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. Electrons deflected from a substrate in the processing area impinge on a surface of a sensor. The electrons result from the deflection of an electron beam from the substrate. Either one or both of an initial profile of an electron beam and an initial location of the electron beam relative to the substrate are determined based on a feedback electron signal corresponding to the impingement of the electrons on the surface of the sensor. With an appropriate profile and location of the electron beam, the build structure is fabricated on the substrate.

A jig structure for manufacturing heat dissipation unit includes a main body, which internally defines a chamber and has a top forming an upper side thereof. The top defines at least one opening, on which at least one silicon dioxide layer is provided. The chamber is in a vacuum-tight state or maintains a positive pressure inert gas atmosphere therein. The jig structure for manufacturing heat dissipation unit can be used with a laser machining tool to provide a better environment and increased flexibility for laser machining or laser welding in manufacturing a heat dissipation unit.

A jig structure for manufacturing heat dissipation unit includes a main body, which internally defines a chamber and has a top forming an upper side thereof. The top defines at least one opening, on which at least one silicon dioxide layer is provided. The chamber is in a vacuum-tight state or maintains a positive pressure inert gas atmosphere therein. The jig structure for manufacturing heat dissipation unit can be used with a laser machining tool to provide a better environment and increased flexibility for laser machining or laser welding in manufacturing a heat dissipation unit.

A metal matrix composite composition includes tungsten carbide in an amount of 45 wt % to 72 wt % of the composition. In addition, the composition includes a binder in an amount of 28 wt % to 55 wt % of the composition. The binder includes nickel in an amount of at least 99 wt % of the binder.

A metal matrix composite composition includes tungsten carbide in an amount of 45 wt % to 72 wt % of the composition. In addition, the composition includes a binder in an amount of 28 wt % to 55 wt % of the composition. The binder includes nickel in an amount of at least 99 wt % of the binder.

An apparatus for forming a three-dimensional article through successive fusion of parts of a powder bed, which parts corresponds to successive cross sections of the three-dimensional article, said apparatus comprising: a powder distributor configured for evenly distributing a layer of powder on top of a work table provided inside a vacuum chamber; and an electron beam source emanating an electron beam configured for fusing the powder layer in selected locations corresponding to said cross section of the three-dimensional article, wherein: said powder distributor being an elongated rod provided movable at a predetermined distance above the powder bed and with its central axis in parallel with a top surface of said work table, wherein at least one sensor is provided on said powder distributor facing towards said electron beam source, a detector for detecting a signal sent out from said sensor when said sensor is interacting with said electron beam.

An apparatus and a method for powder bed fusion additive manufacturing involve a multiple-chamber design achieving a high efficiency and throughput. The multiple-chamber design features concurrent printing of one or more print jobs inside one or more build chambers, side removals of printed objects from build chambers allowing quick exchanges of powdered materials, and capabilities of elevated process temperature controls of build chambers and post processing heat treatments of printed objects. The multiple-chamber design also includes a height-adjustable optical assembly in combination with a fixed build platform method suitable for large and heavy printed objects.

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 for layer-by-layer manufacturing of a three-dimensional metallic work piece, comprising the steps of: delivering a metallic feed material in a substantially solid state into a feed region; emitting an electron beam; and translating the electron beam through a first predetermined raster pattern frame in an x-y plane. The method may also include monitoring a condition of one or both of the feed region or the substrate region in real time for the occurrence of any deviation from a predetermined condition; upon detecting of any deviation, translating the electron beam through at least one second predetermined raster pattern frame in the x-y plane that maintains the melting beam power density level substantially the same as the first predetermined raster pattern frame, but alters the substrate beam power density level.

A method for layer-by-layer manufacturing of a three-dimensional metallic work piece, comprising the steps of: delivering a metallic feed material in a substantially solid state into a feed region; emitting an electron beam; and translating the electron beam through a first predetermined raster pattern frame in an x-y plane. The method may also include monitoring a condition of one or both of the feed region or the substrate region in real time for the occurrence of any deviation from a predetermined condition; upon detecting of any deviation, translating the electron beam through at least one second predetermined raster pattern frame in the x-y plane that maintains the melting beam power density level substantially the same as the first predetermined raster pattern frame, but alters the substrate beam power density level.