A method of calibrating a laser of an additive manufacturing system involves processing a test pattern with the laser while varying one or more of laser power and/or scan speed. Thermal energy emitted from the resulting meltpool is measured while processing the test pattern. The power of the laser is calculated using a relationship between volumetric energy density and the thermal emissions, and the laser power is adjusted based on the calculated laser power. An additive manufacturing system for performing such a method may include a laser, a thermal sensor configured to measure meltpool thermal emissions, a processor configured to calculate a laser power based on the measured meltpool thermal emissions of the test pattern, and a controller configured to adjust the laser power based on the calculated laser power.

A method of calibrating a laser of an additive manufacturing system involves processing a test pattern with the laser while varying one or more of laser power and/or scan speed. Thermal energy emitted from the resulting meltpool is measured while processing the test pattern. The power of the laser is calculated using a relationship between volumetric energy density and the thermal emissions, and the laser power is adjusted based on the calculated laser power. An additive manufacturing system for performing such a method may include a laser, a thermal sensor configured to measure meltpool thermal emissions, a processor configured to calculate a laser power based on the measured meltpool thermal emissions of the test pattern, and a controller configured to adjust the laser power based on the calculated laser power.

A tooling system, such as an additive manufacturing system, includes a tool displacement mechanism mounted on a fixed structure and carrying a system tool such as a printhead. The tool displacement mechanism displaces the system tool along a curvilinear closed path about a system axis and located within a working plane intersecting the system axis. A bed, connecting to the fixed structure, is substantially positioned within the working plane, locally adjacent the closed path and along at least a portion of the closed path.

A tooling system, such as an additive manufacturing system, includes a tool displacement mechanism mounted on a fixed structure and carrying a system tool such as a printhead. The tool displacement mechanism displaces the system tool along a curvilinear closed path about a system axis and located within a working plane intersecting the system axis. A bed, connecting to the fixed structure, is substantially positioned within the working plane, locally adjacent the closed path and along at least a portion of the closed path.

A system for manufacturing assembly units. The system includes a component platform that is movably situated in a conveying direction, at least one layering unit for applying a layer, and at least one irradiation unit, which is situated downstream from the layering unit in the conveying direction of the component platform for selectively irradiating the layer for generatively assembling the layer.

A system for manufacturing assembly units. The system includes a component platform that is movably situated in a conveying direction, at least one layering unit for applying a layer, and at least one irradiation unit, which is situated downstream from the layering unit in the conveying direction of the component platform for selectively irradiating the layer for generatively assembling the layer.

An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a support, and a print head configured to discharge a material and being operatively connected to and moveable by the support in a normal travel direction during material discharge. The print head may include a module located at a trailing side of the discharging material relative to the normal travel direction and being configured to compact the material and expose the material to a cure energy at a tool center point.

An additive manufacturing system is disclosed for use in fabricating a structure. The additive manufacturing system may include a support, and a print head configured to discharge a material and being operatively connected to and moveable by the support in a normal travel direction during material discharge. The print head may include a module located at a trailing side of the discharging material relative to the normal travel direction and being configured to compact the material and expose the material to a cure energy at a tool center point.

An additive manufacturing system having multiple components includes a high power laser to form a laser beam. A beam dump with a fluid chamber having at least one laser transparent window into which the laser beam is directed is provided. A heat exchanger is connected to the fluid chamber, with the heat exchanger acting to provide useful energy to at least one of the multiple components of the additive manufacturing system. An absorbing fluid can be circulated through both the fluid chamber and the heat exchanger.

An additive manufacturing system having multiple components includes a high power laser to form a laser beam. A beam dump with a fluid chamber having at least one laser transparent window into which the laser beam is directed is provided. A heat exchanger is connected to the fluid chamber, with the heat exchanger acting to provide useful energy to at least one of the multiple components of the additive manufacturing system. An absorbing fluid can be circulated through both the fluid chamber and the heat exchanger.