A method and an apparatus for collecting powder samples in real-time in powder bed fusion additive manufacturing may involves an ingester system for in-process collection and characterizations of powder samples. The collection may be performed periodically and uses the results of characterizations for adjustments in the powder bed fusion process. The ingester system of the present disclosure is capable of packaging powder samples collected in real-time into storage containers serving a multitude purposes of audit, process adjustments or actions.

Some variations provide an aluminum alloy feedstock for additive manufacturing, the aluminum alloy feedstock comprising from 79.8 wt % to 88.3 wt % aluminum; from 1.1 wt % to 2.1 wt % copper; from 3.0 wt % to 4.6 wt % magnesium; from 7.1 wt % to 9.0 wt % zinc; and from 0.5 wt % to 2.8 wt % zirconium as a grain-refiner element. The aluminum alloy feedstock may be in the form of an ingot powder. In some variations, the aluminum alloy feedstock comprises from 81.3 wt % to about 87.8 wt % aluminum; from 1.2 wt % to 2.0 wt % copper; from 3.2 wt % to 4.4 wt % magnesium; from 7.3 wt % to 8.7 wt % zinc; and from 0.5 wt % to 2.8 wt % zirconium.

Disclosed are systems, devices, and methods for additive manufacturing that allow for control of composition and/or porosity of components being manufactured. More particularly, in exemplary embodiments, a secondary material can be used in conjunction with a primary feedstock material in a spatially controlled manner during an additive manufacturing process to control a composition of materials and/or porosity of a manufactured component. Systems, devices, and methods for additive manufacturing are also disclosed that allow for control of a pressure of an atmosphere surrounding a build surface during an additive manufacturing process. More particularly, a pressure of an atmosphere surrounding a build surface can be raised to a pressure greater than standard atmospheric pressure. Various features of the exemplary embodiments of the systems, devices, and methods disclosed can be used together to further control for composition and/or porosity and quality of a manufactured part.

Disclosed are systems, devices, and methods for additive manufacturing that allow for control of composition and/or porosity of components being manufactured. More particularly, in exemplary embodiments, a secondary material can be used in conjunction with a primary feedstock material in a spatially controlled manner during an additive manufacturing process to control a composition of materials and/or porosity of a manufactured component. Systems, devices, and methods for additive manufacturing are also disclosed that allow for control of a pressure of an atmosphere surrounding a build surface during an additive manufacturing process. More particularly, a pressure of an atmosphere surrounding a build surface can be raised to a pressure greater than standard atmospheric pressure. Various features of the exemplary embodiments of the systems, devices, and methods disclosed can be used together to further control for composition and/or porosity and quality of a manufactured part.

An apparatus for additively manufacturing three-dimensional objects formed of successive layerwise consolidation of layers of a build material which can be consolidated by an energy beam. The apparatus may include a determination device confirmed to determine at least one parameter of the energy beam for a specific build material, wherein the determination device comprises at least one determination base body arrangeable or arranged in a beam guiding plane, in particular a build plane; and a tempering unit confirmed to temper the determination base body. Determination devices, along with methods, are also provided for determining at least one parameter of an energy beam of an apparatus for additively manufacturing three-dimensional objects.

The present disclosure provides three-dimensional (3D) printing processes, apparatuses, software, and systems for the production of at least one desired 3D object. The 3D printer system (e.g., comprising a processing chamber, build module, or an unpacking station) described herein may retain a desired (e.g., inert) atmosphere around the material bed and/or 3D object at multiple 3D printing stages. The 3D printer described herein comprises one or more build modules that may have a controller separate from the controller of the processing chamber. The 3D printer described herein comprises a platform that may be automatically constructed. The invention(s) described herein may allow the 3D printing process to occur for a long time without operator intervention and/or down time.

A method of manufacturing a part including selective laser melting of a powder including a steel alloy containing, by weight, 16% to 19% chromium and 12.2% to 13.5% nickel, wherein the powder is substantially non-magnetic.

In one example, a print head drop detector (202) is described. The print head drop detector (202) comprises a sampling volume and a fan (208) to cause an airflow though the sampling volume (206). Detection apparatus to detect the presence of non-gaseous material within the sampling volume is also provided.

A method for forming at least one three-dimensional article through successive fusion of parts of a powder bed, which parts correspond to successive cross sections of the three-dimensional article, the method comprising the steps of: providing a model of the at least one three-dimensional article; applying a first powder layer on a work table; directing a first energy beam from a first energy beam source over the work table causing the first powder layer to fuse in first selected locations according to corresponding models to form a first cross section of the three-dimensional article, where the first energy beam is fusing at least a first region of a first cross section with parallel scan lines in a first direction; varying a distance between two adjacent scan lines, which are used for fusing the powder layer, as a function of a mean length of the two adjacent scan lines.

A method and apparatus for manufacturing an equiaxed crystal aluminum alloy cast ingot by using additive manufacturing and rapid solidification techniques are provided. The apparatus comprises: a metal heating mechanism and a negative pressure cooling mechanism. The metal heating mechanism is located above the negative pressure cooling mechanism and is connected thereto by a nozzle. The negative pressure cooling mechanism comprises a vacuum chamber having an air inlet hole and an air outlet hole, and a three-dimensional moving ingot mechanism disposed inside the vacuum chamber. The three-dimensional moving ingot mechanism comprises a moving ingot and a two-dimensional moving platform vertically connected to the moving ingot. A water cooling mechanism is disposed outside the moving ingot, and the moving ingot is driven by a precision motor to precisely move up and down.