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.

An additive processing method includes providing a cover gas in a chamber in connection with additive fabrication of an article in the chamber, the cover gas entraining impurities during the additive fabrication, circulating the cover gas with entrained impurities from the chamber into a gas recirculation loop, removing the entrained impurities from the cover gas in the gas recirculation loop to generate a clean cover gas, circulating the clean cover gas into the chamber during the additive fabrication, and metering an amount of new cover gas provided into the chamber from a cover gas source connected to the chamber, the amount being metered with respect to an amount of the clean cover gas circulated into the chamber from the gas recirculation loop.

An additive processing method includes providing a cover gas in a chamber in connection with additive fabrication of an article in the chamber, the cover gas entraining impurities during the additive fabrication, circulating the cover gas with entrained impurities from the chamber into a gas recirculation loop, removing the entrained impurities from the cover gas in the gas recirculation loop to generate a clean cover gas, circulating the clean cover gas into the chamber during the additive fabrication, and metering an amount of new cover gas provided into the chamber from a cover gas source connected to the chamber, the amount being metered with respect to an amount of the clean cover gas circulated into the chamber from the gas recirculation loop.

A build unit for additively manufacturing three-dimensional objects may include an energy beam system having one or more irradiation devices respectively configured to direct one or more energy beams onto a region of a powder bed, and an inertization system including an irradiation chamber defining an irradiation plenum, one or more supply manifolds, and a return manifold. The one or more supply manifolds may include a downflow manifold configured to provide a downward flow of a process gas through at least a portion of the irradiation plenum defined by the irradiation chamber, and/or a crossflow manifold configured to provide a lateral flow of the process gas through at least a portion of the irradiation plenum defined by the irradiation chamber. The return manifold may evacuate or otherwise remove process gas from the irradiation plenum defined by the irradiation chamber. While irradiating the region of the powder bed, the process gas may flow through the one or more supply manifolds, into the irradiation plenum, and from the irradiation plenum into the return manifold.

A build unit for additively manufacturing three-dimensional objects may include an energy beam system having one or more irradiation devices respectively configured to direct one or more energy beams onto a region of a powder bed, and an inertization system including an irradiation chamber defining an irradiation plenum, one or more supply manifolds, and a return manifold. The one or more supply manifolds may include a downflow manifold configured to provide a downward flow of a process gas through at least a portion of the irradiation plenum defined by the irradiation chamber, and/or a crossflow manifold configured to provide a lateral flow of the process gas through at least a portion of the irradiation plenum defined by the irradiation chamber. The return manifold may evacuate or otherwise remove process gas from the irradiation plenum defined by the irradiation chamber. While irradiating the region of the powder bed, the process gas may flow through the one or more supply manifolds, into the irradiation plenum, and from the irradiation plenum into the return manifold.

A build unit for additively manufacturing three-dimensional objects may include an energy beam system having one or more irradiation devices respectively configured to direct one or more energy beams onto a region of a powder bed, and an inertization system including an irradiation chamber defining an irradiation plenum, one or more supply manifolds, and a return manifold. The one or more supply manifolds may include a downflow manifold configured to provide a downward flow of a process gas through at least a portion of the irradiation plenum defined by the irradiation chamber, and/or a crossflow manifold configured to provide a lateral flow of the process gas through at least a portion of the irradiation plenum defined by the irradiation chamber. The return manifold may evacuate or otherwise remove process gas from the irradiation plenum defined by the irradiation chamber. While irradiating the region of the powder bed, the process gas may flow through the one or more supply manifolds, into the irradiation plenum, and from the irradiation plenum into the return manifold.

A build unit for additively manufacturing three-dimensional objects may include an energy beam system having one or more irradiation devices respectively configured to direct one or more energy beams onto a region of a powder bed, and an inertization system including an irradiation chamber defining an irradiation plenum, one or more supply manifolds, and a return manifold. The one or more supply manifolds may include a downflow manifold configured to provide a downward flow of a process gas through at least a portion of the irradiation plenum defined by the irradiation chamber, and/or a crossflow manifold configured to provide a lateral flow of the process gas through at least a portion of the irradiation plenum defined by the irradiation chamber. The return manifold may evacuate or otherwise remove process gas from the irradiation plenum defined by the irradiation chamber. While irradiating the region of the powder bed, the process gas may flow through the one or more supply manifolds, into the irradiation plenum, and from the irradiation plenum into the return manifold.

According to examples, an apparatus may include a build platform and a chamber. The chamber may support a layer forming station including a spreading component to spread a layer of build material particles onto the build platform and an agent delivery component to apply fusing agent onto selected locations on the spread layer of build material particles and a heating station including a heating component to apply energy onto the spread layer of build material particles and the applied fusing agent, in which the heating station is separated from the layer forming station. The apparatus may also include an actuator to move the chamber with respect to the build platform or vice versa while maintaining the separation between the layer forming station and the heating station.

According to examples, an apparatus may include a build platform and a chamber. The chamber may support a layer forming station including a spreading component to spread a layer of build material particles onto the build platform and an agent delivery component to apply fusing agent onto selected locations on the spread layer of build material particles and a heating station including a heating component to apply energy onto the spread layer of build material particles and the applied fusing agent, in which the heating station is separated from the layer forming station. The apparatus may also include an actuator to move the chamber with respect to the build platform or vice versa while maintaining the separation between the layer forming station and the heating station.

The present disclosure provides three-dimensional (3D) printing systems, apparatuses, software, and methods for safe production of at least one requested 3D object, and for passivation of material accumulated on a filter of the 3D printing system.