Build material handling unit (2) for a powder module (3) for an apparatus for additively manufacturing three-dimensional objects, which apparatus is adapted to successively layerwise selectively irradiate and consolidate layers of a build material (4) which can be consolidated by means of an energy source, wherein the build material handling unit (2) is coupled or can be coupled with a powder module (3), wherein the build material handling unit (2) is adapted to level and/or compact a volume of build material (4) arranged inside a powder chamber (5) of the powder module (3) by controlling the gas pressure inside the powder chamber (5).

An additive manufacturing apparatus for manufacture of aluminum parts layer-by-layer, the apparatus comprising an eddy current sensor for in-process measuring of contour and defects of manufactured layers with a defect resolution of at least 0.25 mm. Preferably, the eddy current sensor is embodied as a differential mode line sensor with dual use of sensor coils. Preferably, the array of the line sensor comprises a zig-zag-arrangement of sensor coils with a cross section of 0.15 mm.sup.2 maximal and with a core with an initial magnetic permeability of at least 5000, preferably a permalloy or metal glass coil core.

A high-energy beam additive manufacturing forming device and forming method, comprising a magnetic field unit for assisting additive forming, and further comprising a forming base (6) for placing a material (12) to be processed, and a high-energy beam generation device which emits a high-energy beam, acts on the material (12) to be processed and forms a molten pool (15). The magnetic field unit comprises a first magnetic field generating device (7), and the first magnetic field generating device (7) comprises an induction coil (20) provided below the molten pool (15). The first magnetic field generating device (7) is detachably provided below a surface, used for containing the material (12) to be processed, of the forming base (6); second magnetic field generating devices (16) are provided above the forming base (6); the induction coil (20) is provided below the molten pool (15), and the molten pool (15) is located in an area, where clustered magnetic induction lines are emitted, of the induction coil (20), so that the clustered magnetic induction lines penetrate through the molten pool (15). Therefore, the magnetic field intensity of the molten pool (15) is concentrated, the control effect of the magnetic field on additive forming is improved, and the control efficiency of the magnetic field unit on the molten pool (15) is improved.

A high-energy beam additive manufacturing forming device and forming method, comprising a magnetic field unit for assisting additive forming, and further comprising a forming base (6) for placing a material (12) to be processed, and a high-energy beam generation device which emits a high-energy beam, acts on the material (12) to be processed and forms a molten pool (15). The magnetic field unit comprises a first magnetic field generating device (7), and the first magnetic field generating device (7) comprises an induction coil (20) provided below the molten pool (15). The first magnetic field generating device (7) is detachably provided below a surface, used for containing the material (12) to be processed, of the forming base (6); second magnetic field generating devices (16) are provided above the forming base (6); the induction coil (20) is provided below the molten pool (15), and the molten pool (15) is located in an area, where clustered magnetic induction lines are emitted, of the induction coil (20), so that the clustered magnetic induction lines penetrate through the molten pool (15). Therefore, the magnetic field intensity of the molten pool (15) is concentrated, the control effect of the magnetic field on additive forming is improved, and the control efficiency of the magnetic field unit on the molten pool (15) is improved.

An additive manufacturing device is provided with a beam irradiation unit irradiating a conductive powder disposed in a layered shape with a beam, a nondestructive inspection unit detecting a flaw in a surface layer of an additively manufactured article formed of the hardened conductive powder, and an energy control unit controlling energy of the beam. The energy control unit increases energy of a beam when a repairing region set in accordance with results of flaw detection by the nondestructive inspection unit is irradiated with the beam.

According to one aspect, there is provided an apparatus for loading powder into a powder supply chamber. The apparatus comprises a powder supply module to supply powder to a supply chamber, a set of powder compaction elements and a controller. The controller is to control the powder supply module to supply powder to the supply chamber, control the compaction member to distribute and compact the supplied powder, and control the height of the supply platform and the flow of powder to the supply chamber to load the supply chamber with powder.

According to one aspect, there is provided an apparatus for loading powder into a powder supply chamber. The apparatus comprises a powder supply module to supply powder to a supply chamber, a set of powder compaction elements and a controller. The controller is to control the powder supply module to supply powder to the supply chamber, control the compaction member to distribute and compact the supplied powder, and control the height of the supply platform and the flow of powder to the supply chamber to load the supply chamber with powder.

According to one aspect, there is provided an apparatus for loading powder into a powder supply chamber. The apparatus comprises a powder supply module to supply powder to a supply chamber, a set of powder compaction elements and a controller. The controller is to control the powder supply module to supply powder to the supply chamber, control the compaction member to distribute and compact the supplied powder, and control the height of the supply platform and the flow of powder to the supply chamber to load the supply chamber with powder.

An additive manufacturing apparatus includes a platform, a dispenser configured to deliver a plurality of successive layers of feed material onto the platform, at least one energy source to selectively fuse feed material in a layer on the platform, and an air knife assembly.

The air knife assembly includes an inlet unit to deliver gas over the platform and an exhaust unit to receive gas from over the platform. The exhaust unit includes a plenum having a port connected to a gas return conduit, and a gas collector that is open at a front end to receive gas from over the platform and has a concave plate at a back end of the gas collector. An aperture is formed at a back of the concave plate between the gas collector and the plenum to provide a constricted flow path for gas from the collector to the plenum.

An additive manufacturing apparatus includes a platform, a dispenser configured to deliver a plurality of successive layers of feed material onto the platform, at least one energy source to selectively fuse feed material in a layer on the platform, and an air knife assembly.

The air knife assembly includes an inlet unit to deliver gas over the platform and an exhaust unit to receive gas from over the platform. The exhaust unit includes a plenum having a port connected to a gas return conduit, and a gas collector that is open at a front end to receive gas from over the platform and has a concave plate at a back end of the gas collector. An aperture is formed at a back of the concave plate between the gas collector and the plenum to provide a constricted flow path for gas from the collector to the plenum.