Devices, systems, and methods for monitoring a powder layer in additive manufacturing are disclosed. A method of monitoring a powder layer includes receiving image data corresponding the powder layer supported by a powder bed within a build chamber from imaging devices, determining leading and trailing regions of interest located adjacent to a leading end and a trailing end of the moving powder distributor, respectively, the leading and trailing regions of interest moving according to movement of the moving powder distributor, selecting at least one point located in the leading region of interest from the image data, determining first characteristics of the point, when the point is located within the trailing region of interest, determining second characteristics of the point, and comparing the first characteristics to the second characteristics.

A 3D printing tool and assembly for dispensing multiple materials includes a barrel holder assembly having at least two barrel orifices extending from a top end of the barrel holder assembly through to a bottom end of the barrel holder assembly, where at least one of the at least two barrel orifices is oriented at an angle from the vertical. A method for operating the 3D printing tool includes positioning a first material distribution barrel within a first barrel orifice, where a first barrel tip is disposed at a first end of the first material distribution barrel. The method further includes dispensing building material from the first material distribution barrel when the first material distribution barrel is substantially vertically oriented and a second material distribution barrel is oriented at an angle from the vertical.

The present disclosure relates to a system for performing an Additive Manufacturing (AM) fabrication process on a powdered material (PM) forming a substrate. The system uses a first optical subsystem to generate an optical signal comprised of electromagnetic (EM) radiation sufficient to melt or sinter a PM of the substrate. The first optical subsystem is controlled to generate a plurality of different power density levels, with a specific one being selected based on a specific PM forming a powder bed being used to form a 3D part. At least one processor controls the first optical subsystem and adjusts a power density level of the optical signal, taking into account a composition of the PM. A second optical subsystem receives the optical signal from the first optical subsystem and controls the optical signal to help facilitate melting of the PM in a layer-by-layer sequence of operations.

A laser-assisted microfluidics manufacturing process has been developed for the fabrication of additively manufactured structures. Roll-to-roll manufacturing is enhanced by the use of a laser-assisted electrospray printhead positioned above the flexible substrate. The laser electrospray printhead sprays microdroplets containing nanoparticles onto the substrate to form both thin-film and structural layers. As the substrate moves, the nanoparticles are sintered using a laser beam directed by the laser electrospray printhead onto the substrate.

Provided is a method which includes a first layer formation step of forming a first layer by using a first composition that contains a constituent material powder, a first powder, and a binder of a three-dimensional shaped article; a second layer formation step of forming a second layer by using a second composition that contains a second powder and a binder; a degreasing step of a stack containing the first layer and the second layer; and a sintering step of the stack, a decomposition point of the first powder is higher than decomposition points of the binder of the first layer and the binder of the second layer, a decomposition point of the second powder is higher than the decomposition point of the first powder, and a sintering temperature of the constituent material powder is higher than the decomposition point of the second powder.

A method for producing a metal shaped article having a porous structure includes a mold formation step of forming a mold having a plurality of columnar structures extending from a substrate by performing a resin material supply step of supplying a liquid containing a resin material to a plurality of places of the substrate at intervals in two directions crossing each other, and a curing step of curing the liquid, a sintering target material supply step of supplying a sintering target material to the mold, a removal step of removing the substrate, a degreasing step of degreasing the columnar structures, and a sintering step of sintering the sintering target material.

A method for producing a metal shaped article having a porous structure includes a mold formation step of forming a mold having a plurality of columnar structures extending from a substrate by performing a resin material supply step of supplying a liquid containing a resin material to a plurality of places of the substrate at intervals in two directions crossing each other, and a curing step of curing the liquid, a sintering target material supply step of supplying a sintering target material to the mold, a removal step of removing the substrate, a degreasing step of degreasing the columnar structures, and a sintering step of sintering the sintering target material.

An AM installation utilising SLM or SLS a chamber of a housing with a protective atmosphere, a support structure in the chamber defines an upper horizontal surface on which a laser source is operable for focusing onto predetermined regions of a build area of the plane of the horizontal surface. The laser beam source is operable so areas of each of successive layers of powder material are sintered or fully molten throughout its layer thickness. A dosing device raises successive quantities of powder to the level of the upper surface to enable a re-coater to form the layers. A separable build device unit defines build chamber opening at the upper surface, and includes a lift table and an electric drive by which the lift table is stepwise vertically adjustable so a progressively built component is lowerable into the build chamber.

A jetted binder printing system includes a carrier substrate configured to travel along a longitudinal direction thereof, an adjustable binder printer configured to deliver an adjustable binder to the carrier substrate, a dispensing module located downstream from the adjustable binder printer on the longitudinal direction of the carrier substrate, the dispensing module including at least one powder container, the dispensing module being configured to dispense powder onto the carrier substrate, and a primary binder printer located downstream from the compaction module along the longitudinal direction of the carrier substrate. The primary binder printer includes a print head configured to print a primary binder on the dispensed powder according to a desired pattern. The primary binder is printed on a surface of the powder that is opposite a surface on which the adjustable binder is printed. The primary binder is printed to match the pattern of the adjustable binder.

A jetted binder printing system includes a carrier substrate configured to travel along a longitudinal direction thereof, an adjustable binder printer configured to deliver an adjustable binder to the carrier substrate, a dispensing module located downstream from the adjustable binder printer on the longitudinal direction of the carrier substrate, the dispensing module including at least one powder container, the dispensing module being configured to dispense powder onto the carrier substrate, and a primary binder printer located downstream from the compaction module along the longitudinal direction of the carrier substrate. The primary binder printer includes a print head configured to print a primary binder on the dispensed powder according to a desired pattern. The primary binder is printed on a surface of the powder that is opposite a surface on which the adjustable binder is printed. The primary binder is printed to match the pattern of the adjustable binder.