beam with the melt region; determining the geometry of the solid layer from the detected backscattered electrons; and storing data relating to the determined geometry of the solid layer. The methods may also include adjusting parameters of the steps of providing a powder layer and/or selectively melting the powder layer to avoid future recurring errors, or generating a virtual 3-D model of the manufactured component, using the stored data.

An article and method of forming an article are provided. The article includes a body portion having an inner surface and an outer surface, the inner surface defining an inner region, and at least one cooling feature positioned within the inner region. The body portion includes a first material and the at least one cooling feature includes a second material, the second material having a higher thermal conductivity than the first material. The method includes manufacturing a body portion by an additive manufacturing technique and manufacturing at least one cooling feature by the additive manufacturing technique. The body portion includes a first material and the at least one cooling feature includes a second material, the second material having a higher thermal conductivity than the first material.

A method of manufacturing a component includes providing a powder layer; scanning the powder layer using an electron beam; detecting back scattered electrons produced by the interaction of the electron beam with the powder layer; identifying, from the detected back scattered electrons, any defects in the powder layer; selectively melting at least a part of the powder layer so as to generate a solid layer; and repeating these steps at least once so as to build up a shape corresponding to the component. The method may also includes steps of making a decision about whether to remove any identified defects in the powder layer, and adjusting one or more parameters of the step of providing a powder and/or adjusting one or more parameters of the selective melting step so as to avoid future recurring defects at that position based on stored data relating to the scanned powder layer.

The present invention relates to a joining component (10) with a joining surface (12) which has an application area (14) to which a joining material (16) is pre-applied and which can be later activated by means of heat treatment, wherein the application area (14) has a retentive surface structure with elevations (20) forming material undercuts (26), and the joining material (16) at least partially covers the application area (14) and is introduced into the material undercuts (26).

The present disclosure generally relates to additive manufacturing systems and methods on a large-scale format. One aspect involves a build unit that can be moved around in three dimensions by a positioning system, building separate portions of a large object. The build unit has an energy directing device that directs, e.g., laser or e-beam irradiation onto a powder layer. In the case of laser irradiation, the build volume may have a gasflow device that provides laminar gas flow to a laminar flow zone above the layer of powder. This allows for efficient removal of the smoke, condensates, and other impurities produced by irradiating the powder (the gas plume) without excessively disturbing the powder layer. The build unit may also have a recoater that allows it to selectively deposit particular quantities of powder in specific locations over a work surface to build large, high quality, high precision objects.

Components and methods of producing hybrid additively manufactured components. A component produced using stock or traditionally produced materials as one section of the finished component and an additively manufactured portion as a second section of the finished component. The component and method of producing the component may be used, along with other benefits to decreased tooling/manufacturing time, decreased cost, and decreased waste of materials. Further the disclosure provides an improved method of producing structurally optimized components.