A method of forming a vitreous bond abrasive article is presented that includes receiving, by a manufacturing device having one or more processors, a digital object comprising data specifying a plurality of layers of a vitreous bond abrasive article precursor. The vitreous bond abrasive article precursor includes abrasive particles bonded together by a vitreous bond precursor material and an organic compound. The vitreous bond abrasive article precursor further comprises at least one of: at least one tortuous cooling channel extending at least partially through the vitreous bond abrasive article precursor or at least one arcuate cooling channel extending at least partially through the vitreous bond abrasive article precursor. The method also includes generating, with the manufacturing device by an additive manufacturing process, the vitreous bond abrasive article precursor based on the digital object.

According to some embodiments, system and methods are provided comprising receiving, via a communication interface of a part parameter dictionary module comprising a processor, geometry data for a plurality of geometric structures forming a plurality of parts, wherein the parts are manufactured with an additive manufacturing machine; determining, using the processor of the part parameter dictionary module, a feature set for each geometric structure; generating, using the processor of the part parameter dictionary module, one of a coupon and a coupon set for the feature set; generating an optimized parameter set for each coupon, using the processor of the part parameter dictionary module, via execution of an iterative learning control process for each coupon; mapping, using the processor of the part parameter dictionary module, one or more parameters of the optimized parameter set to one or more features of the feature set; and generating a dictionary of optimized scan parameter sets to fabricate geometric structures with a material used in additive manufacturing. Numerous other aspects are provided.

This invention teaches a multi-sensor quality inference system for additive manufacturing. This invention still further teaches a quality system that is capable of discerning and addressing three quality issues: i) process anomalies, or extreme unpredictable events uncorrelated to process inputs; ii) process variations, or difference between desired process parameters and actual operating conditions; and iii) material structure and properties, or the quality of the resultant material created by the Additive Manufacturing process. This invention further teaches experimental observations of the Additive Manufacturing process made only in a Lagrangian frame of reference. This invention even further teaches the use of the gathered sensor data to evaluate and control additive manufacturing operations in real time.

An additive manufacturing system includes a laser array including a plurality of laser devices. Each laser device of the plurality of laser devices generates an energy beam for forming a melt pool in a powder bed. The additive manufacturing system further includes at least one optical element. The optical element receives at least one of the energy beams and induces a predetermined power diffusion in the at least one energy beam.

This invention teaches a multi-sensor quality inference system for additive manufacturing. This invention still further teaches a quality system that is capable of discerning and addressing three quality issues: i) process anomalies, or extreme unpredictable events uncorrelated to process inputs; ii) process variations, or difference between desired process parameters and actual operating conditions; and iii) material structure and properties, or the quality of the resultant material created by the Additive Manufacturing process. This invention further teaches experimental observations of the Additive Manufacturing process made only in a Lagrangian frame of reference. This invention even further teaches the use of the gathered sensor data to evaluate and control additive manufacturing operations in real time.

A method for manufacturing structural steel components with local reinforcement is provided. The method comprises selecting at least a zone of the component to be reinforced, providing a steel blank and deforming the blank in a press tool to form a product, wherein the blank and/or the product comprises a groove in the zone to be reinforced, the groove comprising an inner surface and an outer surface. The method further comprises depositing a reinforcement material on the inner surface of groove and locally heating the reinforcement material and the groove of the steel blank or product, to mix the melted reinforcement material with the melted portion of the steel blank or product.

Embodiments of the present disclosure provides methods and systems for preparing a cathode component. The method may include obtaining a three-dimensional (3D) model of the cathode component; obtaining a predetermined parameter, wherein the predetermined parameter includes at least one of a scanning direction of laser, an energy distribution of laser, an output power of laser, or a scanning speed of laser; and controlling a 3D printer to perform, based on the 3D model and the predetermined parameter, a laser scanning on a raw material to obtain the cathode component.

A 3D printed diamond/metal matrix composite material and a preparation method and application thereof are provided. The composite material includes core-shell doped diamond, a metal matrix, and an additive, where the core-shell doped diamond includes a core, a transition layer, a shell, a coating, a porous layer, and a modification layer. The preparation method includes: uniformly mixing the diamond, the metal matrix, and the additive and performing 3D printing according to a 3D CAD slice model to obtain the composite material designed by the model. The metal matrix and the diamond surface of the composite material are mainly metallurgically bound, which can improve the binding strength between the diamond and the metal matrix, thereby improving the use properties of the composite material and a diamond tool. The core-shell doped diamond has good ablation resistance, and can effectively avoid and reduce thermal damage to diamond in a 3D printing forming process.

A processing machine (10) for building an object (11) from a material (12) includes a build platform (16), a platform mover assembly (20), a material supply (22), an irradiation device (26), and an analyzer system (30). The platform mover assembly (20) moves the build platform (16) about a platform movement axis (48X) and along the platform movement axis (48X). The material supply (22) supplies material (12) to build the object (11) on the build platform (16). The irradiation device (26) irradiates at least a portion of the material (12) with an energy beam (26A) to form the object (11) from the material (12) on the build platform (16). The analyzer system (30) is configured to monitor the energy beam (26A). The analyzer system (30) includes an alignment component (36) that rotates concurrently with the build platform (16) about the platform movement axis (48X), but that is inhibited from moving concurrently with the build platform (16) along the platform movement axis (48X).

A processing machine (10) for building an object (11) from a material (12) includes a build platform (16), a platform mover assembly (20), a material supply (22), an irradiation device (26), and an analyzer system (30). The platform mover assembly (20) moves the build platform (16) about a platform movement axis (48X) and along the platform movement axis (48X). The material supply (22) supplies material (12) to build the object (11) on the build platform (16). The irradiation device (26) irradiates at least a portion of the material (12) with an energy beam (26A) to form the object (11) from the material (12) on the build platform (16). The analyzer system (30) is configured to monitor the energy beam (26A). The analyzer system (30) includes an alignment component (36) that rotates concurrently with the build platform (16) about the platform movement axis (48X), but that is inhibited from moving concurrently with the build platform (16) along the platform movement axis (48X).