Implementations provide cold spray additive manufacturing (CSAM) with gas recovery in situ in an open environment without requiring part disassembly and removal to a repair facility. Recapturing and reusing gas in an open environment reduces costs, rendering CSAM more commercially viable and efficient, and avoids risk of new damage to parts from contemporary pre-existing CSAM processes. A gas recovery nozzle attaches to a supersonic nozzle and sends used gas to a gas recovery sub-system by capturing gas that is deflected on impact with the part during CSAM. Captured gas is stored for reuse. A flexible coupling controls distance from the gas recovery nozzle to a part substrate to prevent (1) nozzle clogging; (2) stationary shock wave interference with gas flow; and (3) gas flow misdirection. The gas recovery nozzle also suppresses disruptive supersonic sounds. Implementations enable capture for later reuse of supersonically-propelled gas during in-situ CSAM in open environments.

Implementations provide cold spray additive manufacturing (CSAM) with gas recovery in situ in an open environment without requiring part disassembly and removal to a repair facility. Recapturing and reusing gas in an open environment reduces costs, rendering CSAM more commercially viable and efficient, and avoids risk of new damage to parts from contemporary pre-existing CSAM processes. A gas recovery nozzle attaches to a supersonic nozzle and sends used gas to a gas recovery sub-system by capturing gas that is deflected on impact with the part during CSAM. Captured gas is stored for reuse. A flexible coupling controls distance from the gas recovery nozzle to a part substrate to prevent (1) nozzle clogging; (2) stationary shock wave interference with gas flow; and (3) gas flow misdirection. The gas recovery nozzle also suppresses disruptive supersonic sounds. Implementations enable capture for later reuse of supersonically-propelled gas during in-situ CSAM in open environments.

1. Filter device for the filtration of gases contaminated with particles.

2. A filter device for the filtration of gases contaminated with particles, such as welding gases, which are in particular produced in manufacturing processes using 3D printers in a production room (52), having a filter circuit having at least one filter element (55, 56), which filters the particles from the gas, wherein at least a part of said particles get from this filter element (55, 56) into an assignable receptacle (59), is characterized in that the particles within a back-flushing process get into the respective receptacle (59), and in that at least one further filter circuit, having at least one further filter element (NF1, NF2), is present, which filters a fluid, which has the particles obtained at the back-flushing process.

A 3dimensional object-forming apparatus is provided which may avoid lowering of irradiation efficiency of laser light due to fumes and so forth while avoiding lowering of quality of the formed object. A shroud 20 includes an inside partition wall portion 21 that demarcates an inside space S.sub.1 which extends from one end opening 202 to another end opening 206, and an outside partition wall portion 22 that opens in the other end opening 206 of a shroud 20 on an outside of the inside space S.sub.1 and demarcates, together with the inside partition wall portion 21, an outside space S.sub.2 which closes in a position closer to the one end opening 202 than the other end opening 206 of the shroud. A ventilation area of the inside space S.sub.1 in the other end opening 206 of the shroud 20 is larger than the ventilation area of the inside space S.sub.1 in an upstream portion closer to the one end opening 202 than the other end opening 206.

A method of controlling an additive manufacturing process in which a directed energy source is used to selectively melt material to form a workpiece, forming a melt pool in the process of melting, the method comprising: using an imaging apparatus to generate an image of the melt pool comprising an array of individual image elements, the image including a measurement of at least one physical property for each of the individual image elements; from the measurements, mapping a melt pool boundary of the melt pool; computing a geometric length of the melt pool boundary; and controlling at least one aspect of the additive manufacturing process with reference to the geometric length.

The present disclosure provides three-dimensional (3D) printing processes, apparatuses, software, and systems for controlling and/or treating gas borne debris in an atmosphere of a 3D printer.

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 lamination molding apparatus includes a chamber that covers a molding region, an irradiator that irradiates a material layer formed in the molding region with a laser beam or an electron beam and forms a solidified layer, a supply port that supplies an inert gas to the chamber, a discharge port that discharges the inert gas from the chamber, an inert gas supplier which is connected to the supply port and supplies the inert gas to the chamber, a fume collector, and an oxygen concentration adjustor. The fume collector has an inlet, a charging section, a collecting section, and an outlet. The oxygen concentration adjustor is connected between the discharge port and the charging section and supplies, to the fume collector, an adjusting gas having an oxygen concentration higher than an oxygen concentration of the inert gas which is discharged from the discharge port.

Implementations provide cold spray additive manufacturing (CSAM) with gas recovery in situ in an open environment without requiring part disassembly and removal to a repair facility. Recapturing and reusing gas in an open environment reduces costs, rendering CSAM more commercially viable and efficient, and avoids risk of new damage to parts from contemporary pre-existing CSAM processes. A gas recovery nozzle attaches to a supersonic nozzle and sends used gas to a gas recovery sub-system by capturing gas that is deflected on impact with the part during CSAM. Captured gas is stored for reuse. A flexible coupling controls distance from the gas recovery nozzle to a part substrate to prevent (1) nozzle clogging; (2) stationary shock wave interference with gas flow; and (3) gas flow misdirection. The gas recovery nozzle also suppresses disruptive supersonic sounds. Implementations enable capture for later reuse of supersonically-propelled gas during in-situ CSAM in open environments.

Devices for additive manufacturing of a three-dimensional object from powdered material include a main body providing an object forming chamber and, within a front wall, an opening for accessing the object forming chamber. A work surface delimits the object forming chamber and includes a build platform section for manufacturing thereon the three-dimensional object. A door is provided at the front wall and positionable in a closed state to seal the opening or in an opened state to provide access to the object forming chamber. The devices include a gas flow system for providing a gas flow across the build platform section and including a main body section extending within the main body and a door section being part of the door and including an opening structure arranged to release gas to, or to receive gas from, above the build platform section in the closed state of the door.