Devices and methods to assist wire arc additive manufacturing (WAAM) are provided. A non-contact, multidirectional synchronized ultrasonic device can include multiple ultrasonic probes mounted on a nozzle of a WAAM robotic arm. The probes can include one normal probe and a plurality of lateral probes configured to rotate on a parabolic frame. The ultrasonic probe in the normal direction can act by its continual high-frequency oscillation in the arc plasma to enhance the arc push force, while the lateral probes can act on the shape of both sides of the deposit. The combined effect of the probes can generate ultrasonic waves and cavitation in the molten pool.

A three-dimensional (3D) metal object manufacturing apparatus is equipped with a vessel having a receptacle that holds melted metal. The vessel has a divider that prevents metal dross formed at a solid metal inlet of the receptacle to migrate to a portion of the receptacle where a melted metal level sensor directs light.

An alpha-beta titanium-based alloy including titanium; one of 0.001-1.0 wt. % neodymium, 0.001-1.0 wt. % dysprosium, or 0.001-0.5 wt. % erbium; and at least one of aluminum, zirconium, tin, oxygen, molybdenum, vanadium, niobium, iron, and chromium present in amounts defined based on an aluminum equivalent and a molybdenum equivalent, wherein the aluminum equivalent (Al-eq) is between 0 to 7.5% and the molybdenum equivalent (Mo-eq) is between 2.7 to 47.5, and wherein the aluminum equivalent (Al-eq) and the molybdenum equivalent (Mo-eq) are defined, in weight percents, as follows:
Al-eq=(Al %)+(Zr %)/6+(Sn %)/3+10*(O %)
Mo-eq=(Mo %)+0.67*(V %)+0.33*(Nb %)+2.9*(Fe %)+1.6*(Cr %).

A print head comprising nested chambers for in-situ reactant formation is disclosed. The print head comprises a first chamber nested within a second chamber. The first chamber comprises a first nozzle, the second chamber comprises a second nozzle. The first nozzle is substantially coaxial with the second nozzle. A susceptor to convert electromagnetic energy to heat is within the first chamber. The susceptor comprises one or more openings extending between the upper portion and the lower portion. The susceptor may be heated by induction heating or by optical heating to vaporize a precursor substance within the first chamber. The vapor may react with a reactive gas flowing through the first chamber or expand through a nozzle into a second chamber where the vapor may react with the reactive gas, forming nanoparticles. Patterned films may be written onto a two-dimensional or three-dimensional surfaces.

Controlled manufacturing system suitable for controlling a method for manufacturing, repairing or resurfacing a part by deposition of material under concentrated energy, said controlled manufacturing system comprising: means for obtaining a three-dimensional digital model of the part; means for generating a manufacturing file for the part, based on the three-dimensional digital model of said part, to define manufacturing parameters of an additive manufacturing machine, said manufacturing parameters being associated with manufacturing instructions; means for generating a control file for the part to define control parameters of a control effector, said control parameters being associated with control instructions; analysis means for carrying out an analysis of the manufacturing file and the control file in order to determine if the manufacturing parameters and the control parameters can coexist during the simultaneous application of the manufacturing parameters to the additive manufacturing machine and the control parameters to the control effector; a control module comprising at least one communication channel for receiving and sending the manufacturing instructions to a polyarticulated manufacturing system suitable for supporting the additive manufacturing machine, and at least one communication channel for receiving and sending the control instructions to a polyarticulated control system suited to supporting the control effector, to manage simultaneously the additive manufacturing machine and the control effector.

Controlled manufacturing system suitable for controlling a method for manufacturing, repairing or resurfacing a part by deposition of material under concentrated energy, said controlled manufacturing system comprising: means for obtaining a three-dimensional digital model of the part; means for generating a manufacturing file for the part, based on the three-dimensional digital model of said part, to define manufacturing parameters of an additive manufacturing machine, said manufacturing parameters being associated with manufacturing instructions; means for generating a control file for the part to define control parameters of a control effector, said control parameters being associated with control instructions; analysis means for carrying out an analysis of the manufacturing file and the control file in order to determine if the manufacturing parameters and the control parameters can coexist during the simultaneous application of the manufacturing parameters to the additive manufacturing machine and the control parameters to the control effector; a control module comprising at least one communication channel for receiving and sending the manufacturing instructions to a polyarticulated manufacturing system suitable for supporting the additive manufacturing machine, and at least one communication channel for receiving and sending the control instructions to a polyarticulated control system suited to supporting the control effector, to manage simultaneously the additive manufacturing machine and the control effector.

Disclosed are a high-throughput preparation device for metal fiber based on multi powder and a method for preparing a metal fiber using the device. The high-throughput preparation device includes a metal powder conveying system, a metal powder mixing system, a metal powder melting system and a metal fiber forming system which are connected in sequence, where the metal powder melting system includes an induction powder melting device and a laser powder melting device which are independently disposed. The method for preparing a metal fiber using the high-throughput preparation device includes four steps: powder conveying, powder mixing, melting and forming.

A plasticization device includes: a rotor rotated by a drive motor and having a groove forming surface in which a first groove portion is formed along a rotation direction; a rotor case configured to accommodate the rotor; a barrel facing the groove forming surface and having a through hole; a first heating unit configured to heat the rotor or the barrel; and a cooling mechanism configured to cool a side surface of the rotor. In the plasticization device, a material supplied between the first groove portion and the barrel is plasticized by rotation of the rotor and heating by the first heating unit to flow out from the through hole, and the side surface of the rotor has a material guiding port configured to guide the material to the first groove portion, and a second groove portion configured to feed the material supplied between the rotor and the rotor case to the material guiding port.

A method operates a three-dimensional (3D) metal object manufacturing system to maintain a temperature of an uppermost layer of a 3D metal object being formed within a temperature range conducive for bonding between the uppermost layer and a next layer to be formed. A controller of the system compares a temperature of the uppermost layer with at least a low end temperature of the temperature range and operates an electrical resistance switching network using 3D model data to provide electrical power selectively to heating elements in a modular heater to heat the 3D metal object being formed when the temperature indicated by the signal from the sensor is less than the predetermined temperature.

A service station system for a three-dimensional printing system comprises: a bath, having a fast-release connector at a front side thereof, and a hinge at a back side thereof for hingebly connecting an open top of the bath to a surface of the three-dimensional printing system; and a wiper assembly, having a wiper device detachably connected to a wiper base mounted on a rotatable axis passing through the bath. The wiper device wipes a dispensing face of the printing head of the three-dimensional printing system while the head reciprocally moves above the bath between the back side and the front side. The service station system can also comprise a motor for rotating the axis.