Three-dimensional manufacturing method and apparatus which easily adjust individually a heating amount per unit area for each of solidified and unsolidified regions is provided. Light source and scanning unit heat with a laser beam a layer formed by a layer forming unit. In a layer forming step, a controlling unit causes the layer forming unit to form a layer of material powder. In a laser heating step, the controlling unit controls the light source and the scanning unit to alternately heat with the laser beam the solidified region obtained by fusing and solidifying the layer and the unsolidified region adjacent to the solidified region, thereby integrally fusing and solidifying the solidified region and the unsolidified region.

A three-dimensional manufacturing apparatus and a three-dimensional manufacturing method easily adjust a heating quantity per unit area individually for a solidified region and a non-solidified region of a powder material. A layer formation unit forms a layer of a powder material. Light sources and heat scanning units heat the layer by laser beams. The laser beam heats a solidified region in which the powder material has been fused and solidified. The laser beam heats the non-solidified region of the powder material, which is adjacent to the solidified region. The controlling section controls the light sources and the heat scanning units so as to move the laser beams along a boundary between the solidified region and the non-solidified region, and to fuse and solidify a manufacturing region of the layer.

A three-dimensional manufacturing apparatus and a three-dimensional manufacturing method easily adjust a heating quantity per unit area individually for a solidified region and a non-solidified region of a powder material. A layer formation unit forms a layer of a powder material. Light sources and heat scanning units heat the layer by laser beams. The laser beam heats a solidified region in which the powder material has been fused and solidified. The laser beam heats the non-solidified region of the powder material, which is adjacent to the solidified region. The controlling section controls the light sources and the heat scanning units so as to move the laser beams along a boundary between the solidified region and the non-solidified region, and to fuse and solidify a manufacturing region of the layer.

An additive manufacturing system is provided. The system includes: a stage, a powder supplying device, an energy beam generating device and an atmosphere controlling module. The powder supplying device provides powder to the stage. The energy beam-generating device generates an energy beam and directs the energy beam to the stage. The atmosphere controlling module includes at least one pair of gas inlet-outlet devices coupled around the stage, and a dynamic gas flow controlling device connected with the gas inlet-outlet devices. The dynamic gas flow controlling device dynamically controls an angle between a flow direction of the gas and a moving direction of the energy beam. The angle is predetermined by a scanning strategy.

An additive manufacturing system is provided. The system includes: a stage, a powder supplying device, an energy beam generating device and an atmosphere controlling module. The powder supplying device provides powder to the stage. The energy beam-generating device generates an energy beam and directs the energy beam to the stage. The atmosphere controlling module includes at least one pair of gas inlet-outlet devices coupled around the stage, and a dynamic gas flow controlling device connected with the gas inlet-outlet devices. The dynamic gas flow controlling device dynamically controls an angle between a flow direction of the gas and a moving direction of the energy beam. The angle is predetermined by a scanning strategy.

A sintered metal object comprises metal fibers in a nonwoven web arrangement. The metal fibers comprise stainless steel fibers having a duplex microstructure. The duplex microstructure is a mixed microstructure of austenite and ferrite. The stainless steel fibers are bonded at at least part of their contacting points by means of sinter bonds.

A sintered metal object comprises metal fibers in a nonwoven web arrangement. The metal fibers comprise stainless steel fibers having a duplex microstructure. The duplex microstructure is a mixed microstructure of austenite and ferrite. The stainless steel fibers are bonded at at least part of their contacting points by means of sinter bonds.

A reclamation system for a metal powder, such as a reactive metal powder, is disclosed. The system may include a container; and a pressure source in fluid communication with the container for creating a selected pressure within the container, the container including: an inlet to a lower portion of the tank that is configured to hold a liquid, and an outlet. A controller controls the pressure source to control the pressure applied within the container between: a vacuum state creating a flow of air entrained metal powder to enter the inlet for forming a reclaimed metal powder by removing the metal powder from the air by immersion in the liquid, and an evaporation state that causes evaporation of the liquid to a gas that exits through the outlet. A condenser condenses the gas to a condensed liquid.

A reclamation system for a metal powder, such as a reactive metal powder, is disclosed. The system may include a container; and a pressure source in fluid communication with the container for creating a selected pressure within the container, the container including: an inlet to a lower portion of the tank that is configured to hold a liquid, and an outlet. A controller controls the pressure source to control the pressure applied within the container between: a vacuum state creating a flow of air entrained metal powder to enter the inlet for forming a reclaimed metal powder by removing the metal powder from the air by immersion in the liquid, and an evaporation state that causes evaporation of the liquid to a gas that exits through the outlet. A condenser condenses the gas to a condensed liquid.

Methods and systems comprise new design procedures that can be implemented for additive manufacturing technologies that involve evaluation of stress concentration sites using finite element analysis and implementation of scanning strategies during fabrication that improve performance by spatially adjusting thermal energy at potential failure sites or high stress regions of a part.