Disclosed are methods for building colloidal solids by precipitation from a liquid bridge using a needle through which a colloidal particle suspension is dispensed onto a substrate in a temperature-controlled environment. The substrate can rest on a motion-controlled stage, and freeform shapes can be built by coordinating the motion of the stage with the rate of dispense of colloidal particle suspension. Aspects include a scaling law that governs the rate of assembly and a direct-write colloidal assembly process that combines self-assembly with direct-write 3D printing, and can be used to build exemplary freestanding structures using a diverse materials, such as polystyrene, silica and gold particles. Additionally, disclosed are methods for predicting and eliminating cracking by a geometric relationship between particle size and structure dimensions, enabling the production of macroscale, crack-free colloidal crystals.

A lamination molding apparatus includes: a material layer forming device that forms a material layer in a molding region; an irradiator that sinters or melts the material layer to form a solidified layer; and a cooling device that cools, to a cooling temperature, at least a part including an upper surface of a solidified body. The material layer forming device includes: a base having the molding region, a recoater head disposed on the base, a recoater head driving device that reciprocates the recoater head in a horizontal direction, and a blade that is arranged on the recoater head and that levels material powder to form the material layer. The cooling device includes: a cooling body that is controlled to the cooling temperature and comes into contact with the upper surface of the solidified body, and a mounting member that mounts the cooling body to the recoater head.

A lamination molding apparatus includes: a material layer forming device that forms a material layer in a molding region; an irradiator that sinters or melts the material layer to form a solidified layer; and a cooling device that cools, to a cooling temperature, at least a part including an upper surface of a solidified body. The material layer forming device includes: a base having the molding region, a recoater head disposed on the base, a recoater head driving device that reciprocates the recoater head in a horizontal direction, and a blade that is arranged on the recoater head and that levels material powder to form the material layer. The cooling device includes: a cooling body that is controlled to the cooling temperature and comes into contact with the upper surface of the solidified body, and a mounting member that mounts the cooling body to the recoater head.

A method of additive manufacture is disclosed. The method may include creating, by a 3D printer contained within an enclosure, a part having a weight greater than or equal to 2,000 kilograms. A gas management system may maintain gaseous oxygen within the enclosure atmospheric level. In some embodiments, a wheeled vehicle may transport the part from inside the enclosure, through an airlock, as the airlock operates to buffer between a gaseous environment within the enclosure and a gaseous environment outside the enclosure, and to a location exterior to both the enclosure and the airlock.

Alloy compositions for 3D metal printing procedures which provide metallic parts with high hardness, tensile strengths, yield strengths, and elongation. The alloys include Fe, Cr and Mo and at least three or more elements selected from C, Ni, Cu, Nb, Si and N. As built parts indicate a tensile strength of at least 1000 MPa, yield strength of at least 640 MPa, elongation of at least 3.0% and hardness (HV) of at least 375.

A body, a table that is located on the body and allows powders to be laid thereon by a laying apparatus is disclosed. A layer is created by sintering or fusing the powders laid on the table, a part (P) that is produced by depositing the layers on top of each other using additive manufacturing method, and at least one heat source is located on the body and applies heat treatment to the powders laid on the table.

A powder bed fusion system is provided. The system comprises a build area with a movable build plate. Two powder overflow and extraction (POE) chambers flank the build area on opposite sides. Two dispensing chambers flank the POE chambers, opposite the build area. Two reservoir chambers flank the dispensing chambers, opposite the POE chambers. A recoater device is configured to move build material from the dispensing chambers or reservoir chambers to the build area. An energy source is configured to generate an energy beam. An energy beam positioning device is configured to selectively direct the energy beam within the build area. A controller is programmed to control, according to a 3D model of a part, the energy source, energy beam positioning device, recoater device, build plate, and vertically movable plates within the POE chambers, dispensing chambers, and reservoir chambers.

A powder bed fusion system is provided. The system comprises a build area with a movable build plate. Two powder overflow and extraction (POE) chambers flank the build area on opposite sides. Two dispensing chambers flank the POE chambers, opposite the build area. Two reservoir chambers flank the dispensing chambers, opposite the POE chambers. A recoater device is configured to move build material from the dispensing chambers or reservoir chambers to the build area. An energy source is configured to generate an energy beam. An energy beam positioning device is configured to selectively direct the energy beam within the build area. A controller is programmed to control, according to a 3D model of a part, the energy source, energy beam positioning device, recoater device, build plate, and vertically movable plates within the POE chambers, dispensing chambers, and reservoir chambers.

Methods for direct writing of single crystal super alloys and metals are provided. The method can include: heating a substrate positioned on a base plate to a predetermined temperature using a first heater; using a laser to form a melt pool on a surface of the substrate; introducing a superalloy powder to the melt pool; measuring the temperature of the melt pool; receiving the temperature measured at a controller; and using an auxiliary heat source in communication with the controller to adjust the temperature of the melt pool. The predetermined temperature is below the substrate's melting point. The laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition. An apparatus is also generally provided for direct writing of single crystal super alloys and metals.

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.