The present disclosure provides three-dimensional (3D) objects, 3D printing processes, as well as methods, apparatuses and systems for the production of a 3D object. Methods, apparatuses and systems of the present disclosure may reduce or eliminate the need for auxiliary supports. The present disclosure provides three dimensional (3D) objects printed utilizing the printing processes, methods, apparatuses and systems described herein.

A method for training a machine learning engine for modeling of a physical system includes receiving process data representing measurements of a physical system. The method includes applying a transform to values of the at least two variables of the process data to generate a dimensionless parameter having a parameter value corresponding to each measurement of the physical system for the at least two variables. The method includes training the machine learning engine using a set of generated training data including the non-dimensionalized parameter, to output a prediction of a value of a physical effect of the physical system for values of the variables that are not included in the process data. The method includes controlling an additive manufacturing process for the material by setting the at least one physical property to the value of the at least one process variable during fabrication of a part.

A hybrid method of surface hardening metallic components using a combination of chemical modification achieved through additive manufacturing and/or diffusion-based processing with transformation-based processing using a high energy density heat source. The hybrid process results in increased surface hardness and/or increased average case hardness and/or increased case depth compared to either treatment individually.

In one aspect, an additive manufacturing system is provided. The additive manufacturing system includes a build platform, a first plurality of particles positioned on the build platform, and a particle containment system positioned on the build platform. The particle containment system includes a particle containment wall. The particle containment wall at least partially surrounds the first plurality of particles and includes a second plurality of particles consolidated together. The particle containment wall includes a top end spaced apart from the build platform, an inner face positioned against the first plurality of particles and extending between the build platform and the top end, and an outer face that faces a substantially particle-free region, the outer face positioned opposite the inner face and extending between the build platform and the top end.

Embodiments of the systems can be configured to receive electromagnetic emissions of a substrate (e.g., a build material of a part being made via additive manufacturing) by a detector (e.g., a multi-spectral sensor) and generate a ratio of the electromagnetic emissions to perform spectral analysis with a reduced dependence on location and orientation of a surface of the substrate relative to the multi-spectral sensor. The additive manufacturing process can involve use of a laser to generate a laser beam for fusion of the build material into the part. The system can be configured to set the multi-spectral sensor off-axis with respect to the laser (e.g., an optical path of the multi-spectral sensor is at an angle that is different than the angle of incidence of the laser beam). This can allow the multi-spectral sensor to collect spectral data simultaneously as the laser is used to build the part.

A pre-alloyed powder having a composition consisting of, in weight % (wt. %): C, 0.02-0.04; Si, 0.1-0.4; Mn, 0.1-0.5; Cr, 11-13; Ni, 7-10; Cr+Ni, 19-23; Mo, 1-25; Al, 1.4-2.0; N, 0.01-0.75. Optionally, the pre-alloyed powder contains: Cu, 0.05-2.5; B, 0.002-2.0; S, 0.01-0.25; Nb, 0.01 max; Ti, 2 max; Zr, 2, max; Ta, 2 max; Hf, 2 max; Y, 2 max; Ca, 0.0003-0.009; Mg, 0.01 max; O, 0.003-0.80; and REM, 0.2 max. Fe and impurities comprise the balance.

A build plate-clamping assembly may include a work station having a build plate-receiving surface and a lock-pin extending from the build plate-receiving surface of the work station. The lock-pin may include a hollow pin body, a piston disposed within the hollow pin body, with the piston axially movable from a retracted position to an actuated position, and a plurality of detents, with the plurality of detents radially extensible through respective ones of a plurality of detent-apertures in the hollow pin body responsive to the piston having been axially moved to the actuated position. A methods of working on workpieces may include lockingly engaging a build plate at a first work station, performing a first work-step, releasing the build plate from the first work station, lockingly engaging the build plate at a second work station, and performing a second work-step. An additive manufacturing system may include a vision system with a first build plate-receiving surface and an additive manufacturing machine with a second build plate-receiving surface.

A method for forming a 2-dimensional pattern or 3-dimensional object using an aluminum (Al) 5xxx series alloy includes providing a feedstock that includes the Al 5xxx alloy. The method further includes depositing, using an additive manufacturing process, the feedstock under thermal conditions that permit formation of the pattern or object. The method further includes adjusting a parameter of the additive manufacturing process during the depositing.

A method for forming a 2-dimensional pattern or 3-dimensional object using an aluminum (Al) 5xxx series alloy includes providing a feedstock that includes the Al 5xxx alloy. The method further includes depositing, using an additive manufacturing process, the feedstock under thermal conditions that permit formation of the pattern or object. The method further includes adjusting a parameter of the additive manufacturing process during the depositing.

Disclosed is a switching system for a facility for 3D printing by spraying at least a first powder, including a body defining: at least one first upstream gas conduit configured to receive a gas; at least one first upstream powder conduit configured to receive the first powder; at least one first downstream discharge conduit for discharging the first powder; and a downstream work conduit configured in order to supply a nozzle designed for depositing at least the first powder. The system further includes a distributor that is movable with respect to the body, preferably in rotation about an axis, between a rest position, in which the first upstream powder conduit is fluidly connected, via the distributor, to the first downstream discharge conduit, and at least a first supply position, in which the first upstream powder conduit is fluidly connected, via the distributor, to the downstream work conduit.