Additive-manufacturing systems, surface-processing apparatuses, and methods of forming products using an additive-manufacturing head are provided. In one aspect, an additive-manufacturing system includes an additive-manufacturing head and a surface-processing device coupled to the additive-manufacturing head. In another aspect, a surface-processing apparatus for an additive-manufacturing head includes a housing configured to be coupled to the additive-manufacturing head and a surface-processing device coupled to the housing. In a further aspect, a method of forming a product using an additive-manufacturing head includes forming one or more layers of the product with the additive-manufacturing head and processing at least one of the one or more layers of the product with a surface-processing device coupled to the additive-manufacturing head.

A dissimilar material joined three-dimensional laminated and shaped object is shaped using a three-dimensional laminating and shaping apparatus. The three-dimensional laminating and shaping apparatus includes a material supplier that supplies materials of a three-dimensional laminated and shaped object to a shaping surface, an irradiator that irradiates the materials with a light beam, and a controller that controls the material supplier. The three-dimensional laminated and shaped object is a joined member obtained by joining dissimilar materials. The controller controls the material supplier to form a graded composition of the materials in a boundary region between the dissimilar materials of the three-dimensional laminated and shaped object.

A laser beam is irradiated onto material powder on a manufacturing table to solidify the material powder and form a solidified layer. The material powder is further deposited on the solidified layer and the laser beam is irradiated onto one part of the material powder to solidify the material powder. They are repeated to manufacture a manufactured object. An irradiation output value of the laser beam is determined based on measurement information regarding a deposition surface before depositing the material powder or regarding a surface state of the material powder after deposition that is acquired by a camera. Alternatively, the aforementioned irradiation output value is determined based on parity information regarding a number of solidified layers that were already solidified by irradiation of the energy beam, or determined in accordance with an irradiation output value used when solidifying a solidified layer solidified prior to deposition of the deposited material powder.

A calibration method serves for calibrating a manufacturing device for additively producing a three-dimensional object by applying layer by layer and selectively solidifying a building material. The manufacturing device comprises at least two scanning units, each of which is capable of directing a beam to different target points in the working plane, which are located within a scanning region assigned to the respective scanning unit, wherein the scanning regions region of the at least two scanning units overlap in an overlap area. At least a first of the at least two scanning units is assigned a first monitoring unit whose monitoring region extends to a target point of the first scanning unit and its proximity, wherein a change of a position of the monitoring region is carried out as a function of a change of a position of the target point.

A calibration method serves for calibrating a manufacturing device for additively producing a three-dimensional object by applying layer by layer and selectively solidifying a building material. The manufacturing device comprises at least two scanning units, each of which is capable of directing a beam to different target points in the working plane, which are located within a scanning region assigned to the respective scanning unit, wherein the scanning regions region of the at least two scanning units overlap in an overlap area. At least a first of the at least two scanning units is assigned a first monitoring unit whose monitoring region extends to a target point of the first scanning unit and its proximity, wherein a change of a position of the monitoring region is carried out as a function of a change of a position of the target point.

The present invention addresses the problem of providing: a method for manufacturing a three-dimensional modeled object, with which it is possible to fabricate a three-dimensional modeled object having high strength, using electron beam irradiation. In order to solve said problem, this method for manufacturing a three-dimensional modeled object comprises: a thin layer formation step in which a composition containing a radical polymerizable compound is applied to form a thin layer; and an electron beam irradiation step in which said thin layer is subjected to electron beam irradiation, and the radical polymerizable compound is cured to form a modeled object layer. The thin layer formation step and the electron beam irradiation step are repeated a number of times to layer the modeled object layer. The electron beam irradiation step is carried out in an atmosphere having an oxygen concentration from 50 ppm to less than 5,000 ppm.

The present invention addresses the problem of providing: a method for manufacturing a three-dimensional modeled object, with which it is possible to fabricate a three-dimensional modeled object having high strength, using electron beam irradiation. In order to solve said problem, this method for manufacturing a three-dimensional modeled object comprises: a thin layer formation step in which a composition containing a radical polymerizable compound is applied to form a thin layer; and an electron beam irradiation step in which said thin layer is subjected to electron beam irradiation, and the radical polymerizable compound is cured to form a modeled object layer. The thin layer formation step and the electron beam irradiation step are repeated a number of times to layer the modeled object layer. The electron beam irradiation step is carried out in an atmosphere having an oxygen concentration from 50 ppm to less than 5,000 ppm.

A method for forming a three-dimensional article through successive fusion of parts of a powder bed comprising: providing a model of the three dimensional article, applying a first powder layer on a work table, directing an energy beam over the work table causing the first powder layer to fuse in selected locations according to the model to form a first cross section of the three-dimensional article, applying a second powder layer on the work table, directing the energy beam over the work table causing the second powder layer to fuse in selected locations according to the model to form a second cross section of the three-dimensional article, wherein the second layer is bonded to the first layer, detecting a local thickness in at least two positions in at least the second powder layer, varying an energy beam parameter depending on the detected local thickness of the second powder layer.

A method for forming a three-dimensional article through successive fusion of parts of a powder bed comprising: providing a model of the three dimensional article, applying a first powder layer on a work table, directing an energy beam over the work table causing the first powder layer to fuse in selected locations according to the model to form a first cross section of the three-dimensional article, applying a second powder layer on the work table, directing the energy beam over the work table causing the second powder layer to fuse in selected locations according to the model to form a second cross section of the three-dimensional article, wherein the second layer is bonded to the first layer, detecting a local thickness in at least two positions in at least the second powder layer, varying an energy beam parameter depending on the detected local thickness of the second powder layer.

Systems and methods for simulating a melt pool characteristic for selective laser melting additive manufacturing. The system includes a selective laser melting apparatus and an electronic controller configured to obtain a surface geometry of a previous layer of a component being manufactured using the selective laser melting apparatus, simulate an addition of a powder layer having a desired powder layer thickness to the component based upon the surface geometry of the previous layer, determine a melt pool characteristic based upon geometric information of the simulated powder layer and the desired powder layer thickness, determine an adjustment to the simulated powder layer based upon the melt pool characteristic, and actuate the selective laser melting apparatus based upon the simulated powder layer and the determined adjustment.