An additive manufacturing system may include an energy source, an optical system to modify and direct an energy beam from the energy source toward a component to form a melt pool, and a material delivery device to deliver material to the melt pool. The optical system may form an annular energy beam, direct the annular energy beam toward the component, receive at least a portion of thermal emissions produced by the annular energy beam and the melt pool, and direct the portion of the thermal emissions toward an imaging device, which may be used to control the energy source.

Apparatus for additively manufacturing three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers of a build material which can be consolidated by means of an energy beam, which apparatus comprises an irradiation device adapted to guide an energy beam across a build plane, wherein a calibration device is provided comprising a positioning unit, a determination unit and a calibration unit, preferably arranged in a process chamber of the apparatus, that is adapted to at least partially reflect the energy beam, wherein the irradiation device is adapted to guide the energy beam to the calibration unit for generating a reflected part of the energy beam, wherein the positioning unit is adapted to position the irradiation device dependent on at least one parameter of the reflected part of the energy beam determined via the determination unit.

The present disclosure provides three-dimensional (3D) printing methods, apparatuses, systems and/or software to form one or more 3D objects, some of which may be complex. In some embodiments, the one or more 3D objects comprise an overhang portion, such as a ledge or ceiling of a cavity. The methodologies may be used to form overhang portions with diminished deformation, defects and/or auxiliary support structures.

According to one embodiment, a monitoring system includes a collection device and a processing device. The collection device collects information of a solidified portion that is solidified in additive manufacturing. The additive manufacturing forms a plurality of layers by repeatedly melting and solidifying a metal powder. The processing device generates quality data of an existence or absence of a defect of the solidified portion by using the information to determine the existence or absence of the defect.

The present disclosure provides three-dimensional (3D) printing methods, apparatuses, and systems using, inter alia, a controller that regulates formation of at least one 3D object (e.g., in real time during the 3D printing); and a non-transitory computer-readable medium facilitating the same. For example, a controller that regulates a deformation of at least a portion of the 3D object. The control may be in situ control. The control may be real-time control during the 3D printing process. For example, the control may be during a physical-attribute pulse. The present disclosure provides various methods, apparatuses, systems and software for estimating the fundamental length scale of a melt pool, and for various tools that increase the accuracy of the 3D printing.

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.

An additive manufacturing apparatus includes a powder layer forming portion, an energy beam source, and a contact detection sensor including a plate-like probe. The powder layer forming portion is configured to form a powder layer in a predetermined region. The energy beam source is configured to radiate an energy beam to the powder layer formed by the powder layer forming portion to fuse or sinter the powder layer so that a solidified layer is formed. Presence or absence of a projection portion on a surface of the solidified layer is detected by using the contact detection sensor.

A method of manufacturing a hard-to-weld material by a beam-assisted additive manufacturing process is presented. The method includes depositing a first layer for the material onto the substrate, the first layer including a major fraction of a base material for the component and a minor fraction of a solder, depositing a second layer of the base material for the component and a thermal treatment of the layer arrangement. The thermal treatment includes a first thermal cycle at a first temperature above 1200° C. for a duration of more than 3 hours, a subsequent second thermal cycle at a second temperature above 1000° C. for more than 2 hours, and a subsequent third thermal cycle and a third temperature above 700° C. for more than 12 hours. A manufactured component is also presented.

An internal defect detection system for a three-dimensional additive manufacturing device which performs additive molding by emitting a laser beam to a powder bed is provided. This system specifies a candidate position of an internal defect on the basis of a change amount of a local temperature measured in an irradiated part of a powder bed irradiated by a laser beam. The system calculates a cooling speed at the candidate position on the basis of a temperature distribution and determines whether an internal defect exists on the basis of the cooling speed.

An internal defect detection system for a three-dimensional additive manufacturing device which performs additive molding by emitting a laser beam to a powder bed is provided. This system specifies a candidate position of an internal defect on the basis of a change amount of a local temperature measured in an irradiated part of a powder bed irradiated by a laser beam. The system calculates a cooling speed at the candidate position on the basis of a temperature distribution and determines whether an internal defect exists on the basis of the cooling speed.