Devices, systems, and methods for monitoring a powder layer in additive manufacturing are disclosed. A method of monitoring a powder layer includes receiving image data corresponding the powder layer supported by a powder bed within a build chamber from imaging devices, determining leading and trailing regions of interest located adjacent to a leading end and a trailing end of the moving powder distributor, respectively, the leading and trailing regions of interest moving according to movement of the moving powder distributor, selecting at least one point located in the leading region of interest from the image data, determining first characteristics of the point, when the point is located within the trailing region of interest, determining second characteristics of the point, and comparing the first characteristics to the second characteristics.

Devices, systems, and methods for monitoring a powder layer in additive manufacturing are disclosed. A method of monitoring a powder layer includes receiving image data corresponding the powder layer supported by a powder bed within a build chamber from imaging devices, determining leading and trailing regions of interest located adjacent to a leading end and a trailing end of the moving powder distributor, respectively, the leading and trailing regions of interest moving according to movement of the moving powder distributor, selecting at least one point located in the leading region of interest from the image data, determining first characteristics of the point, when the point is located within the trailing region of interest, determining second characteristics of the point, and comparing the first characteristics to the second characteristics.

A method for additive fabrication by 3D printing includes processing model data representing material transition boundaries of an object to be printed to form build data for use in controlling printing of a plurality of successive layers to form the object, the build data comprising, for each location of a plurality of locations in a two-dimensional arrangement, material transition data for representing heights of material transitions in a third dimension, and repeating for each layer of the plurality of successive layers, receiving surface height data representing a height of a partial fabrication of the object at respective locations of a plurality of locations on a surface of the partial fabrication for each location of the plurality of locations, using the height at the location to access the material transition data corresponding to the location in the build data, and using the material transition data to determine material to be deposited at that location, and causing emission of the determined material at each location of the plurality of locations, thereby causing printing of the layer.

A method for additive fabrication by 3D printing includes processing model data representing material transition boundaries of an object to be printed to form build data for use in controlling printing of a plurality of successive layers to form the object, the build data comprising, for each location of a plurality of locations in a two-dimensional arrangement, material transition data for representing heights of material transitions in a third dimension, and repeating for each layer of the plurality of successive layers, receiving surface height data representing a height of a partial fabrication of the object at respective locations of a plurality of locations on a surface of the partial fabrication for each location of the plurality of locations, using the height at the location to access the material transition data corresponding to the location in the build data, and using the material transition data to determine material to be deposited at that location, and causing emission of the determined material at each location of the plurality of locations, thereby causing printing of the layer.

A supply module (2) for supplying additive manufacturing powder comprises: a main hopper (29) for storing additive manufacturing powder, the main hopper (29) being designed to be connected to a manufacturing module (4) configured to additively manufacture an object from the powder; an inlet (211) of the supply module (2) designed to be connected to the manufacturing module (4) and to receive powder located in the manufacturing module (4); a glovebox (25) being able to be closed in a sealed manner; a provisioning circuit configured to transfer powder located in the glovebox (25) to the main hopper (29); and a circulation system designed to set powder in motion according to a circulation loop closed on itself, the circulation system comprising a suction system (21) designed to evacuate gas present in the circulation loop, the circulation loop passing through the main hopper (29) and the suction system (21).

A supply module (2) for supplying additive manufacturing powder comprises: a main hopper (29) for storing additive manufacturing powder, the main hopper (29) being designed to be connected to a manufacturing module (4) configured to additively manufacture an object from the powder; an inlet (211) of the supply module (2) designed to be connected to the manufacturing module (4) and to receive powder located in the manufacturing module (4); a glovebox (25) being able to be closed in a sealed manner; a provisioning circuit configured to transfer powder located in the glovebox (25) to the main hopper (29); and a circulation system designed to set powder in motion according to a circulation loop closed on itself, the circulation system comprising a suction system (21) designed to evacuate gas present in the circulation loop, the circulation loop passing through the main hopper (29) and the suction system (21).

Provision module (2) for providing additive manufacturing powder, comprising a main hopper (29) for storing additive manufacturing powder, the main hopper (29) being designed to be connected to a manufacturing module (4) configured to additively manufacture an object from the powder located in the main hopper (29), an inlet (211) of the provision module (2), which inlet is designed to be connected to the manufacturing module (4) and to receive powder located in the manufacturing module (4), a glovebox (25) designed to receive a container (28), the glovebox (25) being able to be closed in a sealed manner, a supply circuit configured to transfer powder located in the glovebox (25) to the main hopper (29), an extraction circuit that is different from the supply circuit and is configured to transfer additive manufacturing powder from the inlet (211) of the provision module (2) to the container (28), when the container (28) is received in the glovebox (25), the glovebox (25) comprising gloves (251) for closing the container (28) once it has been filled with powder, while the glovebox (25) is closed.

An additive manufacturing system may include an irradiation device configured to emit an energy beam having a manufacturing power level selected to additively manufacturing a three-dimensional object by irradiating a powder material, and a controller configured to perform one or more beam alignment operations when irradiating the powder material. The irradiation device may include a beam source, one or more beam positioning elements, a beam splitter configured to split a measurement beam from the energy beam, and one or more beam sensors configured to determine one or more parameters of the measurement beam. The one or more beam alignment operations may include determining position information of the energy beam based on the one or more parameters of the measurement beam, and aligning the energy beam with an optical axis of the irradiation device by adjusting a position of the one or more beam positioning elements based on the position information.

A molten metal print deposition device includes a reservoir in fluid communication with a deposition head for controlled deposition of a molten metal print medium defined by molten feedstock, and a capillary structure adapted to maintain the molten feedstock from the melt reservoir in a fluidic state for directing and depositing the feedstock onto a substrate. A print medium is defined by an alloy heated to a fluid state in a temperature range defined by but above a liquidus and solidus. A thermal source and control circuit maintain the molten feedstock at a temperature above the liquidus of the print medium during deposition.

A molten metal print deposition device includes a reservoir in fluid communication with a deposition head for controlled deposition of a molten metal print medium defined by molten feedstock, and a capillary structure adapted to maintain the molten feedstock from the melt reservoir in a fluidic state for directing and depositing the feedstock onto a substrate. A print medium is defined by an alloy heated to a fluid state in a temperature range defined by but above a liquidus and solidus. A thermal source and control circuit maintain the molten feedstock at a temperature above the liquidus of the print medium during deposition.