Methods and apparatuses for identifying an additive manufacturing process for unused output material of an atomization process are described. The method comprises determining a set of characteristics of output material that is unused in a first additive manufacturing process. The method further comprises determining a respective set of parameters associated with respective input material of each of a set of other additive manufacturing processes. The method of further comprises identifying one of the set of other additive manufacturing processes that accepts the output material as input material based on the characteristics of the output material and based on respective sets of parameters.

Methods and apparatuses for identifying an additive manufacturing process for unused output material of an atomization process are described. The method comprises determining a set of characteristics of output material that is unused in a first additive manufacturing process. The method further comprises determining a respective set of parameters associated with respective input material of each of a set of other additive manufacturing processes. The method of further comprises identifying one of the set of other additive manufacturing processes that accepts the output material as input material based on the characteristics of the output material and based on respective sets of parameters.

A three-dimensional shaped article production method is a three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers and includes a first metal powder supply step of supplying a first metal powder having a first average particle diameter to a shaping table, a layer formation step of forming the layer by compressing the first metal powder supplied to the shaping table, a first liquid supply step of supplying a first liquid containing a second metal powder having a second average particle diameter and a binder to a portion of a constituent region of the three-dimensional shaped article, a second liquid supply step of supplying a second liquid containing at least either the second meal powder at a lower concentration than the first liquid or a third metal powder having a larger average particle diameter than the second average particle diameter and containing a binder to at least a portion of a surface layer region, and a sintering step of sintering a metal in the constituent region by heating a stacked body.

A method and an apparatus for collecting powder samples in real-time in powder bed fusion additive manufacturing may involves an ingester system for in-process collection and characterizations of powder samples. The collection may be performed periodically and uses the results of characterizations for adjustments in the powder bed fusion process. The ingester system of the present disclosure is capable of packaging powder samples collected in real-time into storage containers serving a multitude purposes of audit, process adjustments or actions.

A method and an apparatus for collecting powder samples in real-time in powder bed fusion additive manufacturing may involves an ingester system for in-process collection and characterizations of powder samples. The collection may be performed periodically and uses the results of characterizations for adjustments in the powder bed fusion process. The ingester system of the present disclosure is capable of packaging powder samples collected in real-time into storage containers serving a multitude purposes of audit, process adjustments or actions.

An example method of modifying a powder according to the present disclosure includes contacting a powder comprising particles with a nitrogen-containing gas and improved flowability of the powder. A method of providing a powder and a reactor are also disclosed.

An example method of modifying a powder according to the present disclosure includes contacting a powder comprising particles with a nitrogen-containing gas and improved flowability of the powder. A method of providing a powder and a reactor are also disclosed.

A densified, high-strength metallic component is manufactured by: binder jet additive manufacture (BJAM) printing a powder blend to form a printed part; and super solidus sintering the printed part to form the metallic component, which may then be heat treated. The powder blend comprises a blend of water atomized base iron powder and a high-carbon master ferroalloy powder. The high-carbon ferroalloy powder introduces high concentrations of carbon into a powder blend that is readily BJAM printable.

A method for making a three-dimensional object by means of layer-wise application and selective solidification of a pulverulent building material The method includes applying a layer of the pulverulent building material onto a build area by an application device The application device includes a recoating unit movable across the build area in an application direction. The method further includes solidification of the applied powder layer at positions corresponding to a cross-section of the object to be made, and repeating the steps of applying and selective solidification until the object is completed. The pulverulent building material to be applied onto the build area is heated locally by a radiant heater before being applied.

The devices, systems, and methods of the present disclosure are directed to powder spreading and binder distribution techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, a powder may be spread to form a layer along a volume defined by a powder box, a binder may be deposited along the layer to form a layer of a three-dimensional object, and the direction of spreading the layer and depositing the binder may be in a first direction and in a second direction, different from the first direction, thus facilitating rapid formation of the three-dimensional object with each passage of the print carriage over the volume. Powder delivery, powder spreading, thermal energy delivery, and combinations thereof, may facilitate consistently achieving quality standards as the rate of fabrication of the three-dimensional object is increased.