A processing machine (10) for building an object (11) from a material (12) includes a build platform (16), a platform mover assembly (20), a material supply (22), an irradiation device (26), and an analyzer system (30). The platform mover assembly (20) moves the build platform (16) about a platform movement axis (48X) and along the platform movement axis (48X). The material supply (22) supplies material (12) to build the object (11) on the build platform (16). The irradiation device (26) irradiates at least a portion of the material (12) with an energy beam (26A) to form the object (11) from the material (12) on the build platform (16). The analyzer system (30) is configured to monitor the energy beam (26A). The analyzer system (30) includes an alignment component (36) that rotates concurrently with the build platform (16) about the platform movement axis (48X), but that is inhibited from moving concurrently with the build platform (16) along the platform movement axis (48X).

A processing machine (10) for building an object (11) from a material (12) includes a build platform (16), a platform mover assembly (20), a material supply (22), an irradiation device (26), and an analyzer system (30). The platform mover assembly (20) moves the build platform (16) about a platform movement axis (48X) and along the platform movement axis (48X). The material supply (22) supplies material (12) to build the object (11) on the build platform (16). The irradiation device (26) irradiates at least a portion of the material (12) with an energy beam (26A) to form the object (11) from the material (12) on the build platform (16). The analyzer system (30) is configured to monitor the energy beam (26A). The analyzer system (30) includes an alignment component (36) that rotates concurrently with the build platform (16) about the platform movement axis (48X), but that is inhibited from moving concurrently with the build platform (16) along the platform movement axis (48X).

An additive manufacturing apparatus includes: first and second spaced apart side walls extending along a pre-defined path and defining a build chamber therebetween; one or more build units mounted for movement along the pre-defined path, the one or more build units including at least one of: a powder dispenser positioned above the build chamber; an applicator configured to scrape powder dispensed into the build chamber; and a directed energy source configured to fuse the scraped powder.

An additive manufacturing apparatus includes: first and second spaced apart side walls extending along a pre-defined path and defining a build chamber therebetween; one or more build units mounted for movement along the pre-defined path, the one or more build units including at least one of: a powder dispenser positioned above the build chamber; an applicator configured to scrape powder dispensed into the build chamber; and a directed energy source configured to fuse the scraped powder.

Wire arc additive manufacturing-spinning combined machining device and method are provided. The machining device includes a spinning mechanism and a fused deposition modeling mechanism. The spinning mechanism includes a machine tool and a spinning head. The spinning head is installed on the machine tool by a main shaft, and the main shaft is configured to drive the spinning head to rotate to achieve the movement in three vertical directions. The spinning head includes a spinning base and balls. Each of the balls is installed in a corresponding one of arc grooves at a bottom of the spinning base. The fused deposition modeling mechanism includes a moving track, a robot and a heat source generator. The arc moving track is arranged around the machine tool in a surrounding mode. The robot is movably installed on the moving track. The heat source generator is installed at a tail end of the robot.

Systems and methods for real time, nondestructive inspection of an object being formed by additive manufacturing is provided. The disclosed systems and methods can be used with any additive manufacturing system and can detect defects introduced during fabrication. In operation, additive manufacturing of the object can be paused and the object rotated within the build chamber. An x-ray pulse can then be directed through a linear aperture towards the object being formed inside the build chamber. A linear x-ray detector array can detect the x-ray pulse and an x-ray image of the object being formed can be created. By rotating the object being formed during exposure to the x-ray pulse at least one half of one full rotation, the entire volume of the object can be inspected.

The present disclosure generally relates to methods for additive manufacturing (AM) for fabricating multi-walled structures. A multi-walled structure includes a first wall having a first surface and a second wall having a second surface facing the first surface to define a passage having a width between the first surface and the second surface in a first direction. The multi-walled structure also includes an enlarged powder removal feature connecting the first wall and the second wall. The enlarged powder removal feature has an inner dimension greater than the width in the first direction and at least one open end in a direction transverse to the first width.

A fluidized powder additive manufacturing system can include a container defining a powder volume configured to hold a powder, a fluidizer attached to and/or disposed on or within the container, the fluidizer configured to fluidize the powder within the powder volume to form a fluidized powder, and a build area assembly disposed within the container. The build area assembly can include a build surface, and a movement system attached to the build surface and configured to move the build surface within the powder volume when the powder is fluidized.

Methods for removing an object from powder after forming the object in an additive manufacturing apparatus are provided. The method may include: positioning a cover over a build platform with the object being positioned within a powder; removing the build platform from the additive manufacturing apparatus with the cover positioned over the build platform; and thereafter, removing the powder from the build platform to expose the object.

Methods for removing an object from powder after forming the object in an additive manufacturing apparatus are provided. The method may include: positioning a cover over a build platform with the object being positioned within a powder; removing the build platform from the additive manufacturing apparatus with the cover positioned over the build platform; and thereafter, removing the powder from the build platform to expose the object.