In the context of additive manufacturing processes wherein an object is built by layered accumulations of discrete instantaneous deposits of feedstock material at specific locations according to a three-dimensional digital data model, systems and methods are taught for operating multiple independently-moving depositing devices in a shared build space to build the object. In some embodiments, depositing components perform discrete material depositing actions according to sequential lists of deposit location instructions which are dynamically sortable, enabling a control methodology to alleviate collision risks among depositing components and to improve thermal conditions of a workpiece during construction. Further embodiments provide for dynamic apportionment of discrete deposition actions among the available depositing devices for load balancing and fault tolerance.

In the context of additive manufacturing processes wherein an object is built by layered accumulations of discrete instantaneous deposits of feedstock material at specific locations according to a three-dimensional digital data model, systems and methods are taught for operating multiple independently-moving depositing devices in a shared build space to build the object. In some embodiments, depositing components perform discrete material depositing actions according to sequential lists of deposit location instructions which are dynamically sortable, enabling a control methodology to alleviate collision risks among depositing components and to improve thermal conditions of a workpiece during construction. Further embodiments provide for dynamic apportionment of discrete deposition actions among the available depositing devices for load balancing and fault tolerance.

An additive manufacturing system includes an ultrasonic inspection system integrated in such a way as to minimize time needed for an inspection process. The inspection system may have an ultrasonic phased array integrated into a build table for detecting defects in each successive slice of a workpiece and such that each slice may be re-melted if and when defects are detected.

An additive manufacturing system includes an ultrasonic inspection system integrated in such a way as to minimize time needed for an inspection process. The inspection system may have an ultrasonic phased array integrated into a build table for detecting defects in each successive slice of a workpiece and such that each slice may be re-melted if and when defects are detected.

A method for providing control data for manufacturing at least one three-dimensional object by means of a layer-wise solidification of a building material in an additive manufacturing apparatus is provided. The method includes at least the following steps: a) determining the locations corresponding to the cross section of the at least one object, b) determining at least two different regions to be solidified in said at least one layer, wherein said at least two regions are chosen from the group of: sandwiched region, down-facing region and up-facing region, c) defining a scanning sequence for the beam so as to solidify the building material at least at the locations corresponding to said portion of the cross section of the object, wherein at an interface between a first and a second region differing from each other a scan line of the beam is continuous and at least one beam parameter value is changed.

A method for providing control data for manufacturing at least one three-dimensional object by means of a layer-wise solidification of a building material in an additive manufacturing apparatus is provided. The method includes at least the following steps: a) determining the locations corresponding to the cross section of the at least one object, b) determining at least two different regions to be solidified in said at least one layer, wherein said at least two regions are chosen from the group of: sandwiched region, down-facing region and up-facing region, c) defining a scanning sequence for the beam so as to solidify the building material at least at the locations corresponding to said portion of the cross section of the object, wherein at an interface between a first and a second region differing from each other a scan line of the beam is continuous and at least one beam parameter value is changed.

The invention relates to an apparatus (10) for producing a three-dimensional workpiece, comprising: a carrier (12) adapted to receive material (14) for producing the workpiece; at least one mobile production unit (24), a moving unit (18) that is adapted to move the mobile production unit (24) relative to the carrier (12) so as to position the mobile production unit (24) oppositely to different sections of the carrier (12); a sensing unit that is adapted to generate sensor signals relating to a relative arrangement of the mobile production unit (24) and the carrier (12); and a control unit that is configured to, in addition to the positioning of the mobile production unit (24) via the moving unit (18), provide at least one fine positioning function to compensate for an offset from a desired relative arrangement of the mobile production unit (24) and the carrier (18) based on the sensor signals generated by the sensing unit. The invention further relates to a method for producing a three-dimensional workpiece.

The invention relates to an apparatus (10) for producing a three-dimensional workpiece, comprising: a carrier (12) adapted to receive material (14) for producing the workpiece; at least one mobile production unit (24), a moving unit (18) that is adapted to move the mobile production unit (24) relative to the carrier (12) so as to position the mobile production unit (24) oppositely to different sections of the carrier (12); a sensing unit that is adapted to generate sensor signals relating to a relative arrangement of the mobile production unit (24) and the carrier (12); and a control unit that is configured to, in addition to the positioning of the mobile production unit (24) via the moving unit (18), provide at least one fine positioning function to compensate for an offset from a desired relative arrangement of the mobile production unit (24) and the carrier (18) based on the sensor signals generated by the sensing unit. The invention further relates to a method for producing a three-dimensional workpiece.

Provided is a method for monitoring 3D printing equipped with a 3D printing slicer and a recursive loop structure. A 3D printing method according to an embodiment of the present invention sets up a slicing environment for 3D printing of a 3D model, generates a mechanical code by performing slicing according to the setup environment, monitors the status of the 3D printing according to the generated mechanical code, and, depending on the monitoring result, determines whether or not to re-perform the setup and subsequent steps. Accordingly, by semi- or fully automating the 3D printing engineering process, the time and effort for engineering performance involving human participation are reduced, and the human resource is concentrated on a more important area, such that the effects of enhancing the 3D printing output quality and assuring the quality can be expected.

A 3D printer successively fuses sheet material in a stack to form a three-dimensional object. The sheet material may provide a mesh separating islands of material that will be fused to produce the desired three-dimensional object. The mesh provides support for the island material during the fusing process and may be removed afterwards.