The present invention relates to a device as well as a method for the additive manufacture of components by deposition of material layers by layer-by-layer joining of powder particles to one another and/or to an already produced pre-product or substrate, via selective interaction of the powder particles with a high-energy beam, wherein, for smoothing a surface of the component being produced running crosswise to the deposited material layers in between the deposition of two layers of the component, the complete edge region of the last layer that is applied and that runs along a surface of the component being produced is compacted in a direction of action that has a directional component parallel to the build-up direction of the layers, and/or at least one edge region (19) of a surface of the component (3′) is also compacted.

An optical manufacturing process sensing and status indication system is taught that is able to utilize optical emissions from a manufacturing process to infer the state of the process. In one case, it is able to use these optical emissions to distinguish thermal phenomena on two timescales and to perform feature extraction and classification so that nominal process conditions may be uniquely distinguished from off-nominal process conditions at a given instant in time or over a sequential series of instants in time occurring over the duration of the manufacturing process. In other case, it is able to utilize these optical emissions to derive corresponding spectra and identify features within those spectra so that nominal process conditions may be uniquely distinguished from off-nominal process conditions at a given instant in time or over a sequential series of instants in time occurring over the duration of the manufacturing process.

A layer manufacturing apparatus comprising: (a) a main chamber; (b) one or more energy emission devices; (c) one or more work piece supports; (d) a plurality of material delivery devices; wherein the plurality of material delivery devices are connected to one or more spools that are located external of the main chamber.

A method for controlling an energy beam in an additive manufacturing machine when forming a three-dimensional article layer by layer by successive fusion of selected areas of powder layers, which selected areas correspond to successive layers of the article. The method includes steps of radiating a powder layer by the energy beam and creating a set of images of the powder layer for a set of positions on the powder layer by detecting particles emitted, backscattered or reflected from the powder layer when being radiated, comparing data representing the set of images and reference data with each other for identifying a difference between the energy beam when used on the powder layer and the reference data, with respect to at least one energy beam parameter, and adjusting the energy beam based on such an identified difference between the energy beam when used on the powder layer and the reference data.

A method for additively manufacturing a component includes receiving, via an additive manufacturing system, a geometry of the component and melting and fusing, via an energy beam of the additive manufacturing system, material layer by layer atop a build platform according to the geometry so as to build up a plurality of layers that form the component. The method also includes determining a surface area change from one of the plurality of layers to the next based on the geometry. Further, the method includes temporarily discontinuing melting and fusing of the material by the energy beam between building of one or more of the plurality of layers so as to provide a delay after building one or more of the plurality of layers when the surface area change is above a predetermined threshold. As such, the delay allows for one or more previously built layers to at least partially cool so as to eliminate and/or reduce build failures from occurring in the final component.

A system used to additively manufacture an object layer-by-layer using direct energy deposition (DED) includes a base where the object is formed, a depositor configured to deposit material layer-by-layer on the base or a previously deposited layer of the object, an energy source configured to selectively direct an energized beam at the material to fuse a new layer of the material to a previously formed layer, and a heating element in contact with at least a portion of the base and configured to supply heat to the base.

A beam adjustment method includes: installing, on an irradiation surface to which an electron beam is radiated, a detection part having a Faraday cup catching electrical charges of the electron beam, and installing, on a side of an electron gun further than the detection part, a shielding plate having opening holes through which the electron beam is passable. The method includes causing, upon performing beam diameter measurement processing, the electron beam to pass through the opening holes, and radiating the electron beam to the Faraday cup. In addition, the method includes radiating, upon performing normal processing, the electron beam to the shielding plate.

In various embodiments, metallic wires are fabricated by combining one or more powders of substantially spherical metal particles with one or more powders of non-spherical particles within one or more optional metallic tubes. The metal elements within the powders (and the one or more tubes, if present) collectively define a high entropy alloy of five or more metallic elements or a multi-principal element alloy of four or more metallic elements.

An example control component for controlling an engine component includes a housing. The housing defines a cavity configured to receive control circuitry configured to control the engine. The housing includes an exterior layer defining an exterior surface of the housing and an interior polymeric layer defining an interior surface of the housing. The interior polymeric layer is adjacent to and substantially coextensive with the exterior layer. The interior polymeric layer includes an electrically and thermally conductive material. An example technique includes forming the exterior layer and forming the interior polymeric layer.

Methods for the fabrication of metal strain wave gear flexsplines using a specialized metal additive manufacturing technique are provided. The method allows the entire flexspline to be metal printed, including all the components: the output surface with mating features, the thin wall of the cup, and the teeth integral to the flexspline. The flexspline may be used directly upon removal from the building tray.