A 3D printing method providing an improved manufacturing process by providing a plurality of layers forming at least a part of the component, wherein the plurality of layers contains at least one first layer part and at least one second layer part, wherein the at least one first layer part and the at least one second layer part have been manufactured with different manufacturing speeds.

In an example, a method comprises receiving, at a processor, a digital model representing an object to be produced by additive manufacturing. The method may comprise receiving, at the processor, an indication that a first selected region of a surface of the object is to have a first coating applied after printing. The method may further comprise applying a first predefined surface roughness pattern to the first selected region of the surface of the digital model.

In an example, a method comprises receiving, at a processor, a digital model representing an object to be produced by additive manufacturing. The method may comprise receiving, at the processor, an indication that a first selected region of a surface of the object is to have a first coating applied after printing. The method may further comprise applying a first predefined surface roughness pattern to the first selected region of the surface of the digital model.

A geometry model is defined of a part targeted for a manufacturing operation that includes an additive process followed by a subtractive process. Potential build orientations of the geometry model used in the additive processes are defined, as are one or more removal tools of the subtractive process. For each of the potential build orientations, supports that are used by the additive process at the orientation are determined. One of the build orientations is selected that minimizes portions of one of the supports that are inaccessible via at least one of the removal tools.

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.

A spatter protection system for an additive manufacturing machine can include a sheet configured to be disposed over a build area of the additive manufacturing machine. The sheet can include an aperture configured to allow a spatter from the build area to eject through the aperture during energy application and to land on a back side of the sheet to prevent the spatter from landing on the build area. The system can include a motive system supporting the sheet and configured to move the sheet to locate the aperture over an energy application area.

A laser-solid-forming manufacturing device includes a laser emitter, a magnetic field generator, and a forming platform. The laser emitter emits a laser beam which acts on a feedstock to form a molten pool. The magnetic field generator includes a spiral copper coil, a first electrode and a second electrode. The spiral copper coil is formed by spirally winding a copper tube. The first and second electrodes are arranged at respective ends of the copper tube and are used for loading a voltage to generate a magnetic field in the spiral copper coil. At any time, the spiral copper coil sleeves an action point of the laser beam and the feedstock. A corresponding laser-solid-forming manufacturing method is also presented.

An additive manufacturing method includes: forming a powder bed by supplying a raw material powder; and irradiating the raw material powder that forms the powder bed with a light beam having an intensity distribution of a second or higher order mode or of a top hat shape.

Various embodiments include an acoustic-energy deposition and repair system that includes at least one Directed Acoustic Energy Deposition (DAED) tool configured to apply acoustic energy to feedstock material in at least one of three vibrational modes; and a drive system to move the DAED tool in at least one of three-coordinate positions. In various examples, the acoustic-energy deposition and repair system further includes at least one in-situ metrology tool mounted proximal to the DAED tool to measure a grain size of deposited material. Other methods, devices, apparatuses, and systems are disclosed.