A laminate shaping method includes: a unit step repeatedly performed, the unit step including a step of forming a laminate shaped portion by laminating metal layers formed of weld beads, and a step of forming a processed side surface by cutting a shaped portion side surface facing a second direction intersecting a first direction, in which, in the step of forming the processed side surface, the shaped portion side surface is cut so that a receiving portion projecting in the second direction with respect to the processed side surface is formed at an uppermost layer of the laminate shaped portion in the first direction, and when the unit step is repeated, in the step of forming the laminate shaped portion, a new metal layer is laminated so as to overlap an upper surface of the receiving portion in the first direction.

A laminate shaping method includes: a unit step repeatedly performed, the unit step including a step of forming a laminate shaped portion by laminating metal layers formed of weld beads, and a step of forming a processed side surface by cutting a shaped portion side surface facing a second direction intersecting a first direction, in which, in the step of forming the processed side surface, the shaped portion side surface is cut so that a receiving portion projecting in the second direction with respect to the processed side surface is formed at an uppermost layer of the laminate shaped portion in the first direction, and when the unit step is repeated, in the step of forming the laminate shaped portion, a new metal layer is laminated so as to overlap an upper surface of the receiving portion in the first direction.

A low-cost ultrasonic system and method that can be used during powder based fusion additive manufacturing to control the microstructural features of parts built in a metallic system. The system and method include the application of laser acoustic emission technology to monitor the metallic microstructure during a build. The system and method can be built into or added onto existing laser-based powder based fusion additive manufacturing machines.

A low-cost ultrasonic system and method that can be used during powder based fusion additive manufacturing to control the microstructural features of parts built in a metallic system. The system and method include the application of laser acoustic emission technology to monitor the metallic microstructure during a build. The system and method can be built into or added onto existing laser-based powder based fusion additive manufacturing machines.

Methods and apparatuses for manufacturing are disclosed, including (a) providing an apparatus having: a laser; scanner; powder injection system; powder spreading system; dichroic filter; imager-and-processor; and computer; (b) programming the computer with specifications of a sample; (c) using the computer to set initial parameters based on the sample specifications; (d) adjusting a stage to position the sample; (e) focusing and scanning electromagnetic radiation onto the sample while powder is concurrently injected onto the sample in order to deposit a layer; (f) capturing two-dimensional images of the sample and probing the sample to determine whether the deposited layer was manufactured per the specifications; (g) use the computer to adjust the three-dimensional manufacturing parameters based on the determination made in step (f) prior to additively manufacturing a subsequent layer or making repairs; and (h) repeating steps (d), (e), (f), and (g) until the manufacture is complete. Other embodiments are described and claimed.

Methods and apparatuses for manufacturing are disclosed, including (a) providing an apparatus having: a laser; scanner; powder injection system; powder spreading system; dichroic filter; imager-and-processor; and computer; (b) programming the computer with specifications of a sample; (c) using the computer to set initial parameters based on the sample specifications; (d) adjusting a stage to position the sample; (e) focusing and scanning electromagnetic radiation onto the sample while powder is concurrently injected onto the sample in order to deposit a layer; (f) capturing two-dimensional images of the sample and probing the sample to determine whether the deposited layer was manufactured per the specifications; (g) use the computer to adjust the three-dimensional manufacturing parameters based on the determination made in step (f) prior to additively manufacturing a subsequent layer or making repairs; and (h) repeating steps (d), (e), (f), and (g) until the manufacture is complete. Other embodiments are described and claimed.

Transformation steps including drying are incorporated into a process of additive manufacturing of a part. Processes and devices for achieving a transformation are described. A cycle of manufacturing is begun by adding a feedstock such as a metal paste to form a partial part followed by a transformation of the added feedstock, such as removing solvent from a metal paste, to form a transformed part suitable for a manipulation step such as machining. Inclusion of a manipulation process such as machining comprises a single cycle of a manufacturing process. One or more said cycles comprise the process of producing a completed part suitable for further processing such as sintering in the case of a metal paste feedstock to form a finished part.

Transformation steps including drying are incorporated into a process of additive manufacturing of a part. Processes and devices for achieving a transformation are described. A cycle of manufacturing is begun by adding a feedstock such as a metal paste to form a partial part followed by a transformation of the added feedstock, such as removing solvent from a metal paste, to form a transformed part suitable for a manipulation step such as machining. Inclusion of a manipulation process such as machining comprises a single cycle of a manufacturing process. One or more said cycles comprise the process of producing a completed part suitable for further processing such as sintering in the case of a metal paste feedstock to form a finished part.

Transformation steps including drying are incorporated into a process of additive manufacturing of a part. Processes and devices for achieving a transformation are described. A cycle of manufacturing is begun by adding a feedstock such as a metal paste to form a partial part followed by a transformation of the added feedstock, such as removing solvent from a metal paste, to form a transformed part suitable for a manipulation step such as machining. Inclusion of a manipulation process such as machining comprises a single cycle of a manufacturing process. One or more said cycles comprise the process of producing a completed part suitable for further processing such as sintering in the case of a metal paste feedstock to form a finished part.

A system for additive metal manufacturing, including a deposition mechanism, a translation mechanism mounting the deposition mechanism to the working volume, and a stage. A method for additive metal manufacturing including: selectively depositing a material carrier within the working volume; removing an additive from the material carrier; and treating the resultant material.