The present disclosure provides three-dimensional (3D) printing methods, apparatuses, systems and software that effectuate formation of a robust 3D object comprising at least one metal alloy. The 3D object may be formed by 3D printing. The 3D object may comprise diminished defects (e.g., heat cracks). The alloy may be formed by diffusion. The diffusion may be a controlled diffusion. The control may comprise (e.g., real time) temperature control during the formation of the 3D object. The 3D object may comprise controlled crystal structure and/or metallurgical phases.

An article and a process of producing an article are provided. The article includes a base material, a cooling feature arrangement positioned on the base material, the cooling feature arrangement including an additive-structured material, and a cover material. The cooling feature arrangement is between the base material and the cover material. The process of producing the article includes manufacturing a cooling feature arrangement by an additive manufacturing technique, and then positioning the cooling feature arrangement between a base material and a cover material.

An article and a process of producing an article are provided. The article includes a base material, a cooling feature arrangement positioned on the base material, the cooling feature arrangement including an additive-structured material, and a cover material. The cooling feature arrangement is between the base material and the cover material. The process of producing the article includes manufacturing a cooling feature arrangement by an additive manufacturing technique, and then positioning the cooling feature arrangement between a base material and a cover material.

A component pair is provided. The component pairs includes a first component comprising a first mating surface defining a first geometry associated with a geometric key, and a second component comprising a second mating surface defining a second geometry, the second geometry being determined using the geometric key and being complementary to the first geometry. The first component and the second component may be properly mated together only when the first geometry is received by the second geometry.

Disclosed herein is a system and a method for controlling laser energy deposition in order to normalize post-sintering temperatures is presented. Sensors provide feedback for in-situ control of laser power to reduce the influence the pre-sintering thermal profile has on the post-sintering temperatures. By actively controlling the laser during its scanning, the post-sintering temperatures can be more accurately controlled, resulting in mechanical and geometric improvements in part quality.

In an example of a three-dimensional (3D) printing method, a build material (consisting of an inorganic particle and a polymer attached thereto) is applied. The polymer is a continuous coating having a thickness from about 3 nm to about 1500 nm, or nano-beads having an average diameter from about 3 nm to about 1500 nm. The build material is heated to a temperature from about 5° C. to about 50° C. below the polymer's melting point. A coalescent dispersion (including a coalescent agent and inorganic nanoparticles) is selectively applied on a portion of the build material, and the applied build material and coalescent dispersion are exposed to electromagnetic radiation. The coalescent dispersion absorbs the electromagnetic radiation and heats up the portion of the build material in contact therewith to fuse the portion of the build material in contact with the coalescent dispersion and to form a layer of a 3D object.

A variety of additive manufacturing techniques can be adapted to fabricate a substantially net shape object from a computerized model using materials that can be debound and sintered into a fully dense metallic part or the like. However, during sintering, the net shape will shrink as binder escapes and the base material fuses into a dense final part. If the foundation beneath the object does not shrink in a corresponding fashion, the resulting stresses throughout the object can lead to fracturing, warping or other physical damage to the object resulting in a failed fabrication. To address this issue, a variety of techniques are disclosed for substrates and build plates that contract in a manner complementary to the object during debinding and sintering.

An apparatus for manufacturing a three-dimensional object by a layer-by-layer solidification of building material at the points corresponding to the cross-section of the object to be manufactured in a respective layer. The apparatus includes a process chamber in which the object is to be built up layer by layer by selectively solidifying layers of a building material in a build area, a gas supply device, and a recirculating air filter device, wherein the apparatus comprises a pressure stabilization device configured to keep the pressure in the process chamber substantially constant.

An apparatus for manufacturing a three-dimensional object by a layer-by-layer solidification of building material at the points corresponding to the cross-section of the object to be manufactured in a respective layer. The apparatus includes a process chamber in which the object is to be built up layer by layer by selectively solidifying layers of a building material in a build area, a gas supply device, and a recirculating air filter device, wherein the apparatus comprises a pressure stabilization device configured to keep the pressure in the process chamber substantially constant.

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.