A method for designing an additively-manufactured object includes: a slicing step of slicing a shape of the additively-manufactured object into weld bead layers each having a height corresponding to one bead layer using data of the shape of the additively-manufactured object, thereby generating a plurality of virtual bead layers; a reference direction setting step of setting, as a reference direction, a direction in which the sliced layer of the additively-manufactured object is continuously provided and extended in an intermediate layer disposed at a deposition-direction center of the plurality of virtual bead layers; and a bead adjusting step of adjusting a bead size of the weld bead to be formed in the plurality of virtual bead layers depending on a bead shape in a section perpendicular to the reference direction.

Prior to manufacturing a product by additive manufacturing, a stress relief profile including frequency and amplitude parameters of an ultrasonic input is determined based on physical properties of the product, including resonant frequencies of the product and a material from which the product is manufactured. Successive layers of a material are added and energy is applied to incorporate the material of each layer into the product. A processor accesses stress relief profile parameters for each layer, determines whether a layer requires stress relief and determines a frequency and a power level for the stress relief at the layer. An ultrasonic input is applied with the determined parameters to relieve stress as the product is built up.

A method for manufacturing a component of a rotary machine, the component extends in an axial direction and a radial direction vertical thereto, and has an inner channel, extending from a first end in a center of the component to a second end at a radial limiting surface of the component and which is partially closed. A blank includes the center of the component and is limited by an outer surface in the radial direction. The maximum dimension of the outer surface in the radial direction is smaller than the dimension of the limiting surface in the radial direction. A first subtractive process step is performed such that a part of the channel is manufactured by a machining process, with the part extending from the first end of the channel to the outer surface of the blank. Afterwards the channel is finished by a build-up process on the blank.

Provided are a jet device and systems and methods using the jet device for manufacturing objects by additive manufacturing, especially titanium and titanium alloy objects, wherein the jet device directs a cooling gas across a liquid molten pool, or to impinge on the liquid molten pool, or to impinge upon a solidified material adjacent to a liquid-solid boundary of the liquid molten pool, or to impinge on an as-solidified material, or any combination thereof, during the additive manufacturing process. The application of the cooling gas can result in an additively manufactured metal product having refined grain structure with a high proportion of the grains being approximately equiaxed, and can yield an additively manufactured product exhibiting improvements in strength, fatigue resistance, and durability.

A system includes a machine tool having a clamp. The system also includes a processing head configured to be temporarily held by the clamp of the machine tool. The processing head is also configured to deposit one or more media onto a workpiece. The processing head includes a guide configured to direct energy from an energy source onto the workpiece and/or the one or more media. The processing head also includes one or more supplies including one or more reservoirs within the processing head. The one or more reservoirs are configured to receive the one or more media, store the one or more media as the processing head is moved from one location to another location, and provide the one or more media.

A method of manufacturing a metallic part in a weldable material by solid freeform fabrication comprising generating three dimensional model of the part, slicing the three dimensional model into a set of parallel, sliced layers and then dividing each layer into a set of one-dimensional pieces and, with reference to layered weld-bead geometry data, forming a computer-generated, direction specific, layered model of the part. The method also comprises uploading the layered model into a welding control system and directing the welding control system to deposit a sequence of one-dimensional weld beads of the weldable material onto the supporting substrate in a pattern required to form a first layer of the layered model and depositing a second welded layer onto the previous deposited layer in a configuration the same as the second layer, and repeating each successive weld bead until the entire part is completed. The method further includes displacing the atmosphere within the immediate vicinity of the heat source with an inert gas atmosphere which produces a required flow rate, and in which that inert atmosphere contains a maximum oxygen concentration, wherein the inert gas is delivered by an apparatus through a matrix of individual gas diffusers; and engaging an induction heating and closed loop cooling apparatus synergic to a welding control system and pre-heating the substrate material including the deposited weld beads, relevant to the type of weldable material, wherein induction heating and cooling cycles are applied constantly or pulsed from the first layer to the final layer, where optimal heating and/or cooling cycles of the weldable material are relative to the final desired part shape and microstructure.

A method for additive manufacturing at least one intersection of first and second ribs by stacking layers of material, at least one layer of material of a first section of the first rib being obtained by depositing at least one bead of material that extends on respective opposite sides of the intersection. Wherein in that at least one layer of material of a second section of the second rib comprises a first part obtained by depositing at least one bead of material at a distance from the first section that extends in the direction of the second section and a second part obtained by depositing at least one bead of material adjacent to the first section that extends in the first direction. Also a method of manufacturing a ribbed panel and a ribbed panel.

A component of a rotary machine extends to an axial direction and a radial direction vertical thereto, and has an inner channel, extending from a first end of a core of a center of the component and to a second end at a radial limiting surface of the component and which is at least partially closed. A blank includes the core of the component and is limited by an outer surface in the radial direction. The blank is subtractively processed in a first subtractive process step, such that an outer contour is elaborated in the area of the outer surface, which extends in the radial direction, and a part of the channel is manufactured, which radially extends in the blank to the first end. The channel is formed by a build-up process on the blank.

A machine tool arranged to deliver an energy source through a processing head onto a work-piece, wherein; the machine-tool has a clamping mechanism arranged to temporarily receive the processing-head, or another machining or processing-head, to process a work-piece; the processing-head comprising one or more guiding mechanisms arranged to direct the energy source onto a work-piece and a processing-head docking-manifold arranged to have connected thereto one or more media to be, in use, supplied to the processing-head to facilitate processing of the work-piece; wherein the processing-head docking-manifold allows the one or more media to be supplied to the processing-head when the processing-head is connected to the clamping mechanism; and wherein the machine-tool also comprises at least one mechanism arranged to move a supply docking-manifold into and/or out of connection with the processing-head docking-manifold such that when the two manifolds are connected the or each media is supplied to the processing head.

The present disclosure provides three-dimensional (3D) objects, 3D printing processes, as well as methods, apparatuses and systems for the production of a 3D object. Methods, apparatuses and systems of the present disclosure may reduce or eliminate the need for auxiliary supports. The present disclosure provides three dimensional (3D) objects printed utilizing the printing processes, methods, apparatuses and systems described herein.