A High Energy Beam Processing (HEBP) system provides feedback signal monitoring and feedback control for the improvement of process repeatability and three-dimensional (3D) printed part quality. Signals reflecting process parameters and the quality of the fabricated parts are analyzed by monitoring feedback signals from artifact sources with a process controller which adjusts process parameters. In this manner, fabricated parts are produced more accurately and consistently from powder feedstock by compensating for process variation in response to feedback signals.

A novel method for two-dimensional or three-dimensional photo-thermal printing of metals, oxides, alloys, and metal composites to produce objects having predetermined shapes is presented. The method comprises: providing a metal ion solution on a substrate; focusing modulated laser light with an objective lens system into the solution on the substrate, thereby causing a microbubble to form and attaching reduced metal ions to the substrate; and moving the focus of the modulated laser light in the x, y, and z directions to continuously form new microbubbles on the previously deposited structure and directly attach reduced metal ions to the previously deposited structure as metal, metal oxide, alloy, or metal composite until the predetermined shape of the object has been produced. The method can be carried out using both layer by layer printing and vector printing.

A novel method for two-dimensional or three-dimensional photo-thermal printing of metals, oxides, alloys, and metal composites to produce objects having predetermined shapes is presented. The method comprises: providing a metal ion solution on a substrate; focusing modulated laser light with an objective lens system into the solution on the substrate, thereby causing a microbubble to form and attaching reduced metal ions to the substrate; and moving the focus of the modulated laser light in the x, y, and z directions to continuously form new microbubbles on the previously deposited structure and directly attach reduced metal ions to the previously deposited structure as metal, metal oxide, alloy, or metal composite until the predetermined shape of the object has been produced. The method can be carried out using both layer by layer printing and vector printing.

A method of manufacturing a hard-to-weld material by a beam-assisted additive manufacturing process is presented. The method includes depositing a first layer for the material onto the substrate, the first layer including a major fraction of a base material for the component and a minor fraction of a solder, depositing a second layer of the base material for the component and a thermal treatment of the layer arrangement. The thermal treatment includes a first thermal cycle at a first temperature above 1200° C. for a duration of more than 3 hours, a subsequent second thermal cycle at a second temperature above 1000° C. for more than 2 hours, and a subsequent third thermal cycle and a third temperature above 700° C. for more than 12 hours. A manufactured component is also presented.

A system and method for additive manufacturing are provided. The system includes a structure defining a chamber for manufacturing parts via additive manufacturing. A powder metal applicator is configured to deposit layers of powder metal material to build a part on a build platform. A laser source is configured to direct one or more laser beams onto each layer of powder metal material to fuse the powder metal material, wherein metal condensate is created by the laser beam(s) contacting the powder metal material. An element spaced apart from the layers of powder material has a temperature different than the chamber temperature, so that the element is configured to attract or repel the metal condensate by virtue of the temperature differential between the element and the chamber. The method includes using the element having the different temperature to attract or repel the metal condensate within the chamber.

Methods of forming metal multipod nanostructures. The methods may include providing a mixture that includes a metal acetylacetonate, a reducing agent, and a carboxylic acid. The mixture may be contacted with microwaves to form the metal multipod nanostructures. The methods may offer control over the structure and/or morphology of the metal multipod nanostructures.

Equipment for selectively depositing, by shockwave-induced spraying, at least one particle on a deposition surface of a receiver substrate. The equipment including at least one laser source that emits a laser beam, a substrate carrier to which the substrate is fastened, a shockwave-generating layer having a first surface oriented toward the laser beam and a second surface oriented toward the deposition surface of the substrate, an optical system for directing and focusing the laser beam toward a focal region of the first surface. The second surface including a plurality of cavities, each cavity housing at least one particle. The laser beam generates a plasma in the focal region on the first surface and a shockwave that propagates within the generating layer from the first surface to the second surface in order to spray at least one particle in the direction of the deposition surface of the substrate.

Equipment for selectively depositing, by shockwave-induced spraying, at least one particle on a deposition surface of a receiver substrate. The equipment including at least one laser source that emits a laser beam, a substrate carrier to which the substrate is fastened, a shockwave-generating layer having a first surface oriented toward the laser beam and a second surface oriented toward the deposition surface of the substrate, an optical system for directing and focusing the laser beam toward a focal region of the first surface. The second surface including a plurality of cavities, each cavity housing at least one particle. The laser beam generates a plasma in the focal region on the first surface and a shockwave that propagates within the generating layer from the first surface to the second surface in order to spray at least one particle in the direction of the deposition surface of the substrate.

Methods of forming metal multipod nanostructures. The methods may include providing a mixture that includes a metal acetylacetonate, a reducing agent, and a carboxylic acid. The mixture may be contacted with microwaves to form the metal multipod nanostructures. The methods may offer control over the structure and/or morphology of the metal multipod nano structures.

Herein disclosed is a method of making a fuel cell including forming an anode, a cathode, and an electrolyte using an additive manufacturing machine. The electrolyte is between the anode and the cathode. Preferably, electrical current flow is perpendicular to the electrolyte in the lateral direction when the fuel cell is in use. Preferably, the method comprises making an interconnect, a barrier layer, and a catalyst layer using the additive manufacturing machine.