The present disclosure generally relates to methods for additive manufacturing (AM) that utilize support leading edge structures in the process of building objects, as well as novel leading edge support structures to be used within these AM processes. The support structure is positioned adjacent the object between the object and a first side of the powder bed. The support structure has a shape that tapers outward in the direction from the first side to the object

A method of making a component of an electric machine using an additive manufacturing process is disclosed. The method includes forming a first lamina of a conductive material, building a first layer of a second material on a first surface of the first lamina, treating the second material on the first surface of the first lamina to define a first insulative layer, and building on the first insulative layer a second lamina of a conductive material. The steps can be repeated iteratively until a desired thickness or number of layers is reached.

A method of making a component of an electric machine using an additive manufacturing process is disclosed. The method includes forming a first lamina of a conductive material, building a first layer of a second material on a first surface of the first lamina, treating the second material on the first surface of the first lamina to define a first insulative layer, and building on the first insulative layer a second lamina of a conductive material. The steps can be repeated iteratively until a desired thickness or number of layers is reached.

A manufacturing apparatus additively shapes an article by sintering or melting and then solidifying a metal powder through irradiation of a shaping optical beam. The manufacturing apparatus includes: a chamber; a metal powder feeding device that feeds the metal powder to an irradiation area; a shaping optical beam irradiation device that applies the shaping optical beam to the metal powder in the irradiation area; an absorptance enhancement assisting unit that performs a predetermined absorptance enhancement assisting treatment on the metal powder; and a shaping unit that, following implementation of the absorptance enhancement assisting treatment, performs a shaping treatment of additively shaping the article by applying the shaping optical beam and thus heating the metal powder to sinter or melt and then solidify.

Systems and methods are disclosed for forming a three-dimensional object using additive manufacturing. One method includes depositing a first amount of powder material onto a powder print bed of a printing system, spreading the first amount of powder material across the powder print bed to form a first layer, measuring a density of powder material within the powder print bed, and adjusting a parameter of the printing system based on the measured density of the powder material within the powder print bed.

Systems and methods are disclosed for forming a three-dimensional object using additive manufacturing. One method includes depositing a first amount of powder material onto a powder print bed of a printing system, spreading the first amount of powder material across the powder print bed to form a first layer, measuring a density of powder material within the powder print bed, and adjusting a parameter of the printing system based on the measured density of the powder material within the powder print bed.

An additive manufacturing system having a heat source for melting powder particles in a desired shape and pattern to produce a product. A secondary heat source is used for heat treating the product to achieve heat treatment. The secondary heat source is used to peen or anneal residual stresses caused by the additive manufacturing process.

A body and a table located on the body that allows powders to be laid thereon by a laying apparatus is disclosed. At least one layer is created by sintering or fusing the powders laid on the table, a part that is produced by piling up the layers using additive manufacturing method, at least one heat source that is located on the body and applies heat treatment to powders laid on the table, at least one sensor for detecting position and operating status of the heat source and at least one control unit controlling the heat source based on information received from the sensor.

A body and a table located on the body that allows powders to be laid thereon by a laying apparatus is disclosed. At least one layer is created by sintering or fusing the powders laid on the table, a part that is produced by piling up the layers using additive manufacturing method, at least one heat source that is located on the body and applies heat treatment to powders laid on the table, at least one sensor for detecting position and operating status of the heat source and at least one control unit controlling the heat source based on information received from the sensor.

A debinder provides for debinding printed green parts in an additive manufacturing system. The debinder can include a storage chamber, a process chamber, a distill chamber, a waste chamber, and a condenser. The storage chamber stores a liquid solvent for debinding the green part. The process chamber debinds the green part using a volume of the liquid solvent transferred from the storage chamber. The distill chamber collects a solution drained from the process chamber and produces a solvent vapor from the solution. The condenser condenses the solvent vapor to the liquid solvent and transfer the liquid solvent to the storage chamber. The waste chamber collects a waste component of the solution.