An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a print head, and a support configured to move the print head. The support may include a first link, a second link rotationally connected to the first link at a joint, and an encoder-less motor rigidly mounted to the first link and configured to drive rotation of the second link relative to the first link. The support may also include a sole encoder associated with the joint and configured to generate a signal indicative of an angular position of the first link relative to the second link. The additive manufacturing system may further include a controller in communication with the sole encoder and the encoder-less motor. The controller may be configured to selectively trim operation of the encoder-less motor based only on the signal.

An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a print head, and a support configured to move the print head. The support may include a first link, a second link rotationally connected to the first link at a joint, and an encoder-less motor rigidly mounted to the first link and configured to drive rotation of the second link relative to the first link. The support may also include a sole encoder associated with the joint and configured to generate a signal indicative of an angular position of the first link relative to the second link. The additive manufacturing system may further include a controller in communication with the sole encoder and the encoder-less motor. The controller may be configured to selectively trim operation of the encoder-less motor based only on the signal.

Additive fabrication methods for 3D composite objects having preform fiber reinforcements embedded in a matrix material include providing local heat and mechanical energy to at least partially melt, impregnate and solidify the matrix material forming at least one reinforced composite layer of the object. Successive layers are added in accordance to a computer generated tool path to form a three dimensional object with useful features.

A binder jet printing apparatus (10), along with methods of its use, is provided. The binder jet printing apparatus (10) may include: a job box (18) having a actuatable build plate (46) therein; a supply box (54) having a bottom platform (56) that is actuatable within the supply box (54); a print system including at least one print head (32) connected to a binder source (38) and configured to apply a pattern of binder onto an exposed powder layer (42) over the build plate (46) of the job box (18); a recoat system (16) including a recoater configured to move from the supply box (54) to the job box (18) to transfer powder from the supply box (54) to the job box (18) so as to form a new powder layer (48) over the build plate (46) of the job box (18); and a cure system (14) configured to direct electromagnetic radiation onto the job box (18).

A binder jet printing apparatus (10), along with methods of its use, is provided. The binder jet printing apparatus (10) may include: a job box (18) having a actuatable build plate (46) therein; a supply box (54) having a bottom platform (56) that is actuatable within the supply box (54); a print system including at least one print head (32) connected to a binder source (38) and configured to apply a pattern of binder onto an exposed powder layer (42) over the build plate (46) of the job box (18); a recoat system (16) including a recoater configured to move from the supply box (54) to the job box (18) to transfer powder from the supply box (54) to the job box (18) so as to form a new powder layer (48) over the build plate (46) of the job box (18); and a cure system (14) configured to direct electromagnetic radiation onto the job box (18).

A three-dimensional shaped article production method is a three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers and includes a first metal powder supply step of supplying a first metal powder having a first average particle diameter to a shaping table, a layer formation step of forming the layer by compressing the first metal powder supplied to the shaping table, a first liquid supply step of supplying a first liquid containing a binder and a second metal powder having a second average particle diameter that is an average particle diameter 1/10 or more and ½ or less the first average particle diameter to at least a portion of a constituent region of the three-dimensional shaped article, a second liquid supply step of supplying a second liquid that contains a binder, but does not contain a metal powder to at least a portion of a surface layer region in the constituent region, and a sintering step of sintering a metal in the constituent region by heating a stacked body.

The present disclosure generally relates to additive manufacturing systems and methods involving a mechanism for feeding in a desired amount of fresh recoater blade. This can be accomplished by, for example, spooling the fresh blade material from a spool. This helps prevent work stoppage when a portion of a recoater blade becomes damaged. As such, the present disclosure also relates to a system and method for detecting whether a recoater blade is damaged, and if there is damage, then causing a fresh blade portion to be fed in.

A process abnormality detection system for a three-dimensional additive manufacturing device which performs additive modeling by emitting a beam to a powder bed determines that a laying abnormality of the powder bed is occurring if at least one of a first condition that an average height of the powder bed from a reference position is out of a first predetermined range or a second condition that a height variation of the powder bed is out of a second predetermined range is satisfied, on the basis of a detection result of a shape measurement sensor.

Method for manufacturing at least one part (8) of electroconductive material by additive manufacturing on a bed of powder characterized in that it comprises the steps of manufacturing the part on a support plate of a first additive manufacturing machine, layer by layer, said part being bounded by an external contour surface portion which is opposite and spaced apart from said support plate, and which is connected to said support plate by at least one bridge of support material of the part, providing a reference element (51) on the support plate in a predetermined position, mounting said support plate on a second machine (60) for cutting said at least one part, and using a wire (62-66) of said second machine for cutting by electrical discharge machining said at least one part by passing it between said at least one part and said support plate, along and at the level of said surface portion.

An example three-dimensional printing method is described, comprising selectively depositing droplets of a liquid agent on a layer of build material, by depositing liquid agent on the layer of build material from a first distance above the layer, for example on a first part of the layer, and depositing liquid agent on the layer of build material from a second distance above the layer, for example on a second part of the layer. An example 3D printer is also described.