The method for producing a three-dimensional molded object comprises a placing step, a molding step, and an upper surface processing step. The placing step is a step of placing a base plate and a mounting plate within a molding region. A first material powder layer is formed on the base plate; and the base plate is fixed to the mounting plate at a central part of the base plate to an extent that the base plate is not displaced. The molding step is a step of laminating sintered layers to form a sintered body. The sintered layers are laminated by repeatedly spreading material powder to form a material powder layer and irradiating the material powder layer with a beam to form the sintered layer. The upper surface processing step is a step of planarizing an upper surface of the sintered body to form a processed surface.

An additive manufacturing (AM) system includes a housing defining a chamber, a build platform disposed within the chamber, and an upper gas inlet configured to supply an upper gas flow in a first direction parallel to the build platform. The AM system includes a lower gas inlet disposed in the chamber and configured to supply a lower gas flow in a second direction toward a bottom wall of the chamber, and a flow directing system configured to receive the lower gas flow and redirect the lower gas flow in the first direction parallel to the build platform. The AM system includes one or more gas delivery devices fluidly coupled to the upper and lower gas inlets and configured to regulate one or more flow characteristics of the upper and lower gas flows and a gas outlet configured to discharge the upper and lower gas flows from the chamber.

An additive manufacturing (AM) system includes a housing defining a chamber, a build platform disposed in the chamber at a first elevation, and a lower gas inlet disposed at a second elevation and configured to supply a lower gas flow. The AM system includes a contoured surface extending between the lower gas inlet and the build platform to direct the lower gas flow from the second elevation at the lower gas inlet to the first elevation at the build platform, where the contoured surface discharges the lower gas flow in a direction substantially parallel to the build platform. The AM system also includes one or more gas delivery devices coupled to the lower gas inlet to regulate one or more flow characteristics of the lower gas flow, and a gas outlet configured to discharge the lower gas flow.

Disclosed is 3D printer that may precisely irradiate a laser to a spot where the laser is to be irradiated so that a precise three-dimensional product may be output, and prevent a temperature deviation from occurring inside a case including a product forming chamber to improve the quality of the output product, and increase the durability of the output product by enhancing the binding force between powder and powder applied to an output bed and maximizing the melting of the powder.

A direct metal laser melting (DMLM) system includes a rotatable base, and a build plate mounted on and supported by the rotatable base, where the build plate includes a build surface. The DMLM system also includes a first actuator assembly, a first powder dispenser disposed proximate the build plate and configured to deposit a weldable powder on the build surface of the build plate. In addition, the DMLM system includes a first powder spreader disposed proximate the build plate and configured to spread the weldable powder deposited on the build surface of the build plate, and a first laser scanner supported by the first actuator assembly in a position relative to the build plate, such that at least a portion of the build surface is within a field of view of the first laser scanner. The first laser scanner is configured to selectively weld the weldable powder. The first laser scanner is further configured to translate axially relative to the build surface on the first actuator assembly.

A method for producing a three-dimensional shaped product that employs a shaping method based on dispersion of powder by a squeegee and irradiation onto a powder layer with a laser beam or electron beam, includes the following steps: 1. Setting an upper limit value and lower limit value for the amount of circulation passing through an anemometer, and an adjusting value within this range; 2. Measuring the amount of circulation and effecting control as follows: (1) When the measured value is between the upper limit value and lower limit value, the rotational speed of the blower fan is maintained, and (2) When the measured value has fallen below the lower limit value due to clogging of a filter, the rotational speed of the fan is increased and the rotational speed is selected at the stage where the measured value has reached the adjusting value, and the rotational speed is maintained.

A method of filtering gas in a powder bed fusion apparatus, wherein an object is built layer-by-layer by selective solidification of a powder bed, and a powder bed fusion apparatus for executing the method. The apparatus includes a build chamber housing the powder bed, a gas circuit for recirculating the gas, including passing the gas over the powder bed within the build chamber, multiple filter assemblies in the gas circuit for filtering process emissions from the recirculated gas and a valve system regulating gas flow to each filter assembly. The method may include controlling the valve system to divide the gas flow between the filter assemblies. The method includes controlling the valve system such that a first one of the filter assemblies is connected with at least one second one of the filter assemblies such that the gas passes through the filter elements of both filter assemblies.

A system and method for additive manufacturing are provided. The system includes a structure defining a chamber for manufacturing parts via additive manufacturing. A powder metal applicator is configured to deposit layers of powder metal material to build a part on a build platform. A laser source is configured to direct one or more laser beams onto each layer of powder metal material to fuse the powder metal material, wherein metal condensate is created by the laser beam(s) contacting the powder metal material. An element spaced apart from the layers of powder material has a temperature different than the chamber temperature, so that the element is configured to attract or repel the metal condensate by virtue of the temperature differential between the element and the chamber. The method includes using the element having the different temperature to attract or repel the metal condensate within the chamber.

A system and method for additive manufacturing are provided. The system includes a structure defining a chamber for manufacturing parts via additive manufacturing. A powder metal applicator is configured to deposit layers of powder metal material to build a part on a build platform. A laser source is configured to direct one or more laser beams onto each layer of powder metal material to fuse the powder metal material, wherein metal condensate is created by the laser beam(s) contacting the powder metal material. An element spaced apart from the layers of powder material has a temperature different than the chamber temperature, so that the element is configured to attract or repel the metal condensate by virtue of the temperature differential between the element and the chamber. The method includes using the element having the different temperature to attract or repel the metal condensate within the chamber.

A print engine of an additive manufacturing system includes a print station configured to hold a removable cartridge. A laser engine including a frame can be positioned to hold at least one removable field replaceable unit that includes at least some laser optics or patterning optics. An optical alignment system can be attached to at least one of the print station or the laser engine to align the field replaceable unit with respect to the removable cartridge.