A method for manufacturing a three-dimensional object by solidifying selected areas of consecutive powder layers is provided. At least one electron beam successively irradiates predetermined sections of each powder layer by moving an interaction region in which the electron beam interacts with the powder layer. Electromagnetic radiation from a radiation source is directed onto the powder layer to reduce local electrostatic charging in the interaction region. In this way, levitation and scattering of charged powder will be avoided.

The present disclosure relates to an apparatus for additively manufacturing a product in a layer-by-layer sequence, wherein the product is formed using powder particles deposited on an interface layer of a substrate. A laser generates first and second beam components. The second beam component has a higher power level and a shorter duration than the first beam component. A mask creates a 2D optical pattern in which only select portions of the second beam components can irradiate the powder particles. The first beam component heats the powder particles close to a melting point, where the particles experience surface tension forces relative to the interface layer. While the particles are heated, the second beam component further heats the particles and also melts the interface layer before the surface tension forces can act on and distort the particles, enabling the particles and the interface layer are able to bond together.

The present disclosure relates to an apparatus for additively manufacturing a product in a layer-by-layer sequence, wherein the product is formed using powder particles deposited on an interface layer of a substrate. A laser generates first and second beam components. The second beam component has a higher power level and a shorter duration than the first beam component. A mask creates a 2D optical pattern in which only select portions of the second beam components can irradiate the powder particles. The first beam component heats the powder particles close to a melting point, where the particles experience surface tension forces relative to the interface layer. While the particles are heated, the second beam component further heats the particles and also melts the interface layer before the surface tension forces can act on and distort the particles, enabling the particles and the interface layer are able to bond together.

A printing device (106) includes a laser source and a LCOS-SLM (Liquid Crystal on Silicon Spatial Light Modulator). The printing device generates a laser control signal and a LCOS-SLM control signal. The laser source (110) generates a plurality of incident laser beams based on the laser control signal. The LCOS-SLM (112) receives the plurality of incident laser beams, modulates the plurality of incident laser beams based on the LCOS-SLM control signal to generate a plurality of holographic wavefronts (214,216) from the modulated plurality of incident laser beams. Each holographic wavefront forms at least one corresponding focal point. The printing device cures a surface layer or sub-surface layer (406) of a target material (206) at interference points of focal points of the plurality of holographic wavefronts. The cured surface layer of the target material forms a three-dimensional printed content.

A printing device (106) includes a laser source and a LCOS-SLM (Liquid Crystal on Silicon Spatial Light Modulator). The printing device generates a laser control signal and a LCOS-SLM control signal. The laser source (110) generates a plurality of incident laser beams based on the laser control signal. The LCOS-SLM (112) receives the plurality of incident laser beams, modulates the plurality of incident laser beams based on the LCOS-SLM control signal to generate a plurality of holographic wavefronts (214,216) from the modulated plurality of incident laser beams. Each holographic wavefront forms at least one corresponding focal point. The printing device cures a surface layer or sub-surface layer (406) of a target material (206) at interference points of focal points of the plurality of holographic wavefronts. The cured surface layer of the target material forms a three-dimensional printed content.

An additive manufacturing system includes one or more light sources and one or more light valves that can be written with two-dimensional gray scale patterns that the light valves impose on beams from the one or more light sources to obtain one or more patterned beams. The one or more patterned beams are steered to each area of a plurality of areas on a layer of powder. The two-dimensional gray scale patterns are selected to achieve desired material properties at each pixel position of the patterned beam incident on the layer of powder. The light valves may modulate one or more of amplitude, phase, or coherence. The material properties may include one or more of Young's modulus, porosity, grain size, and crystalline microstructure.

Herein disclosed is a method of making a fuel cell including forming an anode, a cathode, and an electrolyte using an additive manufacturing machine. The electrolyte is between the anode and the cathode. Preferably, electrical current flow is perpendicular to the electrolyte in the lateral direction when the fuel cell is in use. Preferably, the method comprises making an interconnect, a barrier layer, and a catalyst layer using the additive manufacturing machine.

Herein disclosed is a method of making a fuel cell including forming an anode, a cathode, and an electrolyte using an additive manufacturing machine. The electrolyte is between the anode and the cathode. Preferably, electrical current flow is perpendicular to the electrolyte in the lateral direction when the fuel cell is in use. Preferably, the method comprises making an interconnect, a barrier layer, and a catalyst layer using the additive manufacturing machine.

Methods, systems, and apparatus, for hybrid additive manufacturing of parts. In one aspect, a method includes providing a workpiece and manufacturing multiple additive layers on a surface of the workpiece. Manufacturing each of the multiple additive layers includes forming one or more formed layers on a surface of the workpiece by depositing a quantity of powder material on a growth surface, the growth surface inclusive of at least one of a first surface of the workpiece and a second surface of a previously formed layer, and applying a first amount of energy to the quantity of powder material to fuse the particles of the powder material into a formed layer fused to the growth surface, where the formed layer includes a formed surface, and further applying a secondary process to a particular area of the formed surface of the one or more formed layers on the workpiece.

Methods, systems, and apparatus, for hybrid additive manufacturing of parts. In one aspect, a method includes providing a workpiece and manufacturing multiple additive layers on a surface of the workpiece. Manufacturing each of the multiple additive layers includes forming one or more formed layers on a surface of the workpiece by depositing a quantity of powder material on a growth surface, the growth surface inclusive of at least one of a first surface of the workpiece and a second surface of a previously formed layer, and applying a first amount of energy to the quantity of powder material to fuse the particles of the powder material into a formed layer fused to the growth surface, where the formed layer includes a formed surface, and further applying a secondary process to a particular area of the formed surface of the one or more formed layers on the workpiece.