Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to unique powder feedstocks such as Tantalum, Yttrium Stabilized Zirconia, Aluminum, water atomized alloys, Rhenium, Tungsten, and Molybdenum. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.

Present embodiments include an additive manufacturing tool configured to receive a metallic anchoring material and to supply a plurality of droplets to a part, wherein each droplet of the plurality of droplets comprises the metallic anchoring material and a mechanical oscillation system configured to mechanically oscillate a structural component of the additive manufacturing tool toward and away from the part, wherein the mechanical oscillation system comprises a motor, a cam coupled to the motor, and a piston coupled to the cam, wherein the piston is fixedly attached to the structural component.

The invention relates to a system and to a method for coating workpieces using a coating device, which is designed to apply a metal coating to a surface of the workpiece. According to the invention, it is provided that a plurality of coating devices, which are designed as identical coating modules, are provided and are arranged in a module group, that an input measuring station is assigned to the module group, by means of which station a surface of the face of the workpiece to be coated can be detected, that a conveying apparatus is provided, by means of which a workpiece can be supplied to one of the coating modules from the input measuring station, and that an output measuring station is assigned to the module group, by means of which station a surface of the coated face of the workpiece can be detected.

The invention relates to a coating device and to a method for metal-coating of workpieces, comprising a housing, which surrounds a working space, a retaining apparatus for retaining at least one workpiece in the working space, at least one deposition apparatus comprising a deposition nozzle for applying a metal powder to the workpiece surface to be coated, and a laser for locally melting the metal powder on the workpiece surface to form a coating, and at least one movement apparatus, by means of which the at least one deposition apparatus can be moved relative to the workpiece surface during the coating. Particularly efficient coating is made possible by at least two deposition apparatuses being arranged in the working space in the housing, which apparatuses are designed to simultaneously apply and melt metal powder.

The invention relates to a coating device and to a method for metal-coating of workpieces, comprising a housing, which surrounds a working space, a retaining apparatus for retaining at least one workpiece in the working space, at least one deposition apparatus comprising a deposition nozzle for applying a metal powder to a workpiece surface to be coated, and a laser for locally melting the metal powder on the workpiece surface to form a coating, at least one movement apparatus, by means of which the at least one deposition apparatus can be moved relative to the workpiece surface during the coating, at least one air supply and at least one air discharge. According to the invention, it is provided that the air supply is arranged in an upper region of the working space above the workpiece and the air discharge is arranged in a lower region of the working space below the workpiece. In addition, a additional suction apparatus is provided with at least one suction opening, which is arranged close to the workpiece.

The invention relates to a method and to a system for metal-coating at least one surface of a workpiece, in which before coating, a surface structure with peaks and troughs in the surface to be coated is detected by means of a measuring apparatus, the coating is carried out by means of at least one deposition apparatus, which is moved relative to the surface and applies coating material in the process, and the deposition apparatus is controlled by a control apparatus on the basis of the detected surface structure, wherein more material is applied in the region of troughs and less material is applied in the region of peaks.

A method and apparatus for applying a bone attachment coating to a prosthetic component, the bone attachment coating being formed from a plurality of particles applied to a surface of the prosthetic component. The method comprising: locally exciting the particles so as to increase the kinetic and/or thermal energy of the particles; and applying pressure to the particles by virtue of a press arranged so as to press the particles against the surface of the prosthetic component at an interface between the press and the prosthetic component. The kinetic and/or thermal energy of the particles causes localised heating of the component such that the particles may be embedded into the surface of the prosthetic component.

A nozzle for the additive manufacturing by spraying and fusion of powder along a hollow tapered stream. The nozzle includes an outer cone, an inner cone, and an intermediate cone. The powder is sprayed into the tapered annular space between the inner surface of the outer cone and the outer surface of the intermediate cone. The outer cone includes two portions detachably assembled along the axis of the cone by an assembler.

A system to adjust and measure an additive manufacturing device via the CLAD method. The system includes a powder spray nozzle and a laser beam passing through the center of the nozzle, and a light source providing a light beam substantially perpendicular a lighting plane. The light source includes a support to position the light source with respect to a material surface. A profile camera is installed such that its optical axis is substantially parallel to the lighting plane. A projector to project a view seen by the center of the nozzle on an optical path and an optical axis of a centering camera is placed on the optical path. A low-power laser shot perforates a target. An acquisition and processing unit collects the images from the two cameras.

A device for metering one or more powder(s) (A, B) to produce a flow (23) of powder(s) and of a carrier gas at a given volume flow rate, comprises: at least a first source (25) suitable for supplying a first flow (27) comprising a first powder (A) and a first carrier gas (G1) substantially at the given volume flow rate, a source (33) of a carrier gas suitable for supplying an adjustment carrier gas flow (35) substantially at the given volume flow rate, an outlet junction (49) for emitting said flow of powder(s) and of carrier gas, a first proportional valve (59), an adjustment proportional valve (75), and a control system (21) suitable for controlling at least the first proportional valve and the adjustment proportional valve so that the flow of powder(s) and of carrier gas has a volume flow rate substantially equal to the given volume flow rate.