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.

Provided is a method for computer-aided processing of quality information of an object manufactured by stacked printed layers in an additive manufacturing system, including the steps of: receiving a quality indicator for each printed layer of the object from the manufacturing system, assigning a color out of a predefined set of colors to each quality indicator depending on the value of the quality indicator, visualizing the quality indicators of the received manufactured layers as a sequence of colored bars ordered according to the sequence of the manufactured layers the color of each bar indicating the value of the quality indicator of the respective printed layer on a graphical user interface.

According to some embodiments, systems and methods are provided comprising receiving, via a communication interface of an authorization module comprising a processor, a part file with instructions to manufacture one or more parts with an additive manufacturing machine; generating a shape signature for the part based on the part file; providing a data store storing one or more stored shape signatures, wherein the one or more stored shape signatures are one of an authorized-to-print stored shape signature and an unauthorized-to-print stored shape signature; determining the generated shape signature of the part corresponds to at least one of the authorized-to-print stored shape signatures or at least one of the unauthorized-to-print stored shape signatures; and receiving the determination of whether the generated shape signature of the part corresponds to at least one authorized-to-print stored shape signature or at least one unauthorized-to-print stored shape signature. Numerous other aspects are provided.

A system for additive metal manufacturing, including a deposition mechanism, a translation mechanism mounting the deposition mechanism to the working volume, and a stage. A method for additive metal manufacturing including: selectively depositing a material carrier within the working volume; removing an additive from the material carrier; and treating the resultant material.

A process for producing a powder witness coupon including additively manufacturing a container simultaneously with a primary part, filling at least a portion of the container with a feed material employed for the part simultaneously with the additive manufacturing of the primary part, and sealing the container during the additive manufacturing of the primary part. An in-situ feed material powder witness coupon including a container additively manufactured simultaneously with a primary part, and a plurality of individual chambers within the container, at least one of the chambers being removable intact from the container. Further, a method for enhancing examination of feed material in an additively manufactured part including additively manufacturing a container simultaneously with a primary part, capturing feed material, density and environment in the container, and sealing the container.

A device comprises a control portion to additively manufacturing a 3D object to include a first interior portion having a first thermal history different from a second thermal history of at least second interior portions surrounding the selectable first interior portion to induce an authentication surface feature at a first exterior surface portion overlying the first interior portion.

A method of forming an additive manufactured part with obfuscated anti-counterfeiting features includes additive manufacturing the part using an approved additive manufacturing method and additive manufacturing a plurality of obfuscated anti-counterfeiting structures on a surface of the part using the approved additive manufacturing method. Each of the plurality of obfuscated anti-counterfeiting structures has at least one of a prohibitive physical dimension and a prohibitive physical shape that is prohibitive from being formed using at least one unapproved additive manufacturing method such that counterfeit manufacture of the part by the at least one unapproved additive manufacturing method is detected by inspecting the surface or observing a build failure by the at least one unapproved additive manufacturing method. The plurality of obfuscated anti-counterfeiting structures includes a plurality of hollow structures, a plurality of solid structures, and/or a plurality of truss structures.

A method and an apparatus of a powder bed fusion additive manufacturing system that enables a quick change in the optical beam delivery size and intensity across locations of a print surface for different powdered materials while ensuring high availability of the system. A dynamic optical assembly containing a set of lens assemblies of different magnification ratios and a mechanical assembly may change the magnification ratios as needed. The dynamic optical assembly may include a transitional and rotational position control of the optics to minimize variations of the optical beam sizes across the print surface.

A method for additively manufacturing a workpiece having lateral workpiece dimensions includes obtaining a first data set defining the workpiece in layers arranged on top of the other. The method includes providing a manufacturing platform having lateral platform dimensions that are greater than the lateral workpiece dimensions. The method includes providing a structuring tool movable relative to the manufacturing platform. The method includes selecting an individual manufacturing region on the manufacturing platform. The method includes obtaining a second data set that represents individual layer deformations that are dependent on the selected manufacturing region. The method includes producing a defined material layer of the workpiece in the manufacturing region by controlling the structuring tool using the first and second data sets. The method includes repeating the producing in order to produce further defined material layers one on top of the other using the first data set and the second data set.

A system for inspecting a part while said part is produced by additive manufacturing, includes an additive manufacturing apparatus having a build tray, the apparatus being configured to fabricate the part layer-by-layer on the tray; an automated tool holder carrying a tool configured to deposit, add or weld layer-upon-layer of material; the tool holder and tray are configured to move relative to one another along a defined path; and an inspection device attached to the tool holder and configured to scan a layer of material in situ. The tool holder alternately arranges the tool and inspection device in a working position so that the tool holder fixes the tool in the working position for depositing, adding, or welding the layer of material and thereafter the tool holder switches said tool with the inspection device into the working position for scanning and detecting defects in the layer of material.