An additive manufacturing machine may include an energy beam system configured to emit an energy beam utilized in an additive manufacturing process, and one or more optical elements utilized by, or defining a portion of, the energy beam system and/or an imaging system of the additive manufacturing machine. The imaging system may be configured to monitor one or more operating parameters of the additive manufacturing process. The additive manufacturing machine may include a light source configured to emit an assessment beam that follows an optical path incident upon the one or more optical elements, and one or more light sensors configured to detect a reflected beam comprising at least a portion of the assessment beam reflected and/or transmitted by at least one of the one or more optical elements. The additive manufacturing machine may include a control system configured to determine, based at least in part on assessment data comprising data from the one or more light sensors, whether the one or more optical elements exhibit an optical anomaly.

A three-dimensional printing system for fabricating a three-dimensional article includes a motorized build platform, a dispensing module, a pulsed light source, an imaging module, a movement mechanism, and a controller. The imaging module receives radiation from the pulsed light source and includes a two-dimensional mirror array. The movement mechanism imparts lateral motion between the imaging module and the build platform. The controller is configured to operate the motorized build platform and the dispensing module to form a layer of build material at a build plane, operate the movement mechanism to laterally scan the imaging module over the build plane, operate the pulsed light source to generate a sequence of radiation pulses that illuminate the mirror array, and operate the mirror array to selectively image the build material.

A three-dimensional printing system for fabricating a three-dimensional article includes a motorized build platform, a dispensing module, a pulsed light source, an imaging module, a movement mechanism, and a controller. The imaging module receives radiation from the pulsed light source and includes a two-dimensional mirror array. The movement mechanism imparts lateral motion between the imaging module and the build platform. The controller is configured to operate the motorized build platform and the dispensing module to form a layer of build material at a build plane, operate the movement mechanism to laterally scan the imaging module over the build plane, operate the pulsed light source to generate a sequence of radiation pulses that illuminate the mirror array, and operate the mirror array to selectively image the build material.

The problem of limited throughput in three-dimensional (3D) printing processes is addressed by systems and methods that employ mirrors to receive energy reflected by the melt pool and to redirect such light back to the melt pool, where it may further heat the melt pool. Multiple such passes of reflection from the melt pool and redirection back to the melt pool may substantially increase the efficiency at which the melt pool absorbs the energy, thereby substantially increasing the throughput of the 3D printing process.

A method of manufacturing a metal member including a first part and a second part includes a first fabrication process of fabricating the first part through a three-dimensional metal stack fabrication by a powder bed method, and a second fabrication process of fabricating an outer circumference of the second part through the three-dimensional metal stack fabrication by the powder bed method, and then sintering metallic powder remaining in an inner portion of the second part by hot isostatic pressing so as to fabricate the second part.

Additive manufacturing systems and methods are provided. An additive manufacturing system includes a build volume; a powder disposed in the build volume, the powder occupying at least a portion of the build volume and having an outer boundary; a beam generator configured to generate a beam to irradiate the powder; and a ram defining a passthrough configured to transmit the beam to an irradiation location disposed within the outer boundary of the powder.

The invention refers to a deflection module comprising a first deflection unit (10a) comprising a first scanning device (12a) for scanning a first working beam (50a) over a first working field and (40a) and a second deflection unit (10b) comprising a second scanning device (12b) for scanning a second working beam (50b) over a second working field (40b). At least a movable mirror (12a-2) of the first scanning device (12a) and at least a movable mirror (12b-2) of the second scanning device (12b) are arranged mirror-symmetrically with respect to each other. The first working field (40a) and the second working field (40b) overlap in a common overlap area (42).

A manufacturing device for additive manufacturing of component parts from a powder material includes a beam producing device, a scanner device configured to displace an energy beam to a plurality of irradiation positions, a deflection device configured to displace the energy beam at an irradiation position to a plurality of beam positions, and a control device configured to control the deflection device and to produce a specific intensity profile in the beam region. The control device does this by dividing and displacing the energy beam to at least two beam positions separated by a distance that is variably settable and/or by displacing the energy beam and by specifying at least one operating parameter of the deflection, such as a residence time at a beam position, a beam position density distribution, a frequency distribution, and an intensity influencing parameter of the energy beam deflected to the beam positions.

A manufacturing device for additive manufacturing of a component part from a powder material includes a beam generating device configured to generate an energy beam, a scanner device configured to displace the energy beam to a plurality of irradiation positions in order to produce the component part from the powder material arranged in the work region using the energy beam, a deflection device configured to displace the energy beam to a plurality of beam positions at an irradiation position of the plurality of irradiation positions within a beam region, and a control device operatively connected to the deflection device and configured to control the deflection device and to change a beam profile of the beam region during production of a component part by changing a control of the deflection device.

A large area sintering platform, system, and methodology. The system includes a convection oven with a projection window disposed within a top surface of the oven. A platform is disposed within the oven below the window at a spaced distance away from the window. A powder is positioned on top of the platform, with a thermocouple positioned within the powder on the platform. A high intensity projector moves in sync with the platform, and uses low intensities and long exposure times to project an image through the window onto the powder and sinter the powder to fabricate the desired model layer by layer.