An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved structure formation, part creation and manipulation, use of multiple additive manufacturing systems, and high throughput manufacturing methods suitable for automated or semi-automated factories are also disclosed.

The invention relates to a method for forming a three-dimensional article through successive fusion of locations of a powder bed. The method comprising: providing a model of said three-dimensional article; applying a powder layer on a work table; determining a maximum scan length of an energy beam; directing said energy beam from a first energy beam source over said work table with constant energy causing said first powder layer to fuse in first selected locations according to said model to form a first cross section of said three-dimensional article, wherein locations with a shorter scan length than said maximum scan length is provided with a time sink before and/or after said scan line so that the time period between each two adjacent scan lines is constant throughout the manufacture of said three-dimensional article.

A method of making a light weight housing for an internal component is provided. The method including the steps of: forming a first metallic foam core into a desired configuration; forming a second metallic foam core into a desired configuration; inserting an internal component into the first metallic foam core; placing the second metallic foam core adjacent to the first metallic core in order to secure the internal component between the first metallic foam core and the second metallic foam core; applying an external metallic shell to an exterior surface of the first metallic foam core and the second metallic foam core; and securing an inlet fitting and an outlet fitting to the housing, wherein a thermal management fluid path for the internal component into and out of the housing is provided by the inlet fitting and the outlet fitting.

A method for selecting an alloy for additive manufacturing includes melting a first material and a second material together to create a material melt, spinning the material melt to create melt spun ribbons, welding the ribbons together to produce a weld, and determining a weld quality of the weld.

Provided are a component and an additive manufacturing method for fabricating a component. The additive manufacturing method for fabricating a component includes providing a first wire segment and a second wire segment, the first and second wire segments each having a cross-sectional stackable geometry; positioning the first wire segment into an alignment with the second wire segment to form a workpiece stack, the alignment aligning adjacent surfaces in a line of sight direction; and directing an energy beam toward the first wire segment and the second wire segment along the alignment to weld the first wire segment to the second wire segment to form a welded stack. The component includes a workpiece stack comprising a plurality of wire segments welded together along aligned adjacent surfaces.

A method and apparatus for forming an object by additive layer manufacturing. The method comprises: a) applying, by a heat source (4), heat to a portion of a surface of a workpiece (1) sufficient to melt said portion; b) adding material to the melted portion and moving the heat source (4) relative to the workpiece (1) whereby progressively to form a layer of material (10) on the workpiece (1); c) cooling the formed layer (10) to bring at least part of the layer (10) to a state of crystallisation, there producing a modified workpiece; d) peening, using a plurality of independently controllable impact treatment devices (7), the modified work-piece so as to plastically deform the cooled at least part of the layer (10); and repeating steps a) to d) as required whereby to form the object.

Method and computer-readable model for additively manufacturing an injector assembly or a ducting arrangement including such assembles, as may be used in a combustion system of a gas turbine engine. The injector assembly may include a reactant-guiding structure (42) that may be configured to define a curvilinear flow path (47) to route a flow of reactants from a first flow direction (50) to a second flow direction (52) toward a cross-flow of combustion gases (60). A cross-flow guiding structure (54) may further define a flow path (58) to route a portion of the cross-flow of combustion gases toward an outlet side of the cross-flow guiding structure. Disclosed injector assemblies can be configured to reduce pressure loss while providing an effective level of mixing of the injected reactants with the passing cross-flow. Respective injector assemblies or the entire ducting arrangement may be formed as a unitized structure, such as a single piece using a rapid manufacturing technology, such as 3D Printing/Additive Manufacturing (AM) technology.

an extruded metal flow 3D printer comprising a rack including a workbench capable of moving along n X-axis and Y-axis direction, and a head capable of moving along an Z-axis direction; a printing device including a printing head, a highfrequency coil and a high frequency electric induction heating device; the printing heal including a tungsten steel nozzle, a ceramic tube bank, a high temperature resistant ceramic protective sleeve, and a stainless steel end cover; the tungsten steel nozzle having an extrusion hole; a feeding device; the head comprising at least one laser mounted on a lower end face thereof and configured to locally preheat and melt a metal layer printed from the metal wire or enhance a binding force between metal layers, so that the print effect and model molding effect of the present invention can be improved, enhancing the marketability.

Example systems may include an energy source, a material delivery device, and a computing device. The computing device, based on a target height of a layer deposited on a component by directed energy deposition, may control an energy source directed at a component and may control a material delivery device. Controlling the energy source may include advancing an energy beam along a first path to form an advancing molten pool on the component. Controlling the material delivery device may include delivering a material to the advancing molten pool. The material may combine with the advancing molten pool to form a first raised track having an actual height. The layer may include the first raised track. A deposited region of the component may include the layer. The actual height may affect a resultant microstructure within the deposited region.

A method of selective laser brazing is provided. The method includes providing a powder including a plurality of parent core particles and a plurality of braze particles, setting a temperature of an energy source, applying the energy source to the powder, and allowing the heated powder to solidify. The plurality of parent core particles are fused together by the plurality of braze material into a desired component.