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.

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.

A method of additive manufacturing includes a) providing a component geometry with a hole and, b) selectively irradiating a powder bed with an energy beam according to the geometry in a layerwise manner, wherein in layers of the component including the hole, the respective regions which define the hole are irradiated with the energy beam such that a supporting structure is generated in the hole having a lower rigidity than a structure of the component. The supporting structure is used for counteracting stress or distortion during the additive buildup. A computer program product and apparatus correspond to the method.

A method of additive manufacturing includes a) providing a component geometry with a hole and, b) selectively irradiating a powder bed with an energy beam according to the geometry in a layerwise manner, wherein in layers of the component including the hole, the respective regions which define the hole are irradiated with the energy beam such that a supporting structure is generated in the hole having a lower rigidity than a structure of the component. The supporting structure is used for counteracting stress or distortion during the additive buildup. A computer program product and apparatus correspond to the method.

A method of additive manufacturing includes a) providing a component geometry with a hole and, b) selectively irradiating a powder bed with an energy beam according to the geometry in a layerwise manner, wherein in layers of the component including the hole, the respective regions which define the hole are irradiated with the energy beam such that a supporting structure is generated in the hole having a lower rigidity than a structure of the component. The supporting structure is used for counteracting stress or distortion during the additive buildup. A computer program product and apparatus correspond to the method.

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.

A method of manufacturing a TiAl alloy impeller includes a blank preparation step in which a blank of the TiAl alloy impeller is prepared, wherein the blank has a shaft portion and a plurality of blades, and a thickness of an outer edge of each of the blades of the blank is set so as to be larger than a thickness of an outer edge of a blade of the TiAl alloy impeller, and an additional work step in which an additional work is performed on each of the blades of the blank. In the additional work step, the additional work is performed on a first surface of a portion that includes at least the outer edge of each of the blades or the first surface and a second surface of the portion thereof.

A method operates a three-dimensional (3D) metal object manufacturing system to compensate for errors that occur during object formation. In the method, thermal image data and dimensional image data of a metal object being formed by the 3D metal object manufacturing system is generated prior to completion of the metal object. Thermal conditions are identified from these data and compared to predetermined ranges corresponding to the identified thermal conditions to identify one or more errors. For identified errors outside a corresponding predetermined difference range, the method performs an error compensation technique. The error compensation includes modification of a surface data model, modification of machine-ready instructions, or operation of a subtractive device.

A method operates a three-dimensional (3D) metal object manufacturing system to compensate for errors that occur during object formation. In the method, thermal image data and dimensional image data of a metal object being formed by the 3D metal object manufacturing system is generated prior to completion of the metal object. Thermal conditions are identified from these data and compared to predetermined ranges corresponding to the identified thermal conditions to identify one or more errors. For identified errors outside a corresponding predetermined difference range, the method performs an error compensation technique. The error compensation includes modification of a surface data model, modification of machine-ready instructions, or operation of a subtractive device.

A system, is disclosed having a polymer-based additive manufacturing subsystem, a metallic-based additive manufacturing subsystem, an exchanger to place at least one of the polymer-based additive manufacturing subsystem and the metallic-based additive manufacturing subsystem into a position to provide a manufacturing process, a build area where a part is created with the polymer-based additive manufacturing subsystem and the metallic-based additive manufacturing subsystem, and an environmental control unit to collect debris produced during operation of the polymer-based additive manufacturing subsystem and the metallic-based additive manufacturing subsystem. Another system and method are also disclosed.