This disclosure provides systems, methods and apparatus systems and methods described herein provide, among other things, a system for additive manufacturing of metal objects. The system includes two electron beams. In one optional implementation, one beam is high powered and acts as a deposition beam that melts a metal feed stock material which is delivered to a deposition zone and onto a work surface and the second electron beam is a low power electron source. The second electron beam acts as an interrogating source that generates an electron beam which interacts with the deposited material. The second electron beam may be active after material is deposited and provides post-deposition in-situ metrology. Various signals generated by this second beam/material interaction are collected and used to provide information about the melted and deposited material.

This disclosure provides systems, methods and apparatus systems and methods described herein provide, among other things, a system for additive manufacturing of metal objects. The system includes two electron beams. In one optional implementation, one beam is high powered and acts as a deposition beam that melts a metal feed stock material which is delivered to a deposition zone and onto a work surface and the second electron beam is a low power electron source. The second electron beam acts as an interrogating source that generates an electron beam which interacts with the deposited material. The second electron beam may be active after material is deposited and provides post-deposition in-situ metrology. Various signals generated by this second beam/material interaction are collected and used to provide information about the melted and deposited material.

This invention quickly supplies a predetermined amount of powder from a hopper to a recoater. A powder supply apparatus includes, as its feature, a hopper, a powder spreader, a powder replenisher, and a pivoting unit. The hopper of the powder supply apparatus stores a powder. The powder spreader spreads the powder on a shaping surface. The powder replenisher of the powder supply apparatus is provided between the hopper and the powder spreader, and replenishes the powder spreader with a predetermined amount of powder. The pivoting unit of the powder supply apparatus causes the powder replenisher to pivot.

This invention quickly supplies a predetermined amount of powder from a hopper to a recoater. A powder supply apparatus includes, as its feature, a hopper, a powder spreader, a powder replenisher, and a pivoting unit. The hopper of the powder supply apparatus stores a powder. The powder spreader spreads the powder on a shaping surface. The powder replenisher of the powder supply apparatus is provided between the hopper and the powder spreader, and replenishes the powder spreader with a predetermined amount of powder. The pivoting unit of the powder supply apparatus causes the powder replenisher to pivot.

An AM continuous welding system (AMCWS) is provided. The AMCWS includes a feedstock dispenser that configured to emit feedstock at a designated location, and a heat source configured to heat the feedstock. The AMCWS also includes a first eddy current sensor array that is configured to generate a first plurality of sensor signals while in current-sensing proximity of a re-solidified feedstock segment. A controller is coupled to the first eddy current sensor array and is configured to determine, based on the first plurality of sensor signals, a first characteristic of the re-solidified feedstock segment. The controller determines that the first characteristic is a first undesirable characteristic, and initiates an action based on the first undesirable characteristic.

An AM continuous welding system (AMCWS) is provided. The AMCWS includes a feedstock dispenser that configured to emit feedstock at a designated location, and a heat source configured to heat the feedstock. The AMCWS also includes a first eddy current sensor array that is configured to generate a first plurality of sensor signals while in current-sensing proximity of a re-solidified feedstock segment. A controller is coupled to the first eddy current sensor array and is configured to determine, based on the first plurality of sensor signals, a first characteristic of the re-solidified feedstock segment. The controller determines that the first characteristic is a first undesirable characteristic, and initiates an action based on the first undesirable characteristic.

The present invention relates to a methods, computer program products, program elements, and apparatuses for forming a three-dimensional article through successively depositing individual layers of powder material that are fused together so as to form the article. The method comprising the steps of providing at least one electron beam source emitting an electron beam for at least one of heating or fusing the powder material, where the electron beam source comprises a cathode and an anode, and varying an accelerator voltage between the cathode and the anode between at least a first and second predetermined value during the forming of the three-dimensional article.

The present invention relates to a methods, computer program products, program elements, and apparatuses for forming a three-dimensional article through successively depositing individual layers of powder material that are fused together so as to form the article. The method comprising the steps of providing at least one electron beam source emitting an electron beam for at least one of heating or fusing the powder material, where the electron beam source comprises a cathode and an anode, and varying an accelerator voltage between the cathode and the anode between at least a first and second predetermined value during the forming of the three-dimensional article.

The present disclosure provides three-dimensional (3D) printing methods, apparatuses, systems, and non-transitory computer-readable medium. The disclosure delineates real time manipulation of three-dimensional printing to reduce deformation. The present disclosure further provides 3D object formed using the methods, apparatuses, and systems.

The present disclosure provides three-dimensional (3D) printing methods, apparatuses, systems, and non-transitory computer-readable medium. The disclosure delineates real time manipulation of three-dimensional printing to reduce deformation. The present disclosure further provides 3D object formed using the methods, apparatuses, and systems.