A system and method for manufacturing three-dimensional structures is provided. The system includes plurality of printing stations and a robotic unit configured to interact with the plurality of printing stations, each of the plurality of printing stations being arranged to be accessible by the robotic unit. Each printing station includes a station controller for controlling at least one deposition control parameter. The system further includes a system controller configured to operate the robotic unit, and wherein the system controller is communicatively coupled to the plurality of printing stations for controlling at least an execution of printing tasks being performed on the plurality of printing stations. The station controllers are at least partially controllable by means of the system controller, wherein the system controller is configured to adjust at least one deposition control parameter of each printing station independent of deposition control parameters of other printing stations of the plurality of printing stations.

A build plate supported on a movable carriage of a 3D printing machine includes a plurality of clamping surfaces that are engageable by a mechanical clamping system that includes a plurality of clamp assemblies mounted on the movable carriage. Each of the clamp assemblies is associated with a corresponding clamping surface and includes a clamping arm configured to rotate and translate to selectively engage the corresponding clamping surface, a follower arm configured to rotate, and a conversion mechanism configured to convert rotation of the follower arm to rotation and translation of the clamping arm. An actuation mechanism includes an actuation face, corresponding to each follower arm. The actuation mechanism is arranged to simultaneously exert a force against the follower arm of each of the clamp assemblies to rotate the follower arm as the carriage moves from a working station to an unloading station of the 3D printing machine. The conversion mechanism then converts the rotation of the follower arm of each clamping assembly to rotation and translation of the respective clamping arm to selectively and simultaneously engage and disengage the clamping surfaces of the build plate.

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.

An unpacking device (4) for unpacking an additively manufactured three-dimensional object (2) from the unsolidified construction material (3) surrounding it after completion of an additive construction process, wherein the unpacking device (4) is formed as a robot (7) having at least three robot axes (A1-A6), especially an industrial robot, wherein at least one unpacking tool (10) is arranged or formed on a robot axis (A6), which is provided for unpacking an additively manufactured three-dimensional object (2) from the unsolidified construction material (3) surrounding it after completion of an additive construction process, or the unpacking device (4) comprises at least one such robot (7).

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.

Systems, methods, and computer-readable media for robotic joining of components, parts, and structures are disclosed. A method in accordance with an aspect of the present disclosure comprises determining a target first position and a target second position in a reference frame, controlling robotic arms to move a first part to the target first position and a second part to the target second position, measuring the parts at the target first and second positions to obtain a measured first and second positions, performing a first operation to determine differences between the measured positions and the target positions, and when the differences exceeds desired tolerances, controlling the robotic arms to move the parts to compensate for the differences, and controlling at least the first or second robotic arm to join the first and second parts after the first and second operations are concluded.

Systems, methods, and computer-readable media for robotic joining of components, parts, and structures are disclosed. A method in accordance with an aspect of the present disclosure comprises determining a target first position and a target second position in a reference frame, controlling robotic arms to move a first part to the target first position and a second part to the target second position, measuring the parts at the target first and second positions to obtain a measured first and second positions, performing a first operation to determine differences between the measured positions and the target positions, and when the differences exceeds desired tolerances, controlling the robotic arms to move the parts to compensate for the differences, and controlling at least the first or second robotic arm to join the first and second parts after the first and second operations are concluded.

A removal apparatus for aiding in the removal of an additive manufacturing build plate from a support structure is provided. The removal apparatus may include a plurality of printed geometries disposed proximate one or more fasteners securing or anchoring the build plate to the support structure. The printed geometries may be printed concurrently with the additive manufacturing article. The apparatus may further include one or more expansion bolts sized for installation between a pair of printed geometries positioned apart from one another. The expansion bolts may include a small lead screw, a large lead screw and a coupling nut. In operation, rotation of the coupling nut in a first direction lengthens the expansion bolt to push the printed geometry outward thereby reducing the distortion in the build plate so that the fastener between the build plate and the support structure may be removed.

A removal apparatus for aiding in the removal of an additive manufacturing build plate from a support structure is provided. The removal apparatus may include a plurality of printed geometries disposed proximate one or more fasteners securing or anchoring the build plate to the support structure. The printed geometries may be printed concurrently with the additive manufacturing article. The apparatus may further include one or more expansion bolts sized for installation between a pair of printed geometries positioned apart from one another. The expansion bolts may include a small lead screw, a large lead screw and a coupling nut. In operation, rotation of the coupling nut in a first direction lengthens the expansion bolt to push the printed geometry outward thereby reducing the distortion in the build plate so that the fastener between the build plate and the support structure may be removed.

Assemblies fabricated by additive manufacturing include an object and a base plate providing support to the object during the manufacturing process. The geometry of the base plate is defined to optimize space and material constraints. During sintering, the base plate is reduced in area in a manner complementing the reduction in the footprint of the object, preserving the fidelity of the finished object.