A method for forming a secondary component from an original component having an original shape includes separating the original component into a parent component and a replaced portion, and forming a replacement coupon using an additive manufacturing system. The replacement coupon is shaped to substantially match the original shape of the replaced portion. The method further includes coupling the replacement coupon to the parent component to form the secondary component. The method also includes at least one of (i) removing the replacement coupon from a build plate of the additive manufacturing system prior to application of any heat treatment to the as-built replacement coupon, wherein the replacement coupon maintains a near-net original shape of the replaced portion after removal, and (ii) entering the secondary component into normal duty with no hot isostatic press treatment of the replacement coupon having been performed.

A build material dispensing device may include a material spreader to spread an amount of build material along a build platform, and at least one hopper for dispensing the build material. The at least one hopper dispenses a plurality of doses of the build material in front of the progression of the material spreader as the material spreader is moved over the build platform.

A build material dispensing device may include a material spreader to spread an amount of build material along a build platform, and at least one hopper for dispensing the build material. The at least one hopper dispenses a plurality of doses of the build material in front of the progression of the material spreader as the material spreader is moved over the build platform.

A powder application device (10) for use in a system (100) for producing a three-dimensional workpiece using a generative layering process comprises a spreading member (12). The spreading member (12) is movable across a surface of a carrier (116) for depositing a raw material powder for producing a workpiece by a generative layering method onto the surface of the carrier (116). Furthermore, the powder application device (10) comprises a powder entrainer (16) which is movable across a carrier plane (E) and which, in the region of a surface (20) facing the carrier plane (E), is provided with a surface profile (22). The surface profile (20) comprises an entraining element (24a, 24b, 24c) and a passage channel (26a, 26b, 26c). The entraining element (24a, 24b, 24c) and the passage channel (26a, 26b, 26c) are shaped and arranged in such a way that, with respect to the movement of the powder entrainer (16) across the carrier plane (E), powdery material deposited in front of the powder entrainer (16) on the carrier plane (E) is entrained by the entraining element (24a, 24b, 24c) during a movement of the powder entrainer (16) across the carrier plane (E) in a first direction of movement (R1), and is guided through the passage channel (26a, 26b, 26c) during a movement of the powder entrainer (16) across the carrier plane (E) in a second direction of movement (R2) opposite to the first direction of movement (R1).

A powder application device (10) for use in a system (100) for producing a three-dimensional workpiece using a generative layering process comprises a spreading member (12). The spreading member (12) is movable across a surface of a carrier (116) for depositing a raw material powder for producing a workpiece by a generative layering method onto the surface of the carrier (116). Furthermore, the powder application device (10) comprises a powder entrainer (16) which is movable across a carrier plane (E) and which, in the region of a surface (20) facing the carrier plane (E), is provided with a surface profile (22). The surface profile (20) comprises an entraining element (24a, 24b, 24c) and a passage channel (26a, 26b, 26c). The entraining element (24a, 24b, 24c) and the passage channel (26a, 26b, 26c) are shaped and arranged in such a way that, with respect to the movement of the powder entrainer (16) across the carrier plane (E), powdery material deposited in front of the powder entrainer (16) on the carrier plane (E) is entrained by the entraining element (24a, 24b, 24c) during a movement of the powder entrainer (16) across the carrier plane (E) in a first direction of movement (R1), and is guided through the passage channel (26a, 26b, 26c) during a movement of the powder entrainer (16) across the carrier plane (E) in a second direction of movement (R2) opposite to the first direction of movement (R1).

Provided are advanced automated fabrication methods and systems which utilize laser fabrication. Also provided are methods for an automated roboticized factory. The disclosed invention utilizes a number of modules to result in automatic fabrication, which provides advantages over manual fabrication of the prior art. Embodiments of the disclosed invention may include a material management module, a build module, an automation module, and a control module. Embodiments of the invention may employ artificial intelligence with machine learning such that the fabrication system becomes even more efficient and accurate over time.

Provided are advanced automated fabrication methods and systems which utilize laser fabrication. Also provided are methods for an automated roboticized factory. The disclosed invention utilizes a number of modules to result in automatic fabrication, which provides advantages over manual fabrication of the prior art. Embodiments of the disclosed invention may include a material management module, a build module, an automation module, and a control module. Embodiments of the invention may employ artificial intelligence with machine learning such that the fabrication system becomes even more efficient and accurate over time.

An additive manufacturing machine (10) comprises a working plane (18) comprising a working zone (20) allowing an overlay of different layers of powder to be received, and a powder dispensing device (32) comprising a powder intake (36) allowing powder to be delivered on top of the working plane. The powder dispensing device (32) comprises a tank (44) of powder mounted to move above the working plane (18) and that can be displaced to under the powder intake (36), the bottom part (45) of the tank (44) comprises a powder dispensing point (P1), and the powder dispensing device (32) comprises a control device (48) controlling the flow of powder via the powder dispensing point during a displacement of the tank. The tank (44) is mounted on a weighing sensor (68).

An additive manufacturing machine (10) comprises a working plane (18) comprising a working zone (20) allowing an overlay of different layers of powder to be received, and a powder dispensing device (32) comprising a powder intake (36) allowing powder to be delivered on top of the working plane. The powder dispensing device (32) comprises a tank (44) of powder mounted to move above the working plane (18) and that can be displaced to under the powder intake (36), the bottom part (45) of the tank (44) comprises a powder dispensing point (P1), and the powder dispensing device (32) comprises a control device (48) controlling the flow of powder via the powder dispensing point during a displacement of the tank. The tank (44) is mounted on a weighing sensor (68).

According to examples, a three-dimensional printed part including a core including a build material; an inner shell including the build material and an antistatic agent, wherein the antistatic agent includes a water soluble compound; and an external shell including the build material is disclosed.