Methods and apparatuses for additive manufacturing are described. A method for additive manufacturing may include exposing a layer of material on a build surface to one or more projections of laser energy including at least one line laser having a substantially linear shape. The intensity of the line laser may be modulated so as to cause fusion of the layer of material according to a desired pattern as the one or more projections of laser energy are scanned across the build surface.

Provided is a technique for fabricating a powder material bedded in advance using a DED nozzle. According to one embodiment, there is provided an AM apparatus for manufacturing a fabricated object. The AM apparatus includes a DED nozzle. The DED nozzle includes: a DED nozzle main body; a laser port disposed at a distal end of the DED nozzle main body and for emitting a laser beam, and a laser passage configured to communicate with the laser port and for allowing the laser beam to pass through the DED nozzle main body; and a powder port disposed at the distal end of the DED nozzle main body and for emitting a powder material, and a powder passage configured to communicate with the powder port and for allowing the powder material to pass through the DED nozzle main body. The AM apparatus further includes a cover configured to surround a peripheral area of the laser port and the powder port of the DED nozzle. The cover is configured to have an opened downstream side in an emission direction of the laser beam. The cover includes a gas supply passage for supplying a gas inside the cover. The gas supply passage is configured to be oriented so as to guide the gas toward the DED nozzle main body.

Provided is a technique for fabricating a powder material bedded in advance using a DED nozzle. According to one embodiment, there is provided an AM apparatus for manufacturing a fabricated object. The AM apparatus includes a DED nozzle. The DED nozzle includes: a DED nozzle main body; a laser port disposed at a distal end of the DED nozzle main body and for emitting a laser beam, and a laser passage configured to communicate with the laser port and for allowing the laser beam to pass through the DED nozzle main body; and a powder port disposed at the distal end of the DED nozzle main body and for emitting a powder material, and a powder passage configured to communicate with the powder port and for allowing the powder material to pass through the DED nozzle main body. The AM apparatus further includes a cover configured to surround a peripheral area of the laser port and the powder port of the DED nozzle. The cover is configured to have an opened downstream side in an emission direction of the laser beam. The cover includes a gas supply passage for supplying a gas inside the cover. The gas supply passage is configured to be oriented so as to guide the gas toward the DED nozzle main body.

The present disclosure relates to an additive manufacturing system. In one embodiment the system makes use of a reservoir for holding a granular material feedstock. A nozzle is in communication with the reservoir for releasing the granular material feedstock in a controlled fashion from the reservoir to form at least one layer of a part. An excitation source is included for applying a signal which induces a controlled release of the granular material feedstock from the nozzle as needed, to pattern the granular material feedstock as necessary to form a layer of the part.

The present disclosure relates to an additive manufacturing system. In one embodiment the system makes use of a reservoir for holding a granular material feedstock. A nozzle is in communication with the reservoir for releasing the granular material feedstock in a controlled fashion from the reservoir to form at least one layer of a part. An excitation source is included for applying a signal which induces a controlled release of the granular material feedstock from the nozzle as needed, to pattern the granular material feedstock as necessary to form a layer of the part.

A printer includes a heat control device configured to prevent a temperature of a part that is printed by the printer from decreasing by more than about 5° C. as a height of the part increases from about 0 mm to about 30 mm. The heat control device includes a gas curtain source that is configured to generate a gas curtain that at least partially surrounds at least a portion of the part.

A printer includes a heat control device configured to prevent a temperature of a part that is printed by the printer from decreasing by more than about 5° C. as a height of the part increases from about 0 mm to about 30 mm. The heat control device includes a gas curtain source that is configured to generate a gas curtain that at least partially surrounds at least a portion of the part.

A high melt superalloy powder mixture is provided for use with additive manufacturing or welding metal components or portions thereof. The high melt superalloy powder may include by weight about 7.7% to about 18% chromium, about 10.6% to about 11% cobalt, about 4.5% to about 6.5% aluminum, about 10.6% to about 11% tungsten, about 0.3% to about 0.55% molybdenum, about 0.05% to about 0.08% carbon, and at least 40% nickel.

A high melt superalloy powder mixture is provided for use with additive manufacturing or welding metal components or portions thereof. The high melt superalloy powder may include by weight about 7.7% to about 18% chromium, about 10.6% to about 11% cobalt, about 4.5% to about 6.5% aluminum, about 10.6% to about 11% tungsten, about 0.3% to about 0.55% molybdenum, about 0.05% to about 0.08% carbon, and at least 40% nickel.

An additive manufacturing system includes a laser array including a plurality of laser devices. Each laser device of the plurality of laser devices generates an energy beam for forming a melt pool in a powder bed. The additive manufacturing system further includes at least one optical element. The optical element receives at least one of the energy beams and induces a predetermined power diffusion in the at least one energy beam.