An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved structure formation, part creation and manipulation, use of multiple additive manufacturing systems, and high throughput manufacturing methods suitable for automated or semi-automated factories are also disclosed.

A method of making a light weight housing for an internal component is provided. The method including the steps of: forming a first metallic foam core into a desired configuration; forming a second metallic foam core into a desired configuration; inserting an internal component into the first metallic foam core; placing the second metallic foam core adjacent to the first metallic core in order to secure the internal component between the first metallic foam core and the second metallic foam core; applying an external metallic shell to an exterior surface of the first metallic foam core and the second metallic foam core; and securing an inlet fitting and an outlet fitting to the housing, wherein a thermal management fluid path for the internal component into and out of the housing is provided by the inlet fitting and the outlet fitting.

A calculation part calculates a maximum temperature reached which is reached by the coolant or component of each part, in the case of machining in accordance with laser machining conditions that were inputted or set, based on the cooling capacity of a chiller, tank volume of the chiller, heat generation amount from the laser oscillator, heat capacity of a cooled part of the laser device, etc. which are recorded in a recording part, and the temperature of each part measured by temperature detection parts, etc. In the case that the maximum temperature reached would exceed the allowed maximum temperature, a warning is made prior to starting laser machining.

A method and apparatus for forming an object by additive layer manufacturing. The method comprises: a) applying, by a heat source (4), heat to a portion of a surface of a workpiece (1) sufficient to melt said portion; b) adding material to the melted portion and moving the heat source (4) relative to the workpiece (1) whereby progressively to form a layer of material (10) on the workpiece (1); c) cooling the formed layer (10) to bring at least part of the layer (10) to a state of crystallisation, there producing a modified workpiece; d) peening, using a plurality of independently controllable impact treatment devices (7), the modified work-piece so as to plastically deform the cooled at least part of the layer (10); and repeating steps a) to d) as required whereby to form the object.

An optical fiber cleaving apparatus that employs a microchip laser system for cleaving an optical fiber is disclosed. The microchip laser system is operably arranged relative to an optical system that receives an initial laser beam and forms a focused laser beam that includes a focus spot. The focus spot is directed to the outer surface of the optical fiber to create an optical damage zone that includes at least one micro-crack necessary for performing the cleaving operation. Methods of aligning the optical fiber to the focus spot and performing the cleaving operation using the cleaving apparatus are also disclosed.

A method and apparatus for direct writing of single crystal super alloys and metals. The method including heating a substrate to a predetermined temperature below its melting point; using a laser to form a melt pool on a surface of the substrate, wherein the substrate is positioned on a base plate, and wherein the laser and the base plate are movable relative to each other, the laser being used for direct metal deposition; introducing a superalloy powder to the melt pool; and controlling the temperature of the melt pool to maintain a predetermined thermal gradient on a solid and liquid interface of the melt pool so as to form a single crystal deposit on the substrate. The apparatus configured to generally achieve the aforementioned method.

A power control method for a laser system comprising laser diodes arranged in diode banks is provided. Each diode bank comprises at least one of the laser diodes and has a maximum power. The method comprises operating a first diode bank of the diode banks to output a first power; and concurrently operating other of the diode banks to output other powers, at least one of the other powers being different than the first power.

Example systems may include an energy source, a material delivery device, and a computing device. The computing device, based on a target height of a layer deposited on a component by directed energy deposition, may control an energy source directed at a component and may control a material delivery device. Controlling the energy source may include advancing an energy beam along a first path to form an advancing molten pool on the component. Controlling the material delivery device may include delivering a material to the advancing molten pool. The material may combine with the advancing molten pool to form a first raised track having an actual height. The layer may include the first raised track. A deposited region of the component may include the layer. The actual height may affect a resultant microstructure within the deposited region.

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. The two-dimensional energy patterning system may be used to control the rate of cooling experienced by each successive additive layer. Accordingly, the system may be used to heat treat the various additive layers.

A reclamation system for a metal powder, such as a reactive metal powder, is disclosed. The system may include a container; and a pressure source in fluid communication with the container for creating a selected pressure within the container, the container including: an inlet to a lower portion of the tank that is configured to hold a liquid, and an outlet. A controller controls the pressure source to control the pressure applied within the container between: a vacuum state creating a flow of air entrained metal powder to enter the inlet for forming a reclaimed metal powder by removing the metal powder from the air by immersion in the liquid, and an evaporation state that causes evaporation of the liquid to a gas that exits through the outlet. A condenser condenses the gas to a condensed liquid.