A locking mechanism (100) for coupling an outlet (16) of a container (12) to an inlet (18) for a component of an additive manufacturing process. The locking mechanism (100) includes one or more locking members (102a, 102b) which are moveable, in use, between at least a first position and a second position. One or more actuators (104a, 104b) are provided and are configured, in use, to control movement of the one or more locking members (102a, 102b) between the first and second positions. The one or more locking members (102a, 102b) are configured to engage an exterior surface of the outlet (16) of the container (12) when in the second position so as to couple the outlet (16) to the inlet (18) for the component of the additive manufacturing process.

A locking mechanism (100) for coupling an outlet (16) of a container (12) to an inlet (18) for a component of an additive manufacturing process. The locking mechanism (100) includes one or more locking members (102a, 102b) which are moveable, in use, between at least a first position and a second position. One or more actuators (104a, 104b) are provided and are configured, in use, to control movement of the one or more locking members (102a, 102b) between the first and second positions. The one or more locking members (102a, 102b) are configured to engage an exterior surface of the outlet (16) of the container (12) when in the second position so as to couple the outlet (16) to the inlet (18) for the component of the additive manufacturing process.

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.

The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.

A powder spreading apparatus includes a hopper having a first end, a second end opposite from the first end, a front wall, a rear wall opposite from the front wall, and a floor. The front wall, the rear wall, the first end, the second end, and the floor define an interior. An impeller is disposed within the interior of the hopper. The impeller includes a plurality of circumferentially spaced flutes and is configured to rotate about an impeller axis that extends from the first end of the hopper to the second end of the hopper to deposit powder onto a print area. A spreader rod is coupled to the hopper and extends along a spreader rod axis parallel to the impeller axis. The spreader rod is configured to rotate about the spreader rod axis to smooth the powder as it is deposited onto the print area. A powder spreading method is disclosed that operates an impeller to start depositing powder from a hopper into a print area located within a build box as a gantry moves the hopper in a first direction across the print area; operating a spreader rod to smooth out the powder on the print area as the gantry moves the hopper and the spreader rod across the print area in the first direction; and upon the gantry reaching a predetermined position in the print area, stopping the impeller to stop depositing the powder while continuing to operate the spreader rod.

A plasticizing device includes a driving motor, a rotor that is rotated by rotation of the driving motor and has a groove-formed surface having a groove formed in a rotation direction, and a barrel that is opposite to the groove-formed surface and has a communication hole and a heater, plasticizes a material supplied between the groove and the barrel by rotation of the rotor and heating by the heater, and causes the plasticized material to flow out from the communication hole. Aside surface of the groove has a protrusion and recess surface including protrusion portions or recess portions.

The devices, systems, and methods of the present disclosure are directed to powder spreading and binder distribution techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, a powder may be spread to form a layer along a volume defined by a powder box, a binder may be deposited along the layer to form a layer of a three-dimensional object, and the direction of spreading the layer and depositing the binder may be in a first direction and in a second direction, different from the first direction, thus facilitating rapid formation of the three-dimensional object with each passage of the print carriage over the volume. Powder delivery, powder spreading, thermal energy delivery, and combinations thereof, may facilitate consistently achieving quality standards as the rate of fabrication of the three-dimensional object is increased.

The devices, systems, and methods of the present disclosure are directed to powder spreading and binder distribution techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, a powder may be spread to form a layer along a volume defined by a powder box, a binder may be deposited along the layer to form a layer of a three-dimensional object, and the direction of spreading the layer and depositing the binder may be in a first direction and in a second direction, different from the first direction, thus facilitating rapid formation of the three-dimensional object with each passage of the print carriage over the volume. Powder delivery, powder spreading, thermal energy delivery, and combinations thereof, may facilitate consistently achieving quality standards as the rate of fabrication of the three-dimensional object is increased.

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.