Methods for repurposing waste materials, such as aluminum powder, are disclosed. A method in accordance with an aspect of the present disclosure may comprise collecting a material in a container, the material comprising oxidized aluminum powder, processing the material, which includes heating the material to melt at least a portion of the oxidized aluminum powder, and forming the processed material into at least one component.

A build-plate with integrally-formed spinal implant constructs and a method used in forming spinal implant constructs on the build-plate and machining the spinal implant constructs formed on the build-plate to manufacture spinal implants is provided. The spinal implant constructs can be formed via additive manufacturing processes by adding material to an upper surface of the build-plate, and then the spinal implant constructs can be subjected to subtractive manufacturing processes to form the spinal implants.

A tooling system, such as an additive manufacturing system, includes a tool displacement mechanism mounted on a fixed structure and carrying a system tool such as a printhead. The tool displacement mechanism displaces the system tool along a curvilinear closed path about a system axis and located within a working plane intersecting the system axis. A bed, connecting to the fixed structure, is substantially positioned within the working plane, locally adjacent the closed path and along at least a portion of the closed path.

A manipulator device such as a robot arm that is capable of increasing manufacturing throughput for additively manufactured parts, and allows for the manipulation of parts that would be difficult or impossible for a human to move is described. The manipulator can grasp various permanent or temporary additively manufactured manipulation points on a part to enable repositioning or maneuvering of the part.

A manipulator device such as a robot arm that is capable of increasing manufacturing throughput for additively manufactured parts, and allows for the manipulation of parts that would be difficult or impossible for a human to move is described. The manipulator can grasp various permanent or temporary additively manufactured manipulation points on a part to enable repositioning or maneuvering of the part.

A powder bed fusion apparatus for building an object in a layer-by-layer manner includes a build platform movable within a build sleeve to define a build volume, a layer formation device for forming layers of powder across the build volume in a working plane and an irradiation device for irradiating powder in the working plane to selectively fuse the powder. The powder bed fusion apparatus further includes a mechanical manipulator arranged to engage with the object and/or a build substrate, to which the object is attached, to tilt the object in a raised position above the working plane such that powder is freed from the object and deposited at a location above the working plane and/or into the build volume.

A 3-dimensional printing system for manufacturing a part is provided. The system includes a building platform having a deposited pattern of metal powder, a sand dispensing nozzle selectively supplying sand to the building platform, a binder dispensing nozzle selectively supplying binder material to the building platform, a robotic arm supporting one or more of the sand dispensing nozzle and the binder dispensing nozzle, the robotic arm moving the one or more of the sand dispensing nozzle and the binder dispensing nozzle, and a processor controlling the robotic arm to position the one or more of the sand dispensing nozzle and the binder dispensing nozzle relative to the deposited pattern of metal powder and control the sand dispensing nozzle and the binder dispensing nozzle to supply powdered sand and binder, respectively, based on a Computer Aided Drafting file associated with the part.

A 3-dimensional printing system for manufacturing a part is provided. The system includes a building platform having a deposited pattern of metal powder, a sand dispensing nozzle selectively supplying sand to the building platform, a binder dispensing nozzle selectively supplying binder material to the building platform, a robotic arm supporting one or more of the sand dispensing nozzle and the binder dispensing nozzle, the robotic arm moving the one or more of the sand dispensing nozzle and the binder dispensing nozzle, and a processor controlling the robotic arm to position the one or more of the sand dispensing nozzle and the binder dispensing nozzle relative to the deposited pattern of metal powder and control the sand dispensing nozzle and the binder dispensing nozzle to supply powdered sand and binder, respectively, based on a Computer Aided Drafting file associated with the part.

A powder dispensing assembly for an additive manufacturing machine is provided. The powder dispensing assembly includes a housing that defines a powder reservoir that receives additive powder; a first plate removably connectable to the housing, the first plate defining a first discharge orifice having a first discharge orifice geometry; and a second plate removably connectable to the housing, the second plate defining a second discharge orifice having a second discharge orifice geometry different than the first discharge orifice geometry, wherein with the first plate connected to the housing, the additive powder flows out of the first discharge orifice at a first dosing rate, and wherein with the second plate connected to the housing, the additive powder flows out of the second discharge orifice at a second dosing rate different than the first dosing rate.

A powder dispensing assembly for an additive manufacturing machine is provided. The powder dispensing assembly includes a housing that defines a powder reservoir that receives additive powder; a first plate removably connectable to the housing, the first plate defining a first discharge orifice having a first discharge orifice geometry; and a second plate removably connectable to the housing, the second plate defining a second discharge orifice having a second discharge orifice geometry different than the first discharge orifice geometry, wherein with the first plate connected to the housing, the additive powder flows out of the first discharge orifice at a first dosing rate, and wherein with the second plate connected to the housing, the additive powder flows out of the second discharge orifice at a second dosing rate different than the first dosing rate.