An additive manufacturing system including a housing configured to contain a powder bed of material, and an array of laser emitters having a field of view. The array is configured to melt at least a portion of the powder bed within the field of view as the array translates relative to the powder bed. The system further includes a spatter collection device including a diffuser configured to discharge a stream of gas across the powder bed, and a collector configured to receive the stream of gas and contaminants entrained in the stream of gas. The collector is spaced from the diffuser such that a collection zone is defined therebetween, and the spatter collection device is configured to translate relative to the powder bed such that the collection zone overlaps with the field of view of the array.

A system for recoating a powder bed includes a build platform holding a powder bed and an electrode assembly including an electrode and an insulating shield. A voltage supply produces a high voltage alternating current and communicates with the powder bed and the electrode. The electrode assembly is positionable over the powder bed, such that when the electrode assembly is over the powder bed, the shield is between the electrode and the powder bed's top surface. The voltage supply produces a high voltage alternating current that creates an alternating electric field between the electrode and the powder bed that causes the powder of the powder bed top surface to oscillate in a region between the shield and the bed and then reposition themselves on the bed such that the top layer of the powder bed is smoother than it was prior to when the powder particles began oscillating.

A 3D printer is disclosed herein. The 3D printer comprises a build material distributor to generate layers of a build material in a spreading direction along a spreading axis; a resonator mounted on the build material distributor to vibrate the build material distributor along the spreading axis at a frequency; and a controller. The controller is to control the resonator to vibrate the build material distributor at the frequency while controlling the build material distributor to spread a volume of build material over a platform to generate a layer of build material.

A 3D printer is disclosed herein. The 3D printer comprises a build material distributor to generate layers of a build material in a spreading direction along a spreading axis; a resonator mounted on the build material distributor to vibrate the build material distributor along the spreading axis at a frequency; and a controller. The controller is to control the resonator to vibrate the build material distributor at the frequency while controlling the build material distributor to spread a volume of build material over a platform to generate a layer of build material.

The present application relates to a method of producing an article by additive manufacturing including the steps of predicting regions of stress in the article, identifying an optimal build orientation for the article and dispensing a first powder and/or a second powder to form the article. The first and second powders are of the same type of powder and have been recycled to different extents and the orientation of the build is optimised so that reduced quantities of the powder which has not been recycled or which has been recycled to a lesser extent is dispensed during the build.

The present application relates to a method of producing an article by additive manufacturing including the steps of predicting regions of stress in the article, identifying an optimal build orientation for the article and dispensing a first powder and/or a second powder to form the article. The first and second powders are of the same type of powder and have been recycled to different extents and the orientation of the build is optimised so that reduced quantities of the powder which has not been recycled or which has been recycled to a lesser extent is dispensed during the build.

The present disclosure relates to a manufacturing system for additive manufacturing of a workpiece and an additive manufacturing method. The manufacturing system for additive manufacturing of a workpiece includes a building panel, a lifting device for the building panel, a blade device, an optical device, and a control unit. The blade device comprises at least one coater element for applying or removing a powder material to the building panel. The optical device comprises an optical element for reception of image data from the building panel and/or from the powder layer. The lifting device is configured to raise and/or lower the building panel. The control unit is configured to control the lifting device based on the image data.

In example implementations, a spreading blade is provided. The spreading blade includes a body portion, an ultrasonic vibration source, and a kicker. The ultrasonic vibration source is coupled to a top portion of the body portion to apply a vibration along a cross-sectional length of the body portion. The kicker is coupled to a side facing a process direction at a bottom end of the body portion. The kicker comprises a tip formed by a combination of two angled surfaces that extend from a lateral side of the body portion.

A method of manufacturing a three-dimensionally shaped object includes a first powder-layer forming process in which a first portion of at least one thickness determining member forms a powder layer by moving in contact with powder, a solidifying process in which a solidified portion is formed in the powder layer formed in the first powder-layer forming process, a second powder-layer forming process, performed after the solidifying process, in which a second portion of the at least one thickness determining member forms a powder layer by moving in contact with the powder, and a renewal process performed between the first powder-layer forming process and the second powder-layer forming process. In the renewal process, the portion having been in contact with the powder is renewed such that the second portion is different from the first portion.

A method of manufacturing a three-dimensionally shaped object includes a first powder-layer forming process in which a first portion of at least one thickness determining member forms a powder layer by moving in contact with powder, a solidifying process in which a solidified portion is formed in the powder layer formed in the first powder-layer forming process, a second powder-layer forming process, performed after the solidifying process, in which a second portion of the at least one thickness determining member forms a powder layer by moving in contact with the powder, and a renewal process performed between the first powder-layer forming process and the second powder-layer forming process. In the renewal process, the portion having been in contact with the powder is renewed such that the second portion is different from the first portion.