A method and an apparatus for additive casting of parts is disclosed. The method may include: depositing, on a build table, a first portion of a mold, such that, the depositing may be performed layer by layer; pouring liquid substance into the first portion of the mold to form a first casted layer; solidifying at least a portion of the first casted layer; depositing a second portion of the mold, on top of the first portion of the mold; pouring the liquid substance into the second portion of the mold to form a second casted layer, on top of at least a portion of the first casted layer; and solidifying at least a portion of the second casted layer. The method may further include joining the first and second casted layers prior to the pouring of a third casted layer.

A method and an apparatus for additive casting of parts is disclosed. The method may include: depositing, on a build table, a first portion of a mold, such that, the depositing may be performed layer by layer; pouring liquid substance into the first portion of the mold to form a first casted layer; solidifying at least a portion of the first casted layer; depositing a second portion of the mold, on top of the first portion of the mold; pouring the liquid substance into the second portion of the mold to form a second casted layer, on top of at least a portion of the first casted layer; and solidifying at least a portion of the second casted layer. The method may further include joining the first and second casted layers prior to the pouring of a third casted layer.

We describe a process chamber, an apparatus, a modular system, a method, a safety device, a positioning system and a system for producing a three-dimensional workpiece and/or for use thereof when producing a three-dimensional workpiece. The process chamber for producing the three-dimensional workpiece via an additive layer construction method comprises: a material supply unit comprising a substantially ring-like shaped end portion at a first side of the process chamber, wherein the material supply unit is adapted to supply, via the end portion, material to a carrier on which the material is to be processed by the process chamber for producing the three-dimensional workpiece, and an opening at the first side of the process chamber for processing, by the process chamber, the material supplied on the carrier in order to produce the three-dimensional workpiece, wherein the substantially ring-like shaped end portion surrounds the opening.

We describe a process chamber, an apparatus, a modular system, a method, a safety device, a positioning system and a system for producing a three-dimensional workpiece and/or for use thereof when producing a three-dimensional workpiece. The process chamber for producing the three-dimensional workpiece via an additive layer construction method comprises: a material supply unit comprising a substantially ring-like shaped end portion at a first side of the process chamber, wherein the material supply unit is adapted to supply, via the end portion, material to a carrier on which the material is to be processed by the process chamber for producing the three-dimensional workpiece, and an opening at the first side of the process chamber for processing, by the process chamber, the material supplied on the carrier in order to produce the three-dimensional workpiece, wherein the substantially ring-like shaped end portion surrounds the opening.

A z-lift and leveling assembly for leveling a platen in a heated chamber of a 3D printer includes first, second, third, and fourth z-actuators in a rectangular configuration. Each z-actuator includes a linear drive configured to supply motion in the z-direction and a mounting bracket secured to the linear drive and configured to move with the linear drive in the z-direction. The assembly includes a set of four pin couplings each associated with one of the first, second, third and fourth z-actuators. Each pin coupling includes a pivot block secured to the mounting bracket with a first pivot pin forming a first pin joint between the mounting bracket and the pivot block, where the pivot block is configured to move relative to the mounting bracket about a first pivot axis of the first pivot pin. The pivot block is secured to the platen or an arm of the platen with a second pivot pin forming a second pin joint such that the pivot block and the platen move relative to each other about a second pivot axis. As the mounting bracket is moved, the pivot block moves relative to the mounting bracket about the first pivot axis and the pivot block moves relative to the platen about the second pivot axis such that a z-position of the platen can be manipulated to and maintained in a substantially level configuration in the z-direction though the independent manipulation of the first, second, third and fourth z-actuators and wherein the substantially level configuration can be maintained when the platen is incremented in the z-direction during printing of a part.

A z-lift and leveling assembly for leveling a platen in a heated chamber of a 3D printer includes first, second, third, and fourth z-actuators in a rectangular configuration. Each z-actuator includes a linear drive configured to supply motion in the z-direction and a mounting bracket secured to the linear drive and configured to move with the linear drive in the z-direction. The assembly includes a set of four pin couplings each associated with one of the first, second, third and fourth z-actuators. Each pin coupling includes a pivot block secured to the mounting bracket with a first pivot pin forming a first pin joint between the mounting bracket and the pivot block, where the pivot block is configured to move relative to the mounting bracket about a first pivot axis of the first pivot pin. The pivot block is secured to the platen or an arm of the platen with a second pivot pin forming a second pin joint such that the pivot block and the platen move relative to each other about a second pivot axis. As the mounting bracket is moved, the pivot block moves relative to the mounting bracket about the first pivot axis and the pivot block moves relative to the platen about the second pivot axis such that a z-position of the platen can be manipulated to and maintained in a substantially level configuration in the z-direction though the independent manipulation of the first, second, third and fourth z-actuators and wherein the substantially level configuration can be maintained when the platen is incremented in the z-direction during printing of a part.

A shaping apparatus is equipped with: a beam shaping system having a beam irradiation section that includes a condensing optical system which emits a beam and a material processing section which supplies a shaping material irradiated by the beam from the beam irradiation section; and a controller which, on the basis of 3D data of a three-dimensional shaped object to be formed on a target surface, controls a workpiece movement system and the beam shaping system such that a target portion on the target surface is shaped by supplying the shaping material from the material processing section while moving the beam from the beam irradiation section and the target surface on a workpiece (or a table) relative to each other. Further the intensity distribution of the beam in the shaping plane facing the emitting surface of the condensing optical system can be modified.

This shaping apparatus is equipped with: a movement system which moves a target surface; a measurement system for acquiring position information of the target surface in a state movable by the movement system, a beam shaping system that has a beam irradiation section and a material processing section which supplies a shaping material irradiated by a beam from beam irradiation section; and a controller. On the basis of 3D data of a three-dimensional shaped object to be formed on a target surface and position information of the target surface acquired using the measurement system, the controller controls the movement system and the beam shaping system such that a target portion on the target surface is shaped by supplying the shaping material while moving the target surface and the beam from beam irradiation section relative to each other.

An apparatus for additive manufacturing having a body; a plurality of articulated arms, each having a jointed connection to the body opposite a free end, the plurality of articulated arms movable relative to each other and the plurality of articulated arms having opposable motions about the jointed connection; an extruder at the free end of each of the plurality of articulated arms, the extruder having an extruder nozzle extending from the free end; and at least one cooling nozzle extending from the free end of each of the plurality of articulated arms.

An apparatus for additive manufacturing having a body; a plurality of articulated arms, each having a jointed connection to the body opposite a free end, the plurality of articulated arms movable relative to each other and the plurality of articulated arms having opposable motions about the jointed connection; an extruder at the free end of each of the plurality of articulated arms, the extruder having an extruder nozzle extending from the free end; and at least one cooling nozzle extending from the free end of each of the plurality of articulated arms.