Excessive evaporation of powder is prevented. A three-dimensional shaping apparatus includes an electron gun that generates an electron beam, at least one deflector that deflects the electron beam one- or two-dimensionally, at least one lens that is provided between the electron gun and the deflector, and that focuses the electron beam, and a controller that controls the deflection direction and scanning speed of the deflector, the deflector scanning and irradiating the predetermined regions. The three-dimensional shaping apparatus further includes a controller that controls the cross-sectional diameter of the electron beam. The process step of melting the powder is divided into two process steps, namely the first melting step and the second melting step in the sequential order of the process steps. In the first melting step, the powder is given the amount of unit-area heat necessary to raise the temperature of the powder from its preheating temperature to its melting point. In the second melting step, the powder is given the amount of unit-area heat equal to or larger than the amount of unit-area heat necessary for the powder to melt by receiving its melting heat. In the second melting step, furthermore, the cross-sectional diameter of the beam is increased so that the powder is given a smaller amount of unit-area amount of unit-area power of the electron beam in the second melting step than in the first melting step.

A method of manufacturing a component using electron beam melting includes providing a powder layer; selectively melting at least a part of the powder layer so as to generate a solid layer of the component using a first electron beam; identifying any defects in the solid layer by scanning the solid layer using a second electron beam; and then repeating these steps at least once so as to build up a shape corresponding to the component. The second electron beam has a lower power than the first electron beam. The method may also include steps of removing any identified defects in the solid layer by using the first electron beam to re-melt at least a part of the solid layer, and adjusting one or more parameters of the selective melting step so as to avoid future recurring defects based on stored data relating to the scanned solid layer.

Systems and methods for multi-materials and varying print parameters in Additive Manufacturing systems are provided. In one example, a layer including a first powder material and a second material different from the first powder material are deposited, such that at least a first portion of the first powder material is in a first area that is devoid of the second material. An energy beam is generated and applied to fuse the layer at a plurality of locations. In another example, a layer of a powder material is deposited based on a first subset of parameters. An energy beam is generated based on a second subset of the parameters, and the energy beam is applied to fuse the layer at a plurality of locations based on a third subset of the parameters. At least one of the parameters is set to have different values during a slice printing operation.

In an additive manufacturing apparatus using electron beam melting for manufacturing three-dimensional structures by laminating layers in which metal powder is selectively molten-solidified with electron beam, defect in current apparatus is to be removed such that electrons accelerated with a constant accelerating voltage are irradiated irrespective of filling rate or density of metal powder to be used for additive manufacturing. Voltage of power supply applied between a grid and an anode provided in an electron gun for generating electron beam is varied corresponding to filling rate and/or density of metal powder. With this, velocity of electron such that a position where thermal energy becomes maximum is taken as most suitable can be obtained.

Methods and systems are provided for using optical interferometry in the context of material modification processes such as surgical laser, sintering, and welding applications. An imaging optical source that produces imaging light. A feedback controller controls at least one processing parameter of the material modification process based on an interferometry output generated using the imaging light. A method of processing interferograms is provided based on homodyne filtering. A method of generating a record of a material modification process using an interferometry output is provided.

Methods and systems are provided for using optical interferometry in the context of material modification processes such as surgical laser or welding applications. An imaging optical source that produces imaging light. A feedback controller controls at least one processing parameter of the material modification process based on an interferometry output generated using the imaging light. A method of processing interferograms is provided based on homodyne filtering. A method of generating a record of a material modification process using an interferometry output is provided.

There is provided electron beam welding apparatus comprising an electron beam gun (50) associated with a welding chamber (54) configured for welding of a battery array (33) to a bus bar (32) and beam adjustment devices (56, 58) operative in response to a controller (60) to modify beam characteristics and position of an electron beam (52) generated by the electron beam gun (50), wherein at least two subsidiary chambers (70, 72) are disposed on opposing sides of the welding chamber (54), all chambers being evacuable to be under a vacuum, and a beam detector (61) is positioned proximal the welding chamber (54) to generate data relating to beam characteristics and position, the controller (60) configured to respond to data from the beam detector (61) to control synchronously the beam adjustment devices (56, 58) and to create a consistent welding penetration depth for welds formed between a bus bar (32) and a battery array (33) regardless of angle of incidence of an electron beam. An associated welding method is also provided.

The present disclosure provides three-dimensional (3D) printing methods, apparatuses, systems and/or software to form one or more three-dimensional objects, some of which may be complex. The three-dimensional objects may be formed by three-dimensional printing using one or more methodologies. In some embodiments, the three-dimensional object may comprise an overhang portion, such as a cavity ceiling, with diminished deformation and/or auxiliary support structures.

The present disclosure provides three-dimensional (3D) printing methods, apparatuses, systems and/or software to form one or more three-dimensional objects, some of which may be complex. The three-dimensional objects may be formed by three-dimensional printing using one or more methodologies. In some embodiments, the three-dimensional object may comprise an overhang portion, such as a cavity ceiling, with diminished deformation and/or auxiliary support structures.

The present disclosure provides three-dimensional (3D) printing methods, apparatuses, systems and/or software to form one or more three-dimensional objects, some of which may be complex. The three-dimensional objects may be formed by three-dimensional printing using one or more methodologies. In some embodiments, the three-dimensional object may comprise an overhang portion, such as a cavity ceiling, with diminished deformation and/or auxiliary support structures.