A method of additive manufacture is disclosed. The method may include creating, by a 3D printer contained within an enclosure, a part having a weight greater than or equal to 2,000 kilograms. A gas management system may maintain gaseous oxygen within the enclosure atmospheric level. In some embodiments, a wheeled vehicle may transport the part from inside the enclosure, through an airlock, as the airlock operates to buffer between a gaseous environment within the enclosure and a gaseous environment outside the enclosure, and to a location exterior to both the enclosure and the airlock.

A three-dimensional printing system includes a motorized build platform, a material coating module, and a beam generation module. The beam generation module is configured to selectively fuse or harden material over a build plane. The build plane defines a centroid. The beam generation module includes a laser beam formation unit, a scan module, and flat field focusing component (FFFC). The scan module has a scanner optical axis that intersects the build plane at a location that is offset from the centroid. The FFFC is configured to focus the laser beam across the build plane. The FFFC includes a plurality of lenses at least one of which has an optical asymmetry relative to the scanner optical axis. The asymmetry includes one or more of a lateral offset with an offset distance D and an angular offset with an offset angle α.

In one example, a three-dimensional (3D) printing method is disclosed. The 3D printing method may partition an entirety of a powder bed into a plurality of portions including a first portion and a second portion. The method may position an energy source over first portion of the powder bed, apply irradiation to the first portion until an irradiation dose is reached, and turn off irradiation to the first portion of the powder bed. The 3D printing method may rearrange the energy source and the powder bed to position the energy source over a second portion of the powder bed, apply irradiation to the second portion until the irradiation dose is reached, and turn off irradiation to the second portion of the powder bed.

One of the objects of the present application is to provide a technique capable of preventing the generation of excessive metallic vapor during fabrication according to an AM technique. Further, one of the objects of the present application is to provide a technique for reducing machining processing after the fabrication as much as possible or eliminating the necessity thereof. According to one aspect, an AM apparatus configured to manufacture a fabrication object is provided. This AM apparatus includes a first DED nozzle configured to fabricate a contour of a fabrication target and a second DED nozzle configured to fabricate an inner portion of the contour.

One of the objects of the present application is to provide a technique capable of preventing the generation of excessive metallic vapor during fabrication according to an AM technique. Further, one of the objects of the present application is to provide a technique for reducing machining processing after the fabrication as much as possible or eliminating the necessity thereof. According to one aspect, an AM apparatus configured to manufacture a fabrication object is provided. This AM apparatus includes a first DED nozzle configured to fabricate a contour of a fabrication target and a second DED nozzle configured to fabricate an inner portion of the contour.

The disclosure provides methods and systems for measuring a base element of a construction cylinder arrangement in machines for the additive manufacture of 3D objects using a high-energy beam, wherein a measurement pattern is produced from laser light that illuminates the base element, and sites of incidence of the laser light are monitored and evaluated with a camera to produce measuring data about the base element, e.g., position information, orientation information, and/or information about the shape of the surface of the base element. The measurement patterns are produced by deflecting measuring laser beams by an optical scanner system towards the base element, and the camera is arranged laterally offset from the deflected laser beams. The new methods and systems enable measuring base elements in a simple and flexible manner, and require only a small amount of space in the processing chamber.

The disclosure provides methods and systems for measuring a base element of a construction cylinder arrangement in machines for the additive manufacture of 3D objects using a high-energy beam, wherein a measurement pattern is produced from laser light that illuminates the base element, and sites of incidence of the laser light are monitored and evaluated with a camera to produce measuring data about the base element, e.g., position information, orientation information, and/or information about the shape of the surface of the base element. The measurement patterns are produced by deflecting measuring laser beams by an optical scanner system towards the base element, and the camera is arranged laterally offset from the deflected laser beams. The new methods and systems enable measuring base elements in a simple and flexible manner, and require only a small amount of space in the processing chamber.

Methods for direct writing of single crystal super alloys and metals are provided. The method can include: heating a substrate positioned on a base plate to a predetermined temperature using a first heater; using a laser to form a melt pool on a surface of the substrate; introducing a superalloy powder to the melt pool; measuring the temperature of the melt pool; receiving the temperature measured at a controller; and using an auxiliary heat source in communication with the controller to adjust the temperature of the melt pool. The predetermined temperature is below the substrate's melting point. The laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition. An apparatus is also generally provided for direct writing of single crystal super alloys and metals.

Apparatus (1) for manufacturing a three-dimensional object from a powder, the apparatus (1) comprising: a build bed (201) having a build area (190), wherein successive layers of said three-dimensional object are formed in the build bed (201); a powder distribution sled (300) operable to distribute a layer of powder within the build area (190), the powder distribution sled (300) being driveable in a first direction along a first axis, across the build area (190), and driveable in a second direction, opposite to the first direction, along the first axis; and a print sled (350) operable to deposit a pattern of fluid onto the layer of powder within the build area (190) to define the cross section of said object in said layer, the print sled (350) being driveable in the first direction along a second axis across the build area, and driveable in the second direction along the second axis; wherein the first axis is parallel to, or coaxial with, the second axis; wherein the print sled (350) comprises one or more droplet deposition heads (370) for depositing the fluid, a first radiation source assembly (L1), and a second radiation source assembly (L2); wherein the powder distribution sled (300) comprises a powder distribution device (320) for distributing the powder, a third radiation source assembly (L3) and a fourth radiation source assembly (L4); and wherein each of the first, second, third and fourth radiation source assemblies is operable to both preheat and sinter powder within the build area (190). A method of manufacturing a three-dimensional object from a powder using such apparatus is also provided.

Apparatus (1) for manufacturing a three-dimensional object from a powder, the apparatus (1) comprising: a build bed (201) having a build area (190), wherein successive layers of said three-dimensional object are formed in the build bed (201); a powder distribution sled (300) operable to distribute a layer of powder within the build area (190), the powder distribution sled (300) being driveable in a first direction along a first axis, across the build area (190), and driveable in a second direction, opposite to the first direction, along the first axis; and a print sled (350) operable to deposit a pattern of fluid onto the layer of powder within the build area (190) to define the cross section of said object in said layer, the print sled (350) being driveable in the first direction along a second axis across the build area, and driveable in the second direction along the second axis; wherein the first axis is parallel to, or coaxial with, the second axis; wherein the print sled (350) comprises one or more droplet deposition heads (370) for depositing the fluid, a first radiation source assembly (L1), and a second radiation source assembly (L2); wherein the powder distribution sled (300) comprises a powder distribution device (320) for distributing the powder, a third radiation source assembly (L3) and a fourth radiation source assembly (L4); and wherein each of the first, second, third and fourth radiation source assemblies is operable to both preheat and sinter powder within the build area (190). A method of manufacturing a three-dimensional object from a powder using such apparatus is also provided.