An additive manufacturing method for making a metal matrix composite component includes melting a powdered mixture with an electron beam. The powdered mixture comprises powdered tungsten carbide in an amount of 45 wt % to 72 wt % of the powdered mixture and a powdered binder in an amount of 28 wt % to 55 wt % of the powdered mixture. The powdered binder comprises boron, silicon, and nickel.

A method and an apparatus pertaining to recycling and reuse of unwanted light in additive manufacturing can multiplex multiple beams of light including at least one or more beams of light from one or more light sources. The multiple beams of light may be reshaped and blended to provide a first beam of light. A spatial polarization pattern may be applied on the first beam of light to provide a second beam of light. Polarization states of the second beam of light may be split to reflect a third beam of light, which may be reshaped into a fourth beam of light. The fourth beam of light may be introduced as one of the multiple beams of light to result in a fifth beam of light.

A method and an apparatus pertaining to polarization combining in additive manufacturing may involve emitting two or more beams of light with a first intensity. Each of the two or more beams of light may be polarized and may have a majority polarization state and a minority polarization state. A respective polarization pattern may be applied on the majority polarization state of each of the two or more beams of light. The two or more beams of light may be combined to provide a single beam of light.

A method of additive manufacture is disclosed. The method may include creating, by a 3D printer contained within an enclosure, a part having a weight greater than or equal to 2,000 kilograms. A gas management system may maintain gaseous oxygen within the enclosure atmospheric level. In some embodiments, a wheeled vehicle may transport the part from inside the enclosure, through an airlock, as the airlock operates to buffer between a gaseous environment within the enclosure and a gaseous environment outside the enclosure, and to a location exterior to both the enclosure and the airlock.

Method for preparing the upper surface of a build platform for additive manufacturing by powder bed deposition, the method comprises at least one step of increasing the roughness of at least one region of the upper surface of the build platform by imprinting a pattern onto this region. The imprinting of the pattern is done inside the machine for additive manufacturing by powder bed deposition in which the build platform is subsequently used for additive manufacturing by powder bed deposition.

A method of additive manufacture suitable for large and high resolution structures is disclosed. The method may include sequentially advancing each portion of a continuous part in the longitudinal direction from a first zone to a second zone. In the first zone, selected granules of a granular material may be amalgamated. In the second zone, unamalgamated granules of the granular material may be removed. The method may further include advancing a first portion of the continuous part from the second zone to a third zone while (1) a last portion of the continuous part is formed within the first zone and (2) the first portion is maintained in the same position in the lateral and transverse directions that the first portion occupied within the first zone and the second zone.

An apparatus for generating electron radiation comprises: an elongated, wire-shaped hot cathode to emit electron radiation having an elongated, line-shaped cross section perpendicular to a direction of propagation of the electron radiation; a cathode electrode; an anode electrode with an opening through which the electron radiation emitted from the hot cathode can pass, wherein a voltage applied between the cathode electrode and the anode electrode accelerates electrons emitted from the hot cathode; and a deflecting unit to deflect the electron radiation downstream of the opening of the anode electrode, wherein a cross section of the electron radiation perpendicular to the direction of propagation is changed by the deflecting unit to decease a longitudinal extent of the electron radiation and to increase a transverse extent of the electron radiation such that longitudinal and transverse extents of the electron radiation perpendicular to the direction of propagation are about the same size.

A method and an apparatus pertaining to recycling and reuse of unwanted light in additive manufacturing can multiplex multiple beams of light including at least one or more beams of light from one or more light sources. The multiple beams of light may be reshaped and blended to provide a first beam of light. A spatial polarization pattern may be applied on the first beam of light to provide a second beam of light. Polarization states of the second beam of light may be split to reflect a third beam of light, which may be reshaped into a fourth beam of light. The fourth beam of light may be introduced as one of the multiple beams of light to result in a fifth beam of light.

A method of additive manufacture suitable for large and high resolution structures is disclosed. The method may include sequentially advancing each portion of a continuous part in the longitudinal direction from a first zone to a second zone. In the first zone, selected granules of a granular material may be amalgamated. In the second zone, unamalgamated granules of the granular material may be removed. The method may further include advancing a first portion of the continuous part from the second zone to a third zone while (1) a last portion of the continuous part is formed within the first zone and (2) the first portion is maintained in the same position in the lateral and transverse directions that the first portion occupied within the first zone and the second zone.

A computing device for controlling the operation of an additive manufacturing machine comprises a memory element and a processing element. The memory element is configured to store a three-dimensional model of a part to be manufactured, wherein the three-dimensional model defines a plurality of cross sections of the part. The processing element is in communication with the memory element. The processing element is configured to receive the three-dimensional model, determine a plurality of paths, each path including a plurality of parallel lines, determine a radiation beam power for each line, such that the radiation beam power varies non-linearly according to a length of the line, and determine a radiation beam scan speed for each line, such that the radiation beam scan speed is a function of a temperature of a material used to manufacture the part, the length of the line, and the radiation beam power for the line.