A process for manufacturing a multi-material part by additive manufacturing, includes the following steps: a) a step of providing a pre-treated metal powder comprising grains and an oxidized and porous layer on a surface of the grains; b) a selective laser powder-bed fusion step comprising implementation of steps i) and ii) as follows: i) a step of forming a layer from the pre-treated metal powder; ii) a step of melting by laser the layer, the melting step being carried out under a reactive atmosphere and comprising changing parameters of application of the laser so that at least a first region of the layer is converted so as to lower the electrical conductivity thereof, thus forming a dielectric, and so that at least a second region of the layer is densified without converting it, the at least a first region being formed when the parameters of application of the laser allow a first energy density to be applied to the first region and/or the laser beam to be kept for a first dwell time on the first region, the at least a second region being formed when the parameters of application of the laser allow a second energy density to be applied to the second region and/or the laser beam to be kept for a second dwell time on the second region, and the first energy density being higher than the second energy density and/or the first dwell time being longer than the second dwell time. A part obtained using the process is also provided.

A process for manufacturing a multi-material part by additive manufacturing, includes the following steps: a) a step of providing a pre-treated metal powder comprising grains and an oxidized and porous layer on a surface of the grains; b) a selective laser powder-bed fusion step comprising implementation of steps i) and ii) as follows: i) a step of forming a layer from the pre-treated metal powder; ii) a step of melting by laser the layer, the melting step being carried out under a reactive atmosphere and comprising changing parameters of application of the laser so that at least a first region of the layer is converted so as to lower the electrical conductivity thereof, thus forming a dielectric, and so that at least a second region of the layer is densified without converting it, the at least a first region being formed when the parameters of application of the laser allow a first energy density to be applied to the first region and/or the laser beam to be kept for a first dwell time on the first region, the at least a second region being formed when the parameters of application of the laser allow a second energy density to be applied to the second region and/or the laser beam to be kept for a second dwell time on the second region, and the first energy density being higher than the second energy density and/or the first dwell time being longer than the second dwell time. A part obtained using the process is also provided.

The illumination optical system includes a beam shaper which converts an intensity distribution of a laser beam in each of a short axis direction and a long axis direction, which is a Gaussian distribution, into an intensity distribution of a parallel beam on a modulation surface of the optical modulator in each of the short axis direction and the long axis direction, which is a top hat distribution. The modulation surface and an irradiated surface are optically conjugated with respect to the long axis direction by a third lens and a fourth lens. Further, the modulation surface and a front focus position of the fourth lens are optically conjugated with respect to the short axis direction by a first lens, a second lens, and the third lens. The fourth lens condenses a beam having a top hat distribution at the front focus position onto the irradiated surface.

A structure for delivering a flow of gas across a window or aperture of an imaging or measurement device within an apparatus for the manufacture of three-dimensional objects by layer-by-layer consolidation of particulate matter, the structure comprising: a hollow body having an upper aperture for mounting in correspondence with the window/aperture of said device, a gas flow intake region below the upper aperture, and a lower aperture; wherein the gas flow intake region is provided on opposing sides of the hollow body when viewed in cross-section along a longitudinal axis that runs from the upper aperture to the lower aperture, and comprises one or more channels configured to allow, in use, a flow of intake gas to enter the hollow body from the opposing sides of the hollow body with a flow component that predominantly lies in a plane parallel to the plane of the upper aperture, and to come into confluence within the hollow body; and wherein the hollow body is symmetrically shaped about the longitudinal axis so as to redirect the confluent flow of intake gas to form a substantially axial flow of gas along the longitudinal axis, and a backflow of gas near the internal wall of the hollow body, wherein the upper aperture is substantially shielded from the backflow by the intake flow, and wherein the velocity of the backflow is relatively low in comparison to the velocity of the intake flow. Also provided is an apparatus for the manufacture of three-dimensional objects by layer-by-layer consolidation of particulate matter, incorporating such a structure, and a method of delivering a flow of gas using such a structure.

A structure for delivering a flow of gas across a window or aperture of an imaging or measurement device within an apparatus for the manufacture of three-dimensional objects by layer-by-layer consolidation of particulate matter, the structure comprising: a hollow body having an upper aperture for mounting in correspondence with the window/aperture of said device, a gas flow intake region below the upper aperture, and a lower aperture; wherein the gas flow intake region is provided on opposing sides of the hollow body when viewed in cross-section along a longitudinal axis that runs from the upper aperture to the lower aperture, and comprises one or more channels configured to allow, in use, a flow of intake gas to enter the hollow body from the opposing sides of the hollow body with a flow component that predominantly lies in a plane parallel to the plane of the upper aperture, and to come into confluence within the hollow body; and wherein the hollow body is symmetrically shaped about the longitudinal axis so as to redirect the confluent flow of intake gas to form a substantially axial flow of gas along the longitudinal axis, and a backflow of gas near the internal wall of the hollow body, wherein the upper aperture is substantially shielded from the backflow by the intake flow, and wherein the velocity of the backflow is relatively low in comparison to the velocity of the intake flow. Also provided is an apparatus for the manufacture of three-dimensional objects by layer-by-layer consolidation of particulate matter, incorporating such a structure, and a method of delivering a flow of gas using such a structure.

A method for detecting a position of an energy beam comprises mapping a first density modulated x-ray signal with a plurality of locations on an energy beam target, thereby generating a model of a background x-ray intensity. The method further comprises forming an x-ray signal time series using subsequent intensity modulated x-ray signals, each resulting from scanning the energy beam along the energy beam target in one of a plurality of directions at one of a plurality of speeds, and determining the position of the energy beam based upon a received x-ray signal strength based on the x-ray signal time series and the model of the background x-ray intensity.

A method for detecting a position of an energy beam comprises mapping a first density modulated x-ray signal with a plurality of locations on an energy beam target, thereby generating a model of a background x-ray intensity. The method further comprises forming an x-ray signal time series using subsequent intensity modulated x-ray signals, each resulting from scanning the energy beam along the energy beam target in one of a plurality of directions at one of a plurality of speeds, and determining the position of the energy beam based upon a received x-ray signal strength based on the x-ray signal time series and the model of the background x-ray intensity.

An additive manufacturing method using an inkjet printhead supplied with a binder fluid, said method comprising the steps of: (a) providing a layer of powdered build material including a monomer; (b) selectively jetting the binder fluid onto predetermined regions of the layer of powdered build material, the binder fluid comprising a catalyst; (c) optionally exposing the layer of powdered build material to an energy source to initiate polymerization of the monomer; and (d) optionally repeating steps (a) to (c).

An additive manufacturing method using an inkjet printhead supplied with a binder fluid, said method comprising the steps of: (a) providing a layer of powdered build material including a monomer; (b) selectively jetting the binder fluid onto predetermined regions of the layer of powdered build material, the binder fluid comprising a catalyst; (c) optionally exposing the layer of powdered build material to an energy source to initiate polymerization of the monomer; and (d) optionally repeating steps (a) to (c).

A method and system for laser metal powder deposition using beam wobbling. The system may include a fiber laser configured to generate a laser beam and a laser head, the laser head configured to receive the laser beam from the fiber laser and including a collimator configured to collimate the laser beam, a wobbler module having first and second movable mirrors, and a focus lens configured to focus the collimated laser beam through a powder nozzle device such that a focal point location of the focused collimated laser beam is positioned below a workpiece surface. The powder nozzle device delivers metal powder to a region on the workpiece surface that is heated by the focused collimated laser beam.