An additive manufacturing system includes build plate with a powdered metal material disposed thereon. The additive manufacturing system also includes at least one wall defining an air-locked build chamber, a conveyor system, and a plurality of operation stations. The conveyor system is disposed within the air-locked build chamber. The conveyor system is configured to transport the build plate. The plurality of operation stations are positioned adjacent to the conveyor system and within the air-locked build chamber. Each operation station of the plurality of operation stations is configured to facilitate execution of at least one additive manufacturing operation on the powdered metal material disposed on the build plate. The conveyor system is configured to transfer the build plate from a first operation station of the plurality of operation stations to a second operation station of the plurality of operation stations.

An additive manufacturing system includes build plate with a powdered metal material disposed thereon. The additive manufacturing system also includes at least one wall defining an air-locked build chamber, a conveyor system, and a plurality of operation stations. The conveyor system is disposed within the air-locked build chamber. The conveyor system is configured to transport the build plate. The plurality of operation stations are positioned adjacent to the conveyor system and within the air-locked build chamber. Each operation station of the plurality of operation stations is configured to facilitate execution of at least one additive manufacturing operation on the powdered metal material disposed on the build plate. The conveyor system is configured to transfer the build plate from a first operation station of the plurality of operation stations to a second operation station of the plurality of operation stations.

The present disclosure generally relates to additive manufacturing systems and methods on a large-scale format. One aspect involves a build unit that can be moved around in three dimensions by a positioning system, building separate portions of a large object. The build unit has an energy directing device that directs, e.g., laser or e-beam irradiation onto a powder layer. In the case of laser irradiation, the build volume may have a gasflow device that provides laminar gas flow to a laminar flow zone above the layer of powder. This allows for efficient removal of the smoke, condensates, and other impurities produced by irradiating the powder (the gas plume) without excessively disturbing the powder layer. The build unit may also have a recoater that allows it to selectively deposit particular quantities of powder in specific locations over a work surface to build large, high quality, high precision objects.

The present disclosure generally relates to additive manufacturing systems and methods on a large-scale format. One aspect involves a build unit that can be moved around in three dimensions by a positioning system, building separate portions of a large object. The build unit has an energy directing device that directs, e.g., laser or e-beam irradiation onto a powder layer. In the case of laser irradiation, the build volume may have a gasflow device that provides laminar gas flow to a laminar flow zone above the layer of powder. This allows for efficient removal of the smoke, condensates, and other impurities produced by irradiating the powder (the gas plume) without excessively disturbing the powder layer. The build unit may also have a recoater that allows it to selectively deposit particular quantities of powder in specific locations over a work surface to build large, high quality, high precision objects.

Disclosed herein are print heads for an additive manufacturing apparatus. The print heads include a housing. A projection element is disposed within the housing and is configured to receive the one or more laser beams generated by a beam emitter and project a plurality of projected laser beams in a pattern. A consolidating optic is disposed within the housing and is located below the projection element. The consolidating optic is configured to consolidate the pattern of the plurality of projected laser beams into a consolidated pattern of projected laser beams.

Disclosed herein are print heads for an additive manufacturing apparatus. The print heads include a housing. A projection element is disposed within the housing and is configured to receive the one or more laser beams generated by a beam emitter and project a plurality of projected laser beams in a pattern. A consolidating optic is disposed within the housing and is located below the projection element. The consolidating optic is configured to consolidate the pattern of the plurality of projected laser beams into a consolidated pattern of projected laser beams.

Disclosed herein are additive manufacturing apparatuses which include a print head supported by a positioning system, the print head including one or more delivery optics contained within the print head; a laser beam source assembly isolated from the positioning system, the laser beam source assembly configured to generate at least one collimated laser beam; and a laser beam receiver assembly isolated from the laser beam source assembly, the laser beam receiver assembly configured to receive the at least one collimated laser beam and direct the at least one collimated laser beam to the one or more delivery optics of the print head.

Disclosed herein are additive manufacturing apparatuses which include a print head supported by a positioning system, the print head including one or more delivery optics contained within the print head; a laser beam source assembly isolated from the positioning system, the laser beam source assembly configured to generate at least one collimated laser beam; and a laser beam receiver assembly isolated from the laser beam source assembly, the laser beam receiver assembly configured to receive the at least one collimated laser beam and direct the at least one collimated laser beam to the one or more delivery optics of the print head.

The present invention relates to a method for the production of a three-dimensional object (2) by way of layered solidification of a powder construction material (11) by way of electromagnetic radiation, in particular laser radiation, having the steps: scanning points, which correspond to a cross section of the object (2) to be produced, of an applied layer of the powder construction material (11) with an electromagnetic beam (22) from a radiation source (21) for purposes of selectively solidifying the powder construction material (11), conducting a gas flow (33) across the applied layer during the scanning with the electromagnetic beam (22) and performing an irregularity determination with regard to the presence of a process irregularity with regard to at least one process parameter during the production, wherein during the scanning by way of the electromagnetic beam (22), the scanning process at at least one present point of the cross section to be solidified is interrupted on the basis of a result of the irregularity determination.

A control system for thermo optical control of focus position of an energy beam in an additive manufacturing apparatus has a first doped medium and a second doped medium, each of which is optically transparent and doped with a dopant. The first doped medium has a positive thermo-optical coefficient (dn/dT) and the second doped medium has a negative thermo-optical coefficient (dn/dT) and is in series with the first doped medium. An energy beam input or coupling is configured to generate or receive an energy beam that is required to be controlled, the energy beam being within a first wavelength range and directed towards the first and second doped mediums. An absorbed beam input or coupling is configured to generate or receive at least one absorbed beam in a second wavelength range which is different from the first wavelength range, the absorbed beam being directed towards the first and second doped mediums. The first and second doped mediums have a higher beam absorption characteristic in the second wavelength range than in the first wavelength range, causing the absorbed beam to have a higher absorption than the energy beam in the first and second doped mediums and the first and second doped mediums each have a coating which allows transmission at both the first and the second wavelength ranges.