2326results about "Additive manufacturing with solids" patented technology

The invention discloses a topological optimization multi-level liquid cooling structure and a manufacturing method, and relates to the technical field of heat dissipation and thermal management, the topological optimization multi-level liquid cooling structure comprises a liquid cooling plate, and a multi-level flow channel network composed of a first macroscopic main flow channel, a second macroscopic main flow channel and micro flow channels is arranged in a cavity of the liquid cooling plate; a liquid inlet and a liquid outlet are formed in the symmetrical positions of the two ends of the upper surface of the liquid cooling plate in the length direction; the liquid inlet is communicated with the first macroscopic main runner; the liquid outlet is communicated with the second macroscopic main runner; the liquid inlet is used for allowing cooling liquid jet flow to enter the multi-level flow channel network; the first macroscopic main flow channel and the second macroscopic main flow channel are communicated with the micro-channel and are lower than the micro-channel; a to-be-cooled heat source abuts against the upper surface of the liquid cooling plate through the heat conduction slide glass. And the horizontal position of the micro-channel in the cavity corresponds to a heat source to be cooled. The heat dissipation requirement under the working condition of high heat flux can be met, the cooling efficiency is high, and the temperature equalization performance is excellent.

Monitoring and control system and method for additive manufacturing an in-situ macro-field thermography that uses an IR camera or near-IR camera to prioritize the data captured from an entire print layer, processes data streams layer-by-layer, and provides thermal history of previously printed layers as feedback to the control system. The system leverages one or more different mathematical thermophysical-based (MTB) models to compute a thermally related specification in order to optimize the printing sequence of islands or stripes layer-by-layer. The thermal feedback from the thermography system calibrates or updates the thermal model layer-by-layer. The system and / or method may provide real-time optimization of scanning topology in chessboard and stripe printing strategies. The method may be implemented by one or more computer programs controlling one or more computer controllers of an additive manufacturing system, such as a 3D printer implementing a metal powder bed fusion additive manufacturing process.

Described herein are systems and methods for detecting flaws during an additive manufacturing (AM) process. A method can include accessing, by a computer, simulation results of a computer-modelled part representing a physical part to be formed using the AM process. The simulation includes a thermal history model for the computer-modelled part. During run-time formation of the physical part, the method includes receiving, from sensor devices, real-time sensor data of temperature values for nodes within regions of the physical part as each region is formed. The method also includes determining, for each region as the region is formed in the physical part, a deviation between the real-time sensor data of temperature values for nodes within the region and temperature values of the thermal history model for the computer-modelled part, and identifying flaws in the physical part based on determining that the deviation satisfies criteria indicating a flaw.

A process of manufacturing a golf club component includes spreading a thin layer of metal powder over a build plane defined over a build platform and bonding, using a laser, portions of the thin layer of metal powder. The spreading and bonding are repeated until the golf club component is formed. The golf club component comprises a lattice structure positioned within an internal cavity of the golf club component and the lattice structure is interrupted by a solid portion that extends along a bottom side of the golf club component from a toe region of the golf club component to a location between the toe region and a heel region of the golf club component.

A process of manufacturing a golf club head that includes the steps of generating, via an additive manufacturing process, a printed part that includes the steps of printing a material, layer by layer, along a build plane and creating at least one blow through aperture that allows fluid to flow through an internal cavity of the printed part. The build plane is offset from a ground plane by between about 5 degrees and about 160 degrees. The ground plane is defined as a horizontal plane parallel to the ground when the golf club head is at address. The process also includes the steps of excavating the printed part by forcing excess material out from within the internal cavity using the at least one blow through aperture and removing excess material formed at one or more material deposits disposed along the printed part golf club head.

Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, an interface layer is formed between the object and support in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering.

An additive manufacturing system includes an energy delivery device configured to deliver energy to a build surface of a component to form a melt pool in the build surface of the component, a powder delivery device configured to direct a powder stream toward the melt pool, at least one sensor configured to generate sensor data representative of at least one process characteristic, and a computing device. The computing device is configured to receive the sensor data from the at least one sensor, determine, based on the sensor data and a predictive model data, at least one powder control parameter configured to achieve a predetermined powder feed rate of the powder stream, and control, based on the at least one powder control parameter, the energy delivery device and the powder delivery device to deposit a plurality of layers.

Method for forming a three-dimensional object by successively melting applied powder, the method comprising the following steps: a. Providing at least one powder container containing powder to be used for forming the three-dimensional object, b. Providing a predetermined amount of powder on a support structure, c. Directing an energy beam over the support structure, causing at least one section of the powder to sinter and at least one section of the powder to bond with the support structure, d. Directing an energy beam over the support structure, causing the powder to melt in selected areas according to a model to form a first section of the three-dimensional object, characterized in that the method further comprises the following steps: e. Rotating the support structure around an axis of rotation to create the three-dimensional object, which is built layer upon layer in a radial direction with reference to the axis of rotation.

The invention discloses a multi-material localized printing device and method based on a selective laser melting technology. The device comprises a laser printing head, a printer shell, a groove type lifting printing table, a powder storage mechanism, a powder feeding execution mechanism, a powder scraping mechanism and a regional powder covering mechanism. The groove type lifting printing table is arranged on the printer shell; the laser printing head is located above the groove type lifting printing table. The powder storage mechanism is located on the side of the groove type lifting printing table. The powder feeding executing mechanism is located below the powder storage mechanism. The powder scraping mechanism is located behind the groove type lifting printing table. The regional powder covering mechanism is located in front of the groove type lifting printing table. Various materials can be selected during one-time forming machining, material conversion in the forming machining process is simpler and faster, multi-material combination can be achieved in different areas of the same-layer structure in the horizontal direction, and multi-material combination can be achieved in different areas or the same area of the different-layer structure in the vertical direction; and the forming requirements of multi-material integrated parts are effectively met.

The invention discloses a wide-temperature-range polyether-ether-ketone-based self-lubricating composite material part for LPBF and a forming method of the wide-temperature-range polyether-ether-ketone-based self-lubricating composite material part, and belongs to the technical field of additive manufacturing. The forming method comprises the steps that polyether-ether-ketone powder and molybdenum disulfide powder are pretreated according to different modes; after pretreatment, the two kinds of powder are mechanically mixed according to a specific proportion, and wide-temperature-range polyether-ether-ketone-based self-lubricating composite material powder is obtained; and carrying out printing forming on the polyether-ether-ketone-based self-lubricating composite material powder by adopting a laser powder bed melting (LPBF) specific process to obtain a wide-temperature-range polyether-ether-ketone-based self-lubricating composite material part. Molybdenum disulfide is adopted to enhance the friction and wear performance of polyether-ether-ketone in a wide temperature range, the printability of powder is improved through special pretreatment, and a high-performance wide-temperature-range polyether-ether-ketone-based self-lubricating composite material part suitable for high and low temperature extreme environments is obtained through forming by adopting specific LPBF processes such as multidirectional cross scanning and the like.

A process of manufacturing a golf club head. The process comprises the step of spreading a thin layer of metal powder over a build plane defined over a build platform. The process also comprises the step of selectively depositing droplets of a binding agent over the thin layer of metal powder in order to bond the metal powder. The process further comprises the step of sintering a green part body to form the golf club head. The golf club head comprises a lattice structure positioned within an internal cavity of the golf club head. The build plane is offset from a ground plane by between about 5 degrees and about 160 degrees. The ground plane defined as a horizontal plane parallel to the ground when the golf club head is at address. The build plane is not a face angle of the golf club head.

An aerospace panel includes a first skin, a second skin spaced apart from the first skin, and a first truss structure connecting the first skin to the second skin. The first truss structure includes a plurality of truss members. Each truss member is integral with the first skin and the second skin, such that the first skin, the second skin, and the first truss structure collectively form a single monolithic joint-free structure. At least one of the skins also includes at least one lattice region that includes a lattice grid and an array of openings.

The invention discloses a light energy focusing vacuum 3D printing fusion forming device and method. The device comprises a vacuum cabin system used for providing a vacuum environment, an optical energy focusing system used for forming fixed high-temperature light spots in the vacuum environment through external optical energy, a powder laying and printing system used for laying powder layer by layer in the vacuum environment and conducting 3D printing through the high-temperature light spots, and a control system used for achieving automatic operation of the whole device. The vacuum cabin system comprises a cabin body, a vacuum pump, a cabin body upper cabin door, a lens mounting seat, a vacuum detection piece and a vacuum valve; the light energy focusing system comprises a condensing lens, a light source and a light shield; the powder laying and printing system is arranged in the cabin body and comprises a powder pool mechanism, a powder laying mechanism and a planar motion mechanism. According to the device, combination of high-energy beam 3D printing fusion forming and vacuum 3D printing is achieved, and the vacuum light energy sintering 3D printing process can be completed under the ground condition.

A method is disclosed for providing a component. During this method, braze powder is additively deposited with a substrate. The braze powder is sintered together during the depositing of the braze powder to provide the substrate with sintered braze material. The sintered braze material is heated to melt the sintered braze material and to diffusion bond the sintered braze material to the substrate to provide braze filler material. A first object is scanned using structured light to provide first object scan data. The first object includes the substrate and the braze filler material diffusion bonded to the substrate. The first object scan data is compared to first object reference data to provide machining data. The first object is machined using the machining data to provide a second object.

The invention relates to the technical field of powder bed heating, and discloses a powder bed heating method of additive manufacturing equipment, the powder bed heating method of the additive manufacturing equipment is realized based on a powder bed heating unit of the additive manufacturing equipment, and the powder bed heating unit of the additive manufacturing equipment comprises a handle bottom plate for providing a basic mounting platform for the whole device; a push-pull type local heating design is adopted for the device, a traditional overall preheating mode is replaced, energy consumption and the equipment use cost are greatly reduced, meanwhile, heat loss is reduced, the heating efficiency is improved, and through cooperation of double positioning and a real-time temperature control system, the energy-saving and environment-friendly effects are achieved. The accurate position of the heating unit is guaranteed through mechanical limiting and sensor detection, high-precision temperature control adjustment is matched, it is guaranteed that the temperature of the powder bed is stabilized within the preset range, part defects caused by temperature fluctuation are avoided, and the forming quality and the mechanical property stability of workpieces are remarkably improved.

A method of operating a laser additive manufacturing machine includes manufacturing at least one first fluid-flow coupon, that includes a plate defining a plurality of holes, at a corresponding beam offset value of the laser additive manufacturing machine. The method further includes disposing the at least one first fluid-flow coupon in a testing rig, directing a fluid flow towards the at least one first fluid-flow coupon, measuring a fluid flow rate through the at least one first fluid-flow coupon, determining a calibration curve by correlating a beam offset of the laser additive manufacturing machine with a flow parameter based on the fluid flow rate through the at least one first fluid-flow coupon and the corresponding beam offset value, determining a target beam offset value corresponding to a target flow value of the flow parameter, and calibrating and operating the laser additive manufacturing machine using the target beam offset value.

A system includes a powder reuse system (PRS) executable via a processor and configured to receive one or more inputs for a build of a first machine component in a sintering system. The PRS is further configured to retrieve a model configured to model a reuse of a sintering powder, and to derive a time during which a surplus unsintered powder left after printing the machine component via the sintering system using the sintering powder may be reused to build a second machine component by applying the one or more inputs to the model.

A 3D printing system build material supply unit includes a tray with an opening that defines a spreading plane in which a recoater spreads build material. A double vane is rotatably mounted inside the tray with the rotation axis extending along the tray below the spreading plane and with each vane having convex front and rear sides. A controller controls rotation of the double vane such as to supply a dose of build material with the front side of one vane to the spreading plane by rotating the double vane into a trimming position in which the front side of the one vane approaches the spreading plane such that the dose of build material is enclosed between the front side of the vane and the spreading plane. Excess build material to be trimmed by the recoater accumulates on the other vane rear side and is lowered into the tray.

The utility model discloses a laser sintering 3D printing device for continuous processing, which relates to the technical field of selective laser sintering processing, and solves the problems that continuous powder supply and non-stop automatic processing cannot be formed, the powder cleaning inside the equipment is complicated, the workpiece is inconvenient to take out after printing, and the loading needs to be done manually, which may cause dust pollution. The utility model realizes non-stop automatic processing and continuous printing, and the printing and powder collection processes are both in a closed environment without causing pollution. The powder inside the equipment is easy to clean and collect, and the collected powder can be reused, which reduces loss and waste. The upper parts of the left upper powder supply module and the right upper powder supply module are both provided with powder supply ports and gas extraction ports, and the gas extraction ports are evacuated to perform negative pressure vacuum, and the material powder is drawn into the left upper powder supply module and the right upper powder supply module, thereby realizing automatic loading without manual loading, and realizing automatic discharging, which is convenient for taking out the workpiece.

A method for additive manufacturing, wherein an additive-manufacturing head (12) is provided, configured both for directing one or more jets of powders, in particular metal powders, onto a region of a working surface (110), and for directing simultaneously a laser beam onto such a region, to form a laser-beam focusing spot (LS) on the region, and wherein, during direction of the powder jets and of the laser beam, the additive-manufacturing head (12) is simultaneously translated in a direction transverse to the direction of the laser beam so as to give rise to a trace (MRP) obtained by melting of the powders as a result of the power transmitted to the powders by the focusing spot (LS). During movement of the additive-manufacturing head (12) in the transverse direction, a dynamic movement is imparted on the laser beam emitted by the head (12), the movement being configured in such a way as to obtain a width of the trace (MRP) that is independent of the size of the focusing spot (LS) of the laser beam (L) and is equivalent to the one that would be produced by an apparent spot having a width substantially corresponding to the width of the trace (MPP), and in such a way that the distribution of the power transmitted by the laser beam to the trace (MPP) varies along the direction of the width of the trace (MPP).

A method for the additive manufacturing of a thin, angled component structure. The method includes adjusting irradiation parameters from a first layer to a following layer in the construction direction, wherein a line energy and / or a scanning speed is changed for the irradiation of the following layer in order to change a melt pool width of an irradiation path for the following layer, and shifting an irradiation path for the following layer from the first layer in such a way that an angled edge is formed on a side of the component structure being formed opposite a movement direction. A correspondingly manufactured component and a computer program product are provided.

Systems and methods for in-process monitoring of additive manufacturing are described. The systems and methods utilize a predictive model trained to identify anomalies within a component which have a likelihood of resulting in a manufacturing defect. The predictive model is trained at least by identifying one or more manufacturing anomalies relating to the additive manufacturing of a test coupon, identifying one or more manufacturing defects within the resulting test coupon, and performing registration between the one or more manufacturing anomalies and the one or more manufacturing defects. The predictive model is used to monitor additive manufacturing processes and optionally inform the updating of process parameters.

Additive manufacturing systems and associated methods are disclosed herein. In some embodiments, the additive manufacturing includes a build chamber that has a central portion and a peripheral portion, a support platform positioned in the central portion and a recoater arm movable in a lateral direction over the support platform. While moving, the recoater arm spreads a powder over the central portion during a build. The additive manufacturing system also includes a powder recycling system positioned to redirect excess amounts of the powder during the build. For example, the powder recycling system can include a powder receptacle positioned the second region of the peripheral portion and a recycling element positioned at least partially in the powder receptacle. The recycling element is movable between a first position abutting an overflow space in the powder receptacle to receive the excess powder and a second position closer to the central portion.

An intelligent method for optimizing scan sequences in additive manufacturing processes is disclosed. The method integrates thermomechanical modeling to optimally select scan paths that minimize part deformation, residual stresses or other thermomechanical metrics of printed parts. Unlike prior approaches that rely solely on thermal models, the disclosed method incorporates both thermal indicators, e.g., derived from simulated or sensor-based temperature distributions, and mechanical indicators, e.g., those capturing deformation or stress via finite element analysis. These indicators are combined into an objective function, which is minimized using an optimization strategy executable within the interlayer time of the additive manufacturing process. The method is compatible with laser powder bed fusion (LPBF), electron beam powder bed fusion (EB-PBF), directed energy deposition (DED). The method is broadly applicable to any process involving localized heating and material deposition.

The application describes a machine tool adapted and arranged to carry out removal and addition of material on a work piece located in a work station, the machine having a first head arranged to remove material from the work piece and at least a second head arranged to process the work piece, each of the first and second heads being arranged to be moveable in at least two axes and preferably in 3, 4 or 5 axes and wherein the machine is arranged to control an environment of the work station. The work station is at least partially sealable. The machine has a clean side and a dirty side. Novel processing heads particularly adapted for use in the new machine tool are disclosed. These may also be retrofitted to CNC machines. The novel heads include heads adapted to carry out two processes simultaneously. Heads adapted to carry out heat and pressure treatment are also disclosed. Use of the processing heads to carry out analysis in manufacturing steps is disclosed as is the provision and use of heads that can carry out analysis as well as processing.

The invention relates to a powder bed fusion additive manufacturing system (1) comprising a build chamber (2) extending along a vertical axis (Z) and a removable container (10) which can be inserted into the build chamber (2) in a manufacturing configuration and removed from the build chamber (2) in a powder removal configuration, the removable container (10) comprises a side wall (20) extending along a vertical axis (Z) and a bottom wall (30) movable within the side wall (20) along the vertical axis (Z), the bottom wall (30) comprising a perforated first wall (31) having a first aperture (33), the first aperture (33) being closed in a manufacturing configuration and opened in a depowdering configuration.

An automated de-powdering system comprises a sleeve alignable with at least a portion of a build chamber and at least one actuator actuatable with respect to a build plate to move at least a portion of an additive manufacturing build out of the build chamber and into the sleeve. At least one support assembly is couplable to the sleeve and includes at least one support member insertable through the sleeve and into the additive manufacturing build. At least one agitation mechanism is couplable to at least one of the at least one support assembly or the sleeve and is actuatable to at least partially convey the powder build material away from at least one object of the additive manufacturing build. The support member is positioned to support the object in an absence of the powder build material around the object.

The present disclosure relates to a fabrication and evaluation process for testing new metallic alloy chemistries and compositions for laser powder bed fusion (L-PBF). The new methodology is efficient and effective for new compositions with a minimal investment of generating large quantities of powder feedstock for required in conventional AM processing. The method allows for subsurface melting of the new alloy composition by varying the depth of penetration by a control of the input power level, power deposition rate, and rastering scan strategy. Post-mortem analysis of the subsurface microstructure permits an analysis of the durability and suitability of the new metallic alloy for this manufacturing mode. The method utilizes available infrastructure, technology, and characterization techniques.

An apparatus for 3D printing an object by photo-curing or selective laser sintering with a hybrid lighting system at a constant wavelength and variable power and speed, wherein said apparatus includes:—a first light source and related optical devices of conditioning the light beam, for the emission and processing of a first light beam for photo-curing or sintering said object, wherein said first light beam has a predetermined wavelength and a linear polarization oriented according to a certain angle;—a second light source and related optical devices of conditioning the light beam, for the emission and processing of a second light beam for photo-curing or sintering said object, wherein said second light beam has a wavelength equal to that of said first light beam and a linear polarization oriented according to an angle orthogonal to that of said first light beam.

A golf club head includes a body formed by an additive manufacturing process. The body defines a toe region, a heel region, and a medial region positioned between the toe region and the heel region. A front face extends across the toe region, medial region, and the heel region and is formed of a sintered material. The body further includes a topline along a top side and a sole along a bottom side, each extending in a heel-toe direction. A plurality of grooves are disposed on the front face. The golf club head defines an internal cavity at least partially enclosed by the front face and the body. The internal cavity extends between the topline and the sole. A plurality of voids are defined by a rear surface of the front face.