A three-dimensional (3D) metal object manufacturing apparatus is equipped with a movable directed energy source to melt hardened metal drops and form an oxidation layer. A metal support structure can be formed over the oxidation layer, an object feature can be formed over the oxidation layer, or both a metal support structure and an object feature can be formed over oxidation layers located at opposite sides of a metal support structure. The oxidation layers weakly attach the metal support structure to the object feature supported by the metal support structure so the support structure can be easily removed after manufacture of the object is complete.

Certain aspects of the present disclosure provide a method for optimizing process parameters for additive manufacturing, including: determining a change to at least one process parameter of a plurality of process parameters while additively manufacturing a first part using an additive manufacturing apparatus according to a build file comprising machine code defining the plurality of process parameters; modifying the build file based on the determined change to the at least one process parameter to generate a modified build file; additively manufacturing a second part using the additive manufacturing apparatus according to the modified build file, wherein: additively manufacturing the first part is performed in a closed-loop control mode, and additively manufacturing the second part is performed in an open-loop control mode.

Certain aspects of the present disclosure provide a method for optimizing process parameters for additive manufacturing, including: determining a change to at least one process parameter of a plurality of process parameters while additively manufacturing a first part using an additive manufacturing apparatus according to a build file comprising machine code defining the plurality of process parameters; modifying the build file based on the determined change to the at least one process parameter to generate a modified build file; additively manufacturing a second part using the additive manufacturing apparatus according to the modified build file, wherein: additively manufacturing the first part is performed in a closed-loop control mode, and additively manufacturing the second part is performed in an open-loop control mode.

A method of feedback controlling a 3D printing process in real time, and a system therefor are disclosed. The method includes collecting big data, generated through 3D printing experiments, related to process variables of 3D printing, measurement signals, and 3D printing quality of the 3D printing object; building an artificial neural network model by performing machine-learning based on the collected big data; evaluating whether or not a 3D printing quality of the 3D printing object is abnormal in real time based on an actual measurement signal of the 3D printing object and the artificial neural network model; and feedback controlling printing quality of the 3D printing object in real time based on the evaluation result of whether or not the 3D printing quality of the 3D printing object is abnormal.

A method of feedback controlling a 3D printing process in real time, and a system therefor are disclosed. The method includes collecting big data, generated through 3D printing experiments, related to process variables of 3D printing, measurement signals, and 3D printing quality of the 3D printing object; building an artificial neural network model by performing machine-learning based on the collected big data; evaluating whether or not a 3D printing quality of the 3D printing object is abnormal in real time based on an actual measurement signal of the 3D printing object and the artificial neural network model; and feedback controlling printing quality of the 3D printing object in real time based on the evaluation result of whether or not the 3D printing quality of the 3D printing object is abnormal.

The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.

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.

A non-destructive testing method for lack-of-fusion (LOF) defects, and a testing standard part and a manufacturing method thereof, used for the non-destructive testing of LOF defects of an additive manufacturing workpiece. The manufacturing method of the LOF defect standard part comprises: step A, setting a LOF defect area of the standard part, in the LOF defect area, a proportion of the LOF defects in the LOF defect area is set as a first proportion value; step B, selecting an additive manufacturing forming process for manufacturing the LOF defect area to obtain a first process parameter of the additive manufacturing forming process corresponding to the first proportion value; step C, performing the additive manufacturing forming process based on the first process parameter to form the LOF defect area.

A processing system is a processing system that is configured to process an object by using an energy beam, and includes: an irradiation optical system that includes a condensing optical system and that is configured to condense the energy beam entering a pupil plane of the condensing optical system to irradiate the object with it; and a detection apparatus that is configured to detect, through the condensing optical system, an object light including a light from the object, at least a part of a path of the object light in the condensing optical system is different from at least a part of a path of the energy beam in the condensing optical system.