A method of manufacturing a three-dimensionally shaped object includes a first powder-layer forming process in which a first portion of at least one thickness determining member forms a powder layer by moving in contact with powder, a solidifying process in which a solidified portion is formed in the powder layer formed in the first powder-layer forming process, a second powder-layer forming process, performed after the solidifying process, in which a second portion of the at least one thickness determining member forms a powder layer by moving in contact with the powder, and a renewal process performed between the first powder-layer forming process and the second powder-layer forming process. In the renewal process, the portion having been in contact with the powder is renewed such that the second portion is different from the first portion.

A method of manufacturing a three-dimensionally shaped object includes a first powder-layer forming process in which a first portion of at least one thickness determining member forms a powder layer by moving in contact with powder, a solidifying process in which a solidified portion is formed in the powder layer formed in the first powder-layer forming process, a second powder-layer forming process, performed after the solidifying process, in which a second portion of the at least one thickness determining member forms a powder layer by moving in contact with the powder, and a renewal process performed between the first powder-layer forming process and the second powder-layer forming process. In the renewal process, the portion having been in contact with the powder is renewed such that the second portion is different from the first portion.

A lamination molding apparatus includes: a material layer forming device that forms a material layer in a molding region; an irradiator that sinters or melts the material layer to form a solidified layer; and a cooling device that cools, to a cooling temperature, at least a part including an upper surface of a solidified body. The material layer forming device includes: a base having the molding region, a recoater head disposed on the base, a recoater head driving device that reciprocates the recoater head in a horizontal direction, and a blade that is arranged on the recoater head and that levels material powder to form the material layer. The cooling device includes: a cooling body that is controlled to the cooling temperature and comes into contact with the upper surface of the solidified body, and a mounting member that mounts the cooling body to the recoater head.

A method may include receiving data associated with a part to be built by additive manufacturing using a recoater, predicting a distortion amount comprising a distance that the part is expected to distort in a vertical direction at one or more layers while the part is being built based on a simulation of the part being built, determining a likelihood of a recoater event based on the predicted distortion amount, determining a severity factor associated with the predicted distortion amount at each of the one or more layers of the part based on an orientation of the part at each of the one or more layers, and determining an adjusted likelihood of a recoater event at each of the one or more layers based on the predicted distortion amount and the determined severity factor. Apparatuses and systems are also provided for enhanced recoater event prediction for DMLM additive manufacturing.

A method may include receiving data associated with a part to be built by additive manufacturing using a recoater, predicting a distortion amount comprising a distance that the part is expected to distort in a vertical direction at one or more layers while the part is being built based on a simulation of the part being built, determining a likelihood of a recoater event based on the predicted distortion amount, determining a severity factor associated with the predicted distortion amount at each of the one or more layers of the part based on an orientation of the part at each of the one or more layers, and determining an adjusted likelihood of a recoater event at each of the one or more layers based on the predicted distortion amount and the determined severity factor. Apparatuses and systems are also provided for enhanced recoater event prediction for DMLM additive manufacturing.

Systems, apparatus, computer-readable medium, and associated methods to monitor, analyze, and adjust at least one of 1) additive machine health and configuration or 2) build health and configuration are disclosed. An example apparatus includes an analytics processor, separate from and in a trusted relationship with an additive manufacturing machine building a part, to process, based on a trigger, data from monitoring of the additive manufacturing machine and the build of the part, the analytics processor including a hybrid model fusing additive process physics and data science to process the data to identify an abnormality in at least one of the build or the additive manufacturing machine and to adjust a configuration of the additive manufacturing machine during the build to address the abnormality.

Systems, apparatus, computer-readable medium, and associated methods to monitor, analyze, and adjust at least one of 1) additive machine health and configuration or 2) build health and configuration are disclosed. An example apparatus includes an analytics processor, separate from and in a trusted relationship with an additive manufacturing machine building a part, to process, based on a trigger, data from monitoring of the additive manufacturing machine and the build of the part, the analytics processor including a hybrid model fusing additive process physics and data science to process the data to identify an abnormality in at least one of the build or the additive manufacturing machine and to adjust a configuration of the additive manufacturing machine during the build to address the abnormality.

An additive manufacturing device includes a recoater configured to push powder onto a build platform. The recoater defines an advancing direction for pushing powder. A gas mover is mounted to the recoater and is configured to flow gas to remove powder from the build platform as the recoater moves along the advancing direction.

An additive manufacturing device includes a recoater configured to push powder onto a build platform. The recoater defines an advancing direction for pushing powder. A gas mover is mounted to the recoater and is configured to flow gas to remove powder from the build platform as the recoater moves along the advancing direction.

Disclosed embodiments relate to recoater systems for use with additive manufacturing systems. A recoater assembly may be used to deposit a material layer onto a build surface of an additive manufacturing system. In some instances, the recoater assembly may include a powder entrainment system that trails behind a recoater blade of the recoater assembly relative to a direction of motion of the recoater blade across a build surface of the additive manufacturing system. The powder entrainment system may generate a flow of fluid across a portion of the build surface behind the recoater blade that at least temporarily entrains powder above a threshold height from the build surface to mitigate, or prevent, the formation of defects on the build surface with heights greater than the threshold height.