An additive manufacturing system including a housing configured to contain a powder bed of material, and an array of laser emitters having a field of view. The array is configured to melt at least a portion of the powder bed within the field of view as the array translates relative to the powder bed. The system further includes a spatter collection device including a diffuser configured to discharge a stream of gas across the powder bed, and a collector configured to receive the stream of gas and contaminants entrained in the stream of gas. The collector is spaced from the diffuser such that a collection zone is defined therebetween, and the spatter collection device is configured to translate relative to the powder bed such that the collection zone overlaps with the field of view of the array.

An additive manufacturing system including a housing configured to contain a powder bed of material, and an array of laser emitters having a field of view. The array is configured to melt at least a portion of the powder bed within the field of view as the array translates relative to the powder bed. The system further includes a spatter collection device including a diffuser configured to discharge a stream of gas across the powder bed, and a collector configured to receive the stream of gas and contaminants entrained in the stream of gas. The collector is spaced from the diffuser such that a collection zone is defined therebetween, and the spatter collection device is configured to translate relative to the powder bed such that the collection zone overlaps with the field of view of the array.

A robot to manufacture a part by additive manufacturing using volume elements or voxels. The robot includes a base and a rotary arm having a plurality of effectors for additive manufacturing radially distributed on the arm. A guiding shaft to translationally move the rotary arm by rotation, in a direction parallel to its axis of rotation, and to translationally and rotationally guide the rotary arm relative to the base. A controller to control the action of the effectors for additive manufacturing as a function of the position of the rotary arm in space. A method for implementing the robot is provided.

Controlled manufacturing system suitable for controlling a method for manufacturing, repairing or resurfacing a part by deposition of material under concentrated energy, said controlled manufacturing system comprising: means for obtaining a three-dimensional digital model of the part; means for generating a manufacturing file for the part, based on the three-dimensional digital model of said part, to define manufacturing parameters of an additive manufacturing machine, said manufacturing parameters being associated with manufacturing instructions; means for generating a control file for the part to define control parameters of a control effector, said control parameters being associated with control instructions; analysis means for carrying out an analysis of the manufacturing file and the control file in order to determine if the manufacturing parameters and the control parameters can coexist during the simultaneous application of the manufacturing parameters to the additive manufacturing machine and the control parameters to the control effector; a control module comprising at least one communication channel for receiving and sending the manufacturing instructions to a polyarticulated manufacturing system suitable for supporting the additive manufacturing machine, and at least one communication channel for receiving and sending the control instructions to a polyarticulated control system suited to supporting the control effector, to manage simultaneously the additive manufacturing machine and the control effector.

An example apparatus to produce a three-dimensional object comprises a controller, a build area configured to receive a layer of particulate material, a printhead, and an ultraviolet light emitting diode energy source. The controller is to cause the printhead to deposit a liquid which absorbs ultraviolet radiation onto the layer of particulate material. The controller is further to cause the ultraviolet light emitting diode energy source to irradiate the liquid, after the liquid has been deposited onto the layer of particulate material, thereby to heat the liquid and cause a portion of the particulate material to solidify.

An example apparatus to produce a three-dimensional object comprises a controller, a build area configured to receive a layer of particulate material, a printhead, and an ultraviolet light emitting diode energy source. The controller is to cause the printhead to deposit a liquid which absorbs ultraviolet radiation onto the layer of particulate material. The controller is further to cause the ultraviolet light emitting diode energy source to irradiate the liquid, after the liquid has been deposited onto the layer of particulate material, thereby to heat the liquid and cause a portion of the particulate material to solidify.

An additive manufacturing system includes a laser array including a plurality of laser devices. Each laser device of the plurality of laser devices generates an energy beam for forming a melt pool in a powder bed. The additive manufacturing system further includes at least one optical element. The optical element receives at least one of the energy beams and induces a predetermined power diffusion in the at least one energy beam.

A selective laser solidification apparatus including; a powder bed onto which powder layers can be deposited, at least one laser module for generating a plurality of laser beams for solidifying the powder material deposited onto the powder bed, a laser scanner for individually steering each laser beam to solidify separate areas in each powder layer, and a processing unit. A scanning zone for each laser beam is defined by the locations on the powder bed to which the laser beam can be steered by the laser scanner. The laser scanner is arranged such that each scanning zone is less than the total area of powder bed and at least two of the scanning zones overlap. The processing unit is arranged for selecting, for at least one powder layers, which laser beam to use to scan an area of the powder layer located within a region wherein the seaming zones overlap.

A method of monitoring an additive manufacturing process in which one or more energy beams are used to selectively fuse a powder to form a workpiece, in the presence of one or more plumes generated by interaction of the one or more energy beams with the powder. The method includes using at least one sensor to generate at least one signal representative of a trajectory of one or more of the plumes.

A method for determining a set point for a thermal sensor. The method includes (a) distributing a layer of particulate material to provide a build bed surface; (b) depositing an amount of absorption modifier over a test region or a surrounding area; (c) heating the test region; (d) measuring a temperature value within the test region with the sensor; (e) distributing a new layer of material over the preceding layer; repeating (b) to (e) until the material of the test region starts to melt, wherein repeated step (b) deposits additional absorption modifier over the test region to absorb more energy from the heat source than the preceding layer; determining a set point for the thermal sensor from a characteristic in the evolution of the measured temperature value within the test region; and applying the set point to subsequent measurements of the thermal sensor.