A computational method for controlling a powder particle uptake by a shielding gas in a laser additive manufacturing system. The computational method includes receiving a gas fluid domain, a powder bed domain, and an inlet shielding gas flow velocity of the laser additive manufacturing system. The method further includes determining a maximum gas flow velocity within the gas fluid domain based on the inlet shielding gas flow velocity and the gas fluid domain. The method also includes determining a threshold uptake flow velocity within the gas fluid domain based on the inlet shielding gas flow velocity and the powder bed domain. The method also includes controlling the powder particle uptake of the shielding gas in the laser additive manufacturing system in response to the maximum gas flow velocity and the threshold uptake flow velocity.

A computational method for controlling a powder particle uptake by a shielding gas in a laser additive manufacturing system. The computational method includes receiving a gas fluid domain, a powder bed domain, and an inlet shielding gas flow velocity of the laser additive manufacturing system. The method further includes determining a maximum gas flow velocity within the gas fluid domain based on the inlet shielding gas flow velocity and the gas fluid domain. The method also includes determining a threshold uptake flow velocity within the gas fluid domain based on the inlet shielding gas flow velocity and the powder bed domain. The method also includes controlling the powder particle uptake of the shielding gas in the laser additive manufacturing system in response to the maximum gas flow velocity and the threshold uptake flow velocity.

One of the objects of the present application is to provide a technique capable of preventing the generation of excessive metallic vapor during fabrication according to an AM technique. Further, one of the objects of the present application is to provide a technique for reducing machining processing after the fabrication as much as possible or eliminating the necessity thereof. According to one aspect, an AM apparatus configured to manufacture a fabrication object is provided. This AM apparatus includes a first DED nozzle configured to fabricate a contour of a fabrication target and a second DED nozzle configured to fabricate an inner portion of the contour.

One of the objects of the present application is to provide a technique capable of preventing the generation of excessive metallic vapor during fabrication according to an AM technique. Further, one of the objects of the present application is to provide a technique for reducing machining processing after the fabrication as much as possible or eliminating the necessity thereof. According to one aspect, an AM apparatus configured to manufacture a fabrication object is provided. This AM apparatus includes a first DED nozzle configured to fabricate a contour of a fabrication target and a second DED nozzle configured to fabricate an inner portion of the contour.

A fluidized powder additive manufacturing system can include a container defining a powder volume configured to hold a powder, a fluidizer attached to and/or disposed on or within the container, the fluidizer configured to fluidize the powder within the powder volume to form a fluidized powder, and a build area assembly disposed within the container. The build area assembly can include a build surface, and a movement system attached to the build surface and configured to move the build surface within the powder volume when the powder is fluidized.

A fluidized powder additive manufacturing system can include a container defining a powder volume configured to hold a powder, a fluidizer attached to and/or disposed on or within the container, the fluidizer configured to fluidize the powder within the powder volume to form a fluidized powder, and a build area assembly disposed within the container. The build area assembly can include a build surface, and a movement system attached to the build surface and configured to move the build surface within the powder volume when the powder is fluidized.

Systems, apparatus, computer-readable medium, and associated methods to monitor, analyze, and adjust at least one of 1) additive machine health and configuration or 2) build health and configuration are disclosed. An example apparatus includes an analytics processor, separate from and in a trusted relationship with an additive manufacturing machine building a part, to process, based on a trigger, data from monitoring of the additive manufacturing machine and the build of the part, the analytics processor including a hybrid model fusing additive process physics and data science to process the data to identify an abnormality in at least one of the build or the additive manufacturing machine and to adjust a configuration of the additive manufacturing machine during the build to address the abnormality.

Disclosed herein is an additive manufacturing system that includes an energy source, a powder supply, and a build chamber. The build chamber includes a base plate and two or more variable build plates coupled to the base plate. The two or more variable build plates each have one or more adjustable features. The two or more variable build plates are configurable to position two or more parts at different heights relative to a top level of the build chamber. The additive manufacturing system also includes a control system configured to control the energy source to fuse material from the powder supply to at least one of the two or more parts while the two or more parts are respectively positioned by the two or more variable build plates at different heights relative to the top level of the build chamber.

Disclosed herein is an additive manufacturing system that includes an energy source, a powder supply, and a build chamber. The build chamber includes a base plate and two or more variable build plates coupled to the base plate. The two or more variable build plates each have one or more adjustable features. The two or more variable build plates are configurable to position two or more parts at different heights relative to a top level of the build chamber. The additive manufacturing system also includes a control system configured to control the energy source to fuse material from the powder supply to at least one of the two or more parts while the two or more parts are respectively positioned by the two or more variable build plates at different heights relative to the top level of the build chamber.

A device for additive manufacturing of a workpiece includes a production platform supporting a defined material layer of particulate material, a structuring tool, an inspection sensor, a control unit, and a position encoder. The inspection sensor has a line scan camera and a line light source and is movable along a movement direction relative to the production platform. The position encoder generates a position signal representing a respective instantaneous position of the inspection sensor relative to the production platform. The control unit generates a spatially resolved image of the defined layer using the line light source, the line scan camera, and the position signal. The control unit controls the structuring tool in order to produce a defined workpiece layer by selectively solidifying particulate material of the defined material layer based on the image of the defined material layer and/or an image of a previously produced workpiece layer.