One of the objects of the present application is to provide a technique capable of preventing the generation of excessive metallic vapor during fabrication according to an AM technique. Further, one of the objects of the present application is to provide a technique for reducing machining processing after the fabrication as much as possible or eliminating the necessity thereof. According to one aspect, an AM apparatus configured to manufacture a fabrication object is provided. This AM apparatus includes a first DED nozzle configured to fabricate a contour of a fabrication target and a second DED nozzle configured to fabricate an inner portion of the contour.

One of the objects of the present application is to provide a technique capable of preventing the generation of excessive metallic vapor during fabrication according to an AM technique. Further, one of the objects of the present application is to provide a technique for reducing machining processing after the fabrication as much as possible or eliminating the necessity thereof. According to one aspect, an AM apparatus configured to manufacture a fabrication object is provided. This AM apparatus includes a first DED nozzle configured to fabricate a contour of a fabrication target and a second DED nozzle configured to fabricate an inner portion of the contour.

Systems, apparatus, computer-readable medium, and associated methods to monitor, analyze, and adjust at least one of 1) additive machine health and configuration or 2) build health and configuration are disclosed. An example apparatus includes an analytics processor, separate from and in a trusted relationship with an additive manufacturing machine building a part, to process, based on a trigger, data from monitoring of the additive manufacturing machine and the build of the part, the analytics processor including a hybrid model fusing additive process physics and data science to process the data to identify an abnormality in at least one of the build or the additive manufacturing machine and to adjust a configuration of the additive manufacturing machine during the build to address the abnormality.

Systems, apparatus, computer-readable medium, and associated methods to monitor, analyze, and adjust at least one of 1) additive machine health and configuration or 2) build health and configuration are disclosed. An example apparatus includes an analytics processor, separate from and in a trusted relationship with an additive manufacturing machine building a part, to process, based on a trigger, data from monitoring of the additive manufacturing machine and the build of the part, the analytics processor including a hybrid model fusing additive process physics and data science to process the data to identify an abnormality in at least one of the build or the additive manufacturing machine and to adjust a configuration of the additive manufacturing machine during the build to address the abnormality.

Certain aspects of the present disclosure provide a method for optimizing process parameters for additive manufacturing, including: determining a change to at least one process parameter of a plurality of process parameters while additively manufacturing a first part using an additive manufacturing apparatus according to a build file comprising machine code defining the plurality of process parameters; modifying the build file based on the determined change to the at least one process parameter to generate a modified build file; additively manufacturing a second part using the additive manufacturing apparatus according to the modified build file, wherein: additively manufacturing the first part is performed in a closed-loop control mode, and additively manufacturing the second part is performed in an open-loop control mode.

Certain aspects of the present disclosure provide a method for optimizing process parameters for additive manufacturing, including: determining a change to at least one process parameter of a plurality of process parameters while additively manufacturing a first part using an additive manufacturing apparatus according to a build file comprising machine code defining the plurality of process parameters; modifying the build file based on the determined change to the at least one process parameter to generate a modified build file; additively manufacturing a second part using the additive manufacturing apparatus according to the modified build file, wherein: additively manufacturing the first part is performed in a closed-loop control mode, and additively manufacturing the second part is performed in an open-loop control mode.

A system for manufacturing a part, the system comprising a power source, a rectifier, an electrical conduit, and a framework. The power source is configured to generate a high frequency, high current electrical signal. The rectifier is configured to convert the electrical signal to a direct current electrical signal. The electrical conduit is configured to carry the electrical signal. The framework is formed of electrically resistive metal having a relatively high melting point and is connected to the electrical conduit and at least partially encased in a powdered metal having a melting point lower than the melting point of the framework so that transmission of the electrical signal through the framework transitions at least some of the powdered metal into its molten state so that at least some of the molten metal cooled into its solidified state forms at least a portion of the part.

Methods for direct writing of single crystal super alloys and metals are provided. The method can include: heating a substrate positioned on a base plate to a predetermined temperature using a first heater; using a laser to form a melt pool on a surface of the substrate; introducing a superalloy powder to the melt pool; measuring the temperature of the melt pool; receiving the temperature measured at a controller; and using an auxiliary heat source in communication with the controller to adjust the temperature of the melt pool. The predetermined temperature is below the substrate's melting point. The laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition. An apparatus is also generally provided for direct writing of single crystal super alloys and metals.

A method and an apparatus for collecting powder samples in real-time in powder bed fusion additive manufacturing may involves an ingester system for in-process collection and characterizations of powder samples. The collection may be performed periodically and uses the results of characterizations for adjustments in the powder bed fusion process. The ingester system of the present disclosure is capable of packaging powder samples collected in real-time into storage containers serving a multitude purposes of audit, process adjustments or actions.

A component carrier includes a carrier body formed of a plurality of electrically conductive layer structures and/or electrically insulating layer structures, a metal surface structure coupled to the layer structures and a metal body directly on the metal surface structure formed by additive manufacturing.