A method of forming a build in a powder bed includes providing a first diode laser fiber array and a second diode laser fiber array, emitting a plurality of laser beams from selected fibers of the second diode laser fiber array onto the powder bed, corresponding to a pattern of a layer of the build, simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build, scanning a first diode laser fiber array along an outer boundary of the powder bed and emitting a plurality of laser beams from selected fibers of the first diode laser fiber array and simultaneously melting powder in the powder bed corresponding to the outer boundary of the layer of the build to contour the layer of the build. An apparatus for forming a build in a powder bed including a first diode laser fiber array and a second diode laser fiber array is also disclosed. The first diode laser fiber array configured to contour the layer of the build.

This blade repair method has: a first welding step in which overlay welding in which a first welding material is used is performed to form a notched part and a bury a first region positioned on a blade-body side with a first welding material; and a second welding step in which, after the first welding step, overlay welding in which a second welding material is used is performed to form a notched part and bury a second region positioned on a front-surface side of a platform with the second welding material. The high-temperature strength of the second welding material is higher than the high-temperature strength of the first welding material, the weldability of the first welding material is higher than the weldability of the second welding material, and the second region is located in a range from 1.0 mm to 3.0 mm (inclusive) from the front surface of the platform toward the blade body.

Systems and methods for printing a printed circuit board (PCB) from substrate to full integration utilize a laser-assisted deposition (LAD) system to print a flowable material on top of a substrate by laser jetting to create a PCB structure to be used as an electronic device. One such system for PCB printing includes a jet printing unit, an imaging unit, curing units, and a drilling unit to print metals and other materials (e.g., epoxies, solder masks, etc.) directly on a PCB substrate such as a glass-reinforced epoxy laminate material (e.g., FR4). The jet printing unit can also be used for sintering and/or ablating materials. Printed materials are cured by heat or by infrared (IR) or ultraviolet (UV) radiation. PCBs produced according to the present systems and methods may be single-sided or double-sided.

Systems and methods for printing a printed circuit board (PCB) from substrate to full integration utilize a laser-assisted deposition (LAD) system to print a flowable material on top of a substrate by laser jetting to create a PCB structure to be used as an electronic device. One such system for PCB printing includes a jet printing unit, an imaging unit, curing units, and a drilling unit to print metals and other materials (e.g., epoxies, solder masks, etc.) directly on a PCB substrate such as a glass-reinforced epoxy laminate material (e.g., FR4). The jet printing unit can also be used for sintering and/or ablating materials. Printed materials are cured by heat or by infrared (IR) or ultraviolet (UV) radiation. PCBs produced according to the present systems and methods may be single-sided or double-sided.

A method includes controlling an additive manufacturing system to fabricate a 3D structure using successive layers of material. The additive manufacturing system includes a build platform having a first region, second region, and overlapping third region between the first and second regions; and multiple sources configured to build (e.g., deposit, bond, melt, solidify) the successive layers of material in the regions of the build platform. Controlling the additive manufacturing system includes controlling the additive manufacturing system to build first, second, and third portions of the 3D structure within the regions of the build platform. Each portion of the 3D structure includes (i) one or more test features that are common to the portions of the 3D structure and (ii) a substrate onto or into which the one or more common test features are formed.

A three-dimensional printing system includes a motorized build platform, a material coating module, and a beam generation module. The beam generation module includes a laser beam formation unit, a scan module, and flat field focusing system. The laser beam formation unit includes a laser configured to output a laser beam. The scan module is configured to receive the laser beam and to scan the laser beam over a build plane that is above the motorized build platform. The flat field focusing system is configured to focus the laser beam across the laser beam and includes an input component and an output component. The input component is configured to receive the laser beam from the beam formation unit and to pass the laser beam to the scan module. The output component is configured to receive the laser beam from the scan module and pass the laser beam to the build plane.

An additive manufacturing system can include at least one laser source and a speckle reduction system that receives light from the at least one laser source. The speckle reduction system provides laser light to an optical homogenizer that increases uniformity of laser light and can provide the light to an area patterning system.

A method for manufacturing an additively manufactured article, the method comprising subjecting a powder material comprising a first powder containing a precipitation hardening stainless steel and a second powder containing titanium carbide to weaving irradiation with a laser beam to melt and solidify the powder material, thereby laminating at least one hardened clad layer on a base material. In the step for laminating the clad layer, the following requirements are satisfied: 20≤A≤35, 1.1≤B≤1.3, and (40% by mass)≤R2≤(65% by mass). In the formulae, A represents a laser heat input index, B represents a powder feeding rate index, and R2 represents a content ratio of the second powder in the powder material.

A method for manufacturing an additively manufactured article, the method comprising subjecting a powder material comprising a first powder containing a precipitation hardening stainless steel and a second powder containing titanium carbide to weaving irradiation with a laser beam to melt and solidify the powder material, thereby laminating at least one hardened clad layer on a base material. In the step for laminating the clad layer, the following requirements are satisfied: 20≤A≤35, 1.1≤B≤1.3, and (40% by mass)≤R2≤(65% by mass). In the formulae, A represents a laser heat input index, B represents a powder feeding rate index, and R2 represents a content ratio of the second powder in the powder material.

Articles prepared by additive manufacturing of preforms that are coated by electrodeposition of nanolaminate materials, and methods of their production are described.