An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved structure formation, part creation and manipulation, use of multiple additive manufacturing systems, and high throughput manufacturing methods suitable for automated or semi-automated factories are also disclosed.

An article having a metal substrate and a channel in the metal substrate which is partly or completely open to the surface, wherein the cross section of the channel has a local width maximum (5) between the channel base (7) and the contact plane (1), measured parallel to the contact plane and at right angles to the longitudinal channel axis in the section perpendicular to the surface. (FIG. 1a)

An article having a metal substrate and a channel in the metal substrate which is partly or completely open to the surface, wherein the cross section of the channel has a local width maximum (5) between the channel base (7) and the contact plane (1), measured parallel to the contact plane and at right angles to the longitudinal channel axis in the section perpendicular to the surface. (FIG. 1a)

An alien substance removing apparatus according to one embodiment of the present invention may comprise: a hood unit provided adjacent to an electrical steel sheet and for collecting an alien substance generated in the electrical steel sheet by laser irradiation; and a scraping unit coupled to the hood unit and scraping and removing the alien substance attached to one surface of the hood unit facing the electrical steel sheet.

An alien substance removing apparatus according to one embodiment of the present invention may comprise: a hood unit provided adjacent to an electrical steel sheet and for collecting an alien substance generated in the electrical steel sheet by laser irradiation; and a scraping unit coupled to the hood unit and scraping and removing the alien substance attached to one surface of the hood unit facing the electrical steel sheet.

Byproduct condensate generated during additive manufacturing is controlled by providing at least one electrode inside a chamber. The condensate may be electrically charged as it is generated or an electrical charge may be imparted to the condensate. The electrode may have either a positive or negative bias to either attract or repel the condensate. The electrode may be located on a wall of the chamber or associated with a transparent window through which a laser beam passes into the chamber.

Byproduct condensate generated during additive manufacturing is controlled by providing at least one electrode inside a chamber. The condensate may be electrically charged as it is generated or an electrical charge may be imparted to the condensate. The electrode may have either a positive or negative bias to either attract or repel the condensate. The electrode may be located on a wall of the chamber or associated with a transparent window through which a laser beam passes into the chamber.

In a device for separating a longitudinally-extended cylindrical workpiece, which has a diameter in the sub-millimeter range, into individual segments, the workpiece is guided in a clamping device. The clamping device includes a first and a second clamping jaw and a feed opening for the workpiece. The feed opening is fitted between the clamping jaws on the side facing the other clamping jaw and a longitudinal groove which defines a direction of advancement of the workpiece for receiving and guiding the workpiece between the clamping jaws. The clamping device has a passage for a laser beam and a cutting gas, which passage defines a working zone, disrupts the longitudinal groove and runs parallel thereto. A cutter head is arranged in the working zone and has an outlet opening for the laser beam and the cutting gas, which outlet opening is aligned with the passage.

In a device for separating a longitudinally-extended cylindrical workpiece, which has a diameter in the sub-millimeter range, into individual segments, the workpiece is guided in a clamping device. The clamping device includes a first and a second clamping jaw and a feed opening for the workpiece. The feed opening is fitted between the clamping jaws on the side facing the other clamping jaw and a longitudinal groove which defines a direction of advancement of the workpiece for receiving and guiding the workpiece between the clamping jaws. The clamping device has a passage for a laser beam and a cutting gas, which passage defines a working zone, disrupts the longitudinal groove and runs parallel thereto. A cutter head is arranged in the working zone and has an outlet opening for the laser beam and the cutting gas, which outlet opening is aligned with the passage.

A method of laser welding a workpiece stack-up includes directing a laser beam at a top surface of a first metal workpiece to form a key-hole that entirely penetrates the workpiece stack-up, including an underlying second metal workpiece, so that the keyhole reaches a bottom surface of the second metal workpiece. A zone of negative pressure established under the bottom surface of the second metal workpiece extracts vapors that are produced by the laser beam. The vapors, in particular, are extracted from the bottom surface of the second metal workpiece through the keyhole. A bottom workpiece holder that supports the bottom metal workpiece during laser welding may be constructed to establish the zone of negative pressure.