A method of manufacturing an article comprises depositing a layering material on a substrate or a worktable; applying a magnetic field to the layering material according to a preset pattern; and additively forming the article.

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.

A complex concentrated alloy (CCA) and/or high entropy alloy (HEA) additive manufacturing nozzle can include a nozzle body defining at least four powder channels. Each powder channel can be configured to be connected to a powder supply of a plurality of powder supplies to receive a powder from the powder supply for ejecting the powder toward a build area to form an additively manufactured article having a CCA and/or an HEA.

A complex concentrated alloy (CCA) and/or high entropy alloy (HEA) additive manufacturing nozzle can include a nozzle body defining at least four powder channels. Each powder channel can be configured to be connected to a powder supply of a plurality of powder supplies to receive a powder from the powder supply for ejecting the powder toward a build area to form an additively manufactured article having a CCA and/or an HEA.

A complex concentrated alloy (CCA) and/or high entropy alloy (HEA) additive manufacturing nozzle can include a nozzle body defining at least four powder channels. Each powder channel can be configured to be connected to a powder supply of a plurality of powder supplies to receive a powder from the powder supply for ejecting the powder toward a build area to form an additively manufactured article having a CCA and/or an HEA.

A nozzle device includes three or more rail members, three or more slider members, three or more arm members, a nozzle portion, and a drive mechanism. The three or more rail members each includes rails parallel with each other. The three or more slider members are connected to the rail members to be movable along the rails, respectively. The three or more arm members are connected to the slider members, and movably and rotatably supported in the rail members through the slider members, respectively. The nozzle portion is rotatably connected to the three or more arm members to inject a material and emit an energy beam. The drive mechanism includes at least five actuators that set one of a relative position and a relative angle between each of combinations of two mutually connected elements among the rail members, the slider members, the arm members, and the nozzle portion.

A lamination molding apparatus, including a chamber covering a molding region; a powder layer forming apparatus to form a material powder layer by discharging the material powder onto the molding region and planarizing the material powder on the molding region; a laser beam emitter to emit a laser beam for sintering the material powder to form a sintered body; a cutting machine to cut the sintered body; a horizontal drive device to move both the cutting machine and the powder layer forming apparatus in a horizontal direction parallel to the molding region; a first vertical drive device to reciprocate the cutting machine in a vertical direction orthogonal to the horizontal direction; and a second vertical drive device to reciprocate the powder layer forming apparatus in the vertical direction, is provided.

A lamination molding apparatus, including a chamber covering a molding region; a powder layer forming apparatus to form a material powder layer by discharging the material powder onto the molding region and planarizing the material powder on the molding region; a laser beam emitter to emit a laser beam for sintering the material powder to form a sintered body; a cutting machine to cut the sintered body; a horizontal drive device to move both the cutting machine and the powder layer forming apparatus in a horizontal direction parallel to the molding region; a first vertical drive device to reciprocate the cutting machine in a vertical direction orthogonal to the horizontal direction; and a second vertical drive device to reciprocate the powder layer forming apparatus in the vertical direction, is provided.

A method for performing sub-surface porosity detection in an additively manufactured part. The method includes providing, by a laser radiation source, a first radiation to a region of a powder bed along a beam of the first radiation, the region of the powder bed being part of a corresponding region of an additively manufactured part. Infrared imaging of the region of the powder bed is performed while the first radiation is being provided to the powder bed. A processor generates data sets indicative of the temperature of the region of the powder bed; and the processor further detects, from the data sets, a defect signature indicative of the formation and/or presence of a sub-surface defect in the region of the additively manufactured part.

A method for performing sub-surface porosity detection in an additively manufactured part. The method includes providing, by a laser radiation source, a first radiation to a region of a powder bed along a beam of the first radiation, the region of the powder bed being part of a corresponding region of an additively manufactured part. Infrared imaging of the region of the powder bed is performed while the first radiation is being provided to the powder bed. A processor generates data sets indicative of the temperature of the region of the powder bed; and the processor further detects, from the data sets, a defect signature indicative of the formation and/or presence of a sub-surface defect in the region of the additively manufactured part.