A device for additive manufacturing of a workpiece includes a production platform supporting a defined material layer of particulate material, a structuring tool, an inspection sensor, a control unit, and a position encoder. The inspection sensor has a line scan camera and a line light source and is movable along a movement direction relative to the production platform. The position encoder generates a position signal representing a respective instantaneous position of the inspection sensor relative to the production platform. The control unit generates a spatially resolved image of the defined layer using the line light source, the line scan camera, and the position signal. The control unit controls the structuring tool in order to produce a defined workpiece layer by selectively solidifying particulate material of the defined material layer based on the image of the defined material layer and/or an image of a previously produced workpiece layer.

A configurable build volume system for a powder bed fusion manufacturing process includes a chamber wall defining a chamber, the chamber wall extending in the X-, Y-, and Z-axis directions, a plurality of build platforms enclosed within the chamber, a plurality of adjustment mechanisms coupled to the plurality of build platforms such that each build platform is coupled to a separate adjustment mechanism, a sensor mounted within the chamber and configured to capture data regarding a Z-axis position of each of the plurality of build platforms, and a controller in electronic communication with the plurality of adjustment mechanisms and the sensor. The controller receives the Z-axis position data and generates a plurality of control signals to adjust a Z-axis position of each of the plurality of build platforms and each of the plurality of build platforms is actively and independently controlled by the controller.

A configurable build volume system for a powder bed fusion manufacturing process includes a chamber wall defining a chamber, the chamber wall extending in the X-, Y-, and Z-axis directions, a plurality of build platforms enclosed within the chamber, a plurality of adjustment mechanisms coupled to the plurality of build platforms such that each build platform is coupled to a separate adjustment mechanism, a sensor mounted within the chamber and configured to capture data regarding a Z-axis position of each of the plurality of build platforms, and a controller in electronic communication with the plurality of adjustment mechanisms and the sensor. The controller receives the Z-axis position data and generates a plurality of control signals to adjust a Z-axis position of each of the plurality of build platforms and each of the plurality of build platforms is actively and independently controlled by the controller.

Build receptacles for additive manufacturing apparatuses are disclosed. The build receptacle may comprise a housing comprising a sidewall at least partially enclosing a build chamber. A build platform may be positioned within the build chamber. A position of the build platform may be slidably adjustable within the build chamber in a vertical direction from a lower position to one of a plurality of upper positions and from the one of the plurality of upper positions to the lower position. The build receptacle may further comprise a plurality of heating elements disposed around the build chamber.

Additive manufacturing apparatuses are disclosed. In one embodiment, an additive manufacturing apparatus may comprise a support chassis including a print bay, a build bay, and a material supply bay. Each bay may comprise an upper compartment and a lower compartment. A working surface may separate each of the print bay, the build bay, and the material supply bay into the upper compartment and the lower compartment, wherein: the build bay may be disposed between the print bay and the material supply bay. The lower compartment of the build bay comprises bulkheads sealing the lower compartment of the build bay from the lower compartment of the print bay and the lower compartment of the material supply bay.

A light-based measurement system is capable of directing a light beam to a cooperative target used in conjunction with a cable robot to accurately control the position of the end effector within a large volume working environment defined by a single coordinate system. By measuring the end effector while the device is in operation, the cable robot control system can be adjusted in real time to correct for errors that are introduced through the design of the robot itself providing accuracy in the tens or hundreds of micron range. A coordination processor runs control software that communicates with both the laser tracker and the cable robot. An action plan file is loaded by the software that defines the coordinate system of the working volume, the locations where actions need to be performed by the cable robot, and the actions to be taken.

A light-based measurement system is capable of directing a light beam to a cooperative target used in conjunction with a cable robot to accurately control the position of the end effector within a large volume working environment defined by a single coordinate system. By measuring the end effector while the device is in operation, the cable robot control system can be adjusted in real time to correct for errors that are introduced through the design of the robot itself providing accuracy in the tens or hundreds of micron range. A coordination processor runs control software that communicates with both the laser tracker and the cable robot. An action plan file is loaded by the software that defines the coordinate system of the working volume, the locations where actions need to be performed by the cable robot, and the actions to be taken.

An additive manufacturing device is an additive manufacturing device manufacturing an additively manufactured article by melting or sintering layered powder by partially applying energy to the powder. The additive manufacturing device includes a powder holding unit holding the layered powder, a heating unit preheating the powder held by the powder holding unit, a reflection unit where a reflective film including a reflective surface is disposed, the reflective surface reflecting radiant heat radiated from an object including at least one of the powder and the additively manufactured article to the powder holding unit side, and a reflective surface update unit disposing a new reflective surface in the reflection unit by moving the reflective film.

A three-dimensional, additive manufacturing system is disclosed. The first and second printer modules form sequences of first patterned single-layer objects and second patterned single-layer objects on the first and second carrier substrates, respectively. The patterned single-layer objects are assembled into a three-dimensional object on the assembly plate of the assembly station. A controller controls the sequences and patterns of the patterned single-layer objects formed at the printer modules, and a sequence of assembly of the first patterned single-layer objects and the second patterned single-layer objects into the three-dimensional object on the assembly plate. The first transfer module transfers the first patterned single-layer objects from the first carrier substrate to the assembly apparatus in a first transfer zone and the second transfer module transfers the second patterned single-layer objects from the second carrier substrate to the assembly apparatus in a second transfer zone. The first and second printer modules are configured to deposit first and second materials under first and second deposition conditions, respectively. The first and second materials are different and/or the first and second deposition conditions are different.

A three-dimensional, additive manufacturing system is disclosed. The first and second printer modules form sequences of first patterned single-layer objects and second patterned single-layer objects on the first and second carrier substrates, respectively. The patterned single-layer objects are assembled into a three-dimensional object on the assembly plate of the assembly station. A controller controls the sequences and patterns of the patterned single-layer objects formed at the printer modules, and a sequence of assembly of the first patterned single-layer objects and the second patterned single-layer objects into the three-dimensional object on the assembly plate. The first transfer module transfers the first patterned single-layer objects from the first carrier substrate to the assembly apparatus in a first transfer zone and the second transfer module transfers the second patterned single-layer objects from the second carrier substrate to the assembly apparatus in a second transfer zone. The first and second printer modules are configured to deposit first and second materials under first and second deposition conditions, respectively. The first and second materials are different and/or the first and second deposition conditions are different.