Part Manipulation Using Printed Manipulation Points

A manipulator device such as a robot arm that is capable of increasing manufacturing throughput for additively manufactured parts, and allows for the manipulation of parts that would be difficult or impossible for a human to move is described. The manipulator can grasp various permanent or temporary additively manufactured manipulation points on a part to enable repositioning or maneuvering of the part.

Chamber Systems For Additive Manufacturing

A method of additive manufacture is disclosed. The method may include creating, by a 3D printer contained within an enclosure, a part having a weight greater than or equal to 2,000 kilograms. A gas management system may maintain gaseous oxygen within the enclosure atmospheric level. In some embodiments, a wheeled vehicle may transport the part from inside the enclosure, through an airlock, as the airlock operates to buffer between a gaseous environment within the enclosure and a gaseous environment outside the enclosure, and to a location exterior to both the enclosure and the airlock. 1. A method of additive manufacture , the method comprising:creating, by a first machine contained within a first enclosure, a first part via a first process comprising additive manufacture using a patterned energy beam, wherein the first part has a weight greater than or equal to 2,000 kilograms;maintaining, by a first gas management system during the creating, gaseous oxygen within the first enclosure below atmospheric levels;transporting the first part from inside the first enclosure, through an airlock as the airlock operates to buffer between a gaseous environment within the first enclosure and a gaseous environment outside the first enclosure, and to a location exterior to both the first enclosure and the airlock; andcontinuously supporting the weight of the first part during the transporting.2. The method of claim 1 , further comprising the step of transporting and continuously supporting the first part by using a wheeled vehicle.3. The method of claim 2 , wherein the second process comprises removal of unamalgamated granular material claim 2 , heat treatment claim 2 , peening claim 2 , cutting claim 2 , or painting.4. The method of claim 3 , wherein the location is within a second enclosure.5. The method of claim 4 , further comprising maintaining claim 4 , by a second gas management system during the performing claim 4 , gaseous oxygen within the second enclosure at or below ...

Variable Print Chamber Walls For Powder Bed Fusion Additive Manufacturing

Additive manufacturing can involve dispensing a powdered material to form a layer of a powder bed on a support surface of a build platform. A portion of the layer of the powder bed may be selectively melted or fused to form one or more temporary walls out of the fused portion of the layer of the powder bed to contain another portion of the layer of the powder bed on the build platform 1. A method of additively manufacturing temporary walls , comprising:dispensing a powdered material to form a first layer of a powder bed on a support surface of a build platform;directing a patterned energy beam toward the powder bed; andselectively fusing a portion of the first layer of the powder bed to form one or more first walls out of the fused portion of the first layer of the powder bed such that the one or more first walls contain another portion of the first layer of the powder bed on the build platform.2. The method of claim 1 , wherein the one or more first walls comprise multiple walls surrounding an area interior of the build platform to create a region devoid of the powdered material.3. The method of claim 1 , further comprising:dispensing the powdered material to form a second layer of the powder bed on the first layer of the powder bed; andselectively fusing a portion of the second layer of the powder bed to form one or more second walls out of the fused portion of the second layer of the powder bed such that the one or more second walls contain another portion of the second layer of the powder bed.4. The method of claim 3 , wherein the one or more first walls comprise multiple first walls surrounding the another portion of the first layer of the powder bed over a first area of the build platform claim 3 , wherein the one or more second walls comprise multiple second walls surrounding the another portion of the second layer of the powder bed over a second area of the first layer of the powder bed claim 3 , and wherein the second area is smaller than the first area.5. ...

Auxiliary light source associated with an industrial application

Systems and techniques for providing an auxiliary light source associated with an industrial application are presented. A luminescent label is attached to an optical assembly via a pressure sensitive adhesive. The luminescent label comprises at least a fluorophore layer configured to transform light received from a light source into output light that is projected the optical assembly.

Integration of optical area monitoring with industrial machine control

An industrial safety system is provided that integrates optical safety monitoring with machine control. The safety system includes an imaging sensor device supporting pixel array processing functions that allow time-of-flight (TOF) analysis to be performed on selected portions of the pixel array, while two-dimensional imaging analysis is performed on the remaining portions of the array, reducing processing load and response time relative to performing TOF analysis for all pixels of the array. The portion of the pixel array designated for TOF analysis can be pre-defined through configuration of the imaging sensor device, or can be dynamically selected based on object detection and classification by the two-dimensional imaging analysis. The imaging sensor device can also implement a number of safety and redundancy functions to achieve a high degree of safety integrity.

RECYCLING POWDERED MATERIAL FOR ADDITIVE MANUFACTURING

A method and an apparatus for collecting a powdered material after a print job in powder bed fusion additive manufacturing may involve a build platform supporting a powder bed capable of tilting, inverting, and shaking to separate the powder bed substantially from the build platform in a hopper. The powdered material may be collected in a hopper for reuse in later print jobs. The powder collecting process may be automated to increase efficiency of powder bed fusion additive manufacturing. 1. A method , comprising:dispensing, by a powder dispensing assembly, a plurality of layers of a powdered material onto a build platform to form a powder bed;separating the powder bed substantially from the build platform by moving the build platform; andcollecting a substantial portion of the powdered material from the powder bed in a hopper in response to moving the build platform.2. The method of claim 1 , wherein the separating of the powder bed substantially from the build platform comprises performing at least one of;shaking the build platform;inverting the build platform; andsweeping the build platform.3. The method of claim 1 , wherein the separating of the powder bed substantially from the build platform comprises dislodging lingering powders of the powdered material on the build platform by vacuuming or gas-jetting.4. The method of claim 1 , wherein the step of collecting of the substantial portion of the powdered material of the powder bed in the hopper further comprises collecting the substantial portion of the powdered material of the powder bed in a hopper having one or more sloped walls to facilitate gravitational movement of the powdered material claim 1 , and wherein the hopper is located below the build platform.5. The method of claim 1 , wherein step of collecting of the substantial portion of the powdered material of the powder bed in the hopper comprises removing from the powder bed one or more integral objects formed by bonding of the powdered material.6. The ...

Additive Manufacturing System And Method

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved optical systems supporting beam combining, beam steering, and both patterned and unpatterned beam recycling and re-use are described. 1. A beam combining system for additive manufacturing , comprising:a first laser to emit a light beam at a first wavelength;a second laser to emit a light beam at a second wavelength different from the first wavelength;beam shaping optics that form a single beam, the beam shaping optics including at least one wavelength filter to pass light of the first wavelength and reflect light of the second wavelength in a common beam; anda light patterning unit to receive the common beam and form a two-dimensional patterned beam.2. The beam combining system of claim 1 , wherein the beam shaping optics further comprise transmissive optics.3. The beam combining system of claim 1 , wherein the beam shaping optics further comprise at least one of reflective and diffractive optics.4. The beam combining system of claim 1 , wherein the beam shaping optics further comprise more than three lasers claim 1 , and combine at least three wavelengths of light.5. An additive manufacturing system claim 1 , comprising:a high energy photon source to produce a beam;a reflective patterning unit to receive the beam and reflect a two-dimensional patterned beam; andan image relay to receive the two-dimensional patterned beam and focus it as a two-dimensional image on a powder bed.6. The additive manufacturing system of claim 5 , wherein the reflective patterning unit is optically addressed.7. The additive manufacturing system of claim 5 , wherein the high energy photon source further comprises multiple semiconductor lasers.8. The additive manufacturing system of claim 5 , wherein the reflective light patterning unit further comprises a highly transmissive layer claim 5 , a twisted nematic (TN) liquid crystal layer claim 5 , and a ...

POLARIZATION COMBINING SYSTEM IN ADDITIVE MANUFACTURING

A method and an apparatus pertaining to polarization combining in additive manufacturing may involve emitting two or more beams of light with a first intensity. Each of the two or more beams of light may be polarized and may have a majority polarization state and a minority polarization state. A respective polarization pattern may be applied on the majority polarization state of each of the two or more beams of light. The two or more beams of light may be combined to provide a single beam of light. 1. A method , comprising:emitting two or more beams of light with a first intensity, each of the two or more beams of light being polarized and having a majority polarization state and a minority polarization state;applying a respective polarization pattern on the majority polarization state of each of the two or more beams of light; andcombining the two or more beams of light to provide a single beam of light with a second intensity greater than the first intensity.2. The method of claim 1 , wherein the majority polarization state and the minority polarization state of the two or more beams of light are respectively patterned by a mask or a light rejection device claim 1 , and wherein the two or more beams of light are combined because of the different polarization states.3. The method of claim 1 , wherein light not in a majority polarization state is rejected before applying the respective majority polarization pattern.4. The method of claim 1 , wherein the applying of the respective polarization pattern on the majority polarization state of each of the two or more beams of light comprises applying claim 1 , by a respective one of two or more optically addressed light valves or two or more liquid crystal display devices claim 1 , the respective polarization pattern on the majority polarization state of each of the two or more beams of light.5. A method claim 1 , comprising:emitting one or more beams of light, each of the one or more beams of light being polarized; ...

CHAMBER SYSTEMS FOR ADDITIVE MANUFACTURING

An apparatus and a method for powder bed fusion additive manufacturing involve a multiple-chamber design achieving a high efficiency and throughput. The multiple-chamber design features concurrent printing of one or more print jobs inside one or more build chambers, side removals of printed objects from build chambers allowing quick exchanges of powdered materials, and capabilities of elevated process temperature controls of build chambers and post processing heat treatments of printed objects. The multiple-chamber design also includes a height-adjustable optical assembly in combination with a fixed build platform method suitable for large and heavy printed objects. 1. An apparatus , comprising:a print head comprising an energy source capable of providing one or more two-dimensional patterned incident beams of sufficient energy to process a plurality of powdered materials;a plurality of build chambers, each of the build chambers configured to at least partially surround a plurality of build platforms able to hold a powder bed formed by a powdered material; anda plurality of optical-mechanical assemblies arranged to receive and direct the one or more incident beams into the build chambers respectively.2. The apparatus of claim 1 , wherein the build platform is height adjustable.3. The apparatus of claim 1 , wherein at least one build chamber is configured to accommodate side removal of the build platform.4. The apparatus of claim 1 , wherein at least one the plurality of build chambers further comprises a thermal regulation system including at least one of a plurality of heating sources and a plurality of cooling components embedded in the build platforms and one or more walls forming the build chambers.5. The apparatus of claim 4 , wherein the build chambers further comprise a plurality of temperature sensors embedded in the build platforms and the one or more walls.6. The apparatus of claim 4 , wherein the build chambers further comprise an insulating or low ...

Enclosed Additive Manufacturing System

A method of additive manufacture is disclosed. The method may include restricting, by an enclosure, an exchange of gaseous matter between an interior of the enclosure and an exterior of the enclosure. The method may further include running multiple machines within the enclosure. Each of the machines may execute its own process of additive manufacture. While the machines are running, a gas management system may maintain gaseous oxygen within the enclosure at or below a limiting oxygen concentration for the interior. 1. A method of additive manufacture , the method comprising:restricting, by an enclosure, an exchange of gaseous matter between an interior of the enclosure and an exterior of the enclosure;identifying a plurality of machines located within the enclosure;executing, by each machine of the plurality of machines, an independent process of additive manufacture comprising directing a patterned energy beam at a powder bed; andmaintaining, by a gas management system during the executing, gaseous oxygen within the enclosure below atmospheric level.2. The method of claim 1 , wherein the enclosure comprises an airlock interfacing between the interior and the exterior.3. The method of claim 2 , further comprising removing from the enclosure through the airlock a first part manufactured by a first machine of the plurality of machines in a first process of additive manufacture.4. The method of claim 3 , further comprising removing from the enclosure through the airlock a second part manufactured by a second machine of the plurality of machines a second process of additive manufacture claim 3 , the second processing being independent of the first process.5. The method of claim 4 , further comprising assisting claim 4 , by a human claim 4 , in removing unamalgamated granular material from around the first part;6. The method of claim 5 , wherein the assisting occurs within the enclosure;7. The method of claim 6 , further comprising wearing claim 6 , by the human during ...

Additive Manufacturing System And Method

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved chamber designs, multiple chambers, powder handling and re-use systems, and powder characterization methods are disclosed. 1. An apparatus , comprising:a print head comprising an energy source capable of providing one or more incident beams of sufficient energy to process a plurality of powdered materials and an energy patterning unit to provide two-dimensional patterned energy beams;a plurality of build chambers, each of the build chambers configured to at least partially surround a plurality of build platforms able to hold a powder bed formed by a powdered material; anda plurality of optical-mechanical assemblies arranged to receive and direct the one or more incident two-dimensional patterned energy beams into the build chambers respectively.2. The apparatus of claim 1 , wherein the build platform is at least one of height adjustable or fixed height.3. The apparatus of claim 1 , wherein at least one build chamber is configured to accommodate side removal of the build platform.4. The apparatus of claim 1 , wherein at least one the plurality of build chambers further comprises a thermal regulation system embedded in at least one of the build platforms and walls forming the build chambers.5. A method claim 1 , comprising:dispensing a powdered material to form a first layer of a powder bed on a support surface of a build platform;directing a two-dimensional patterned energy beam toward the powder bed; andselectively fusing a portion of the first layer of the powder bed to form one or more first walls out of the fused portion of the first layer of the powder bed such that the one or more first walls contain another portion of the first layer of the powder bed on the build platform.6. The method of claim 5 , wherein the one or more first walls comprise multiple walls surrounding an area interior of the build platform to create a region ...

LIGHT RECYCLING FOR ADDITIVE MANUFACTURING OPTIMIZATION

A method and an apparatus pertaining to recycling and reuse of unwanted light in additive manufacturing can multiplex multiple beams of light including at least one or more beams of light from one or more light sources. The multiple beams of light may be reshaped and blended to provide a first beam of light. A spatial polarization pattern may be applied on the first beam of light to provide a second beam of light. Polarization states of the second beam of light may be split to reflect a third beam of light, which may be reshaped into a fourth beam of light. The fourth beam of light may be introduced as one of the multiple beams of light to result in a fifth beam of light.

Dynamic Optical Assembly For Laser-Based Additive Manufacturing

A method and an apparatus of a powder bed fusion additive manufacturing system that enables a quick change in the optical beam delivery size and intensity across locations of a print surface for different powdered materials while ensuring high availability of the system. A dynamic optical assembly containing a set of lens assemblies of different magnification ratios and a mechanical assembly may change the magnification ratios as needed. The dynamic optical assembly may include a transitional and rotational position control of the optics to minimize variations of the optical beam sizes across the print surface. 1. An apparatus , comprising:a plurality of lens assemblies comprising swappable portions configured to provide a plurality of magnification ratios that proportionally increase or decrease a size of an image of an incident light; anda mechanical assembly capable of selecting one of the lens assemblies to provide one of the magnification ratios to convert a first image of the incident light to a second image of the incident light according to the one of the magnification ratios.2. The apparatus of claim 1 , wherein the lens assemblies comprise a plurality of first sets of optical lenses and a plurality of second sets of optical lenses respectively claim 1 , and wherein the second sets of optical lenses are swappable among the lens assemblies.3. The apparatus of claim 2 , wherein each lens assembly of the lens assemblies is associated with a magnification ratio and comprises a respective set of the first sets of optical lenses and a respective set of the second sets of optical lenses claim 2 , and wherein the respective set of the first sets of optical lenses and the respective set of the second sets of the optical lens in each lens assembly of the lens assemblies are aligned in an optical axis of the respective lens assembly to allow the incident light to pass through.4. The apparatus of claim 2 , wherein the mechanical assembly is operable to perform a ...

Waveform reconstruction in a time-of-flight sensor

A time-of-flight (TOF) sensor device is provided that is capable of accurately recovering waveforms of reflected light pulses incident on the sensor's photo-receiver array using a low sampling rate. A number of samples for a received light pulse incident on a given photo-receiver are obtained by emitting a light pulse to the viewing field, integrating the electrical output generated by the photo receiver over an integration period, and adding the integral values for respective integration cycles to yield an accumulation value. This process is repeated for multiple accumulation cycles; however, for each consecutive accumulation cycle the start of the integration period is delayed relative the start time of the integration period for the previous cycle by a delay period. Sampled values for the waveform are obtained by determining the difference values between consecutive accumulation values for the respective accumulation cycles.

Additive Manufacturing System And Method

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved structure formation, part creation and manipulation, use of multiple additive manufacturing systems, and high throughput manufacturing methods suitable for automated or semi-automated factories are also disclosed. 1. A manufacturing method , comprising the steps of:providing a powdered material;providing an energy source that can produce an energy beam;directing the energy beam from the energy source toward an energy beam patterning unit to form a two-dimensional patterned energy beam;directing the two-dimensional patterned energy beam against the powder material to form a part having a manipulation point; andmoving the part using a manipulator device to engage the manipulation point.2. The method of claim 1 , wherein the manipulator device further comprises a robot arm.3. The method of claim 1 , further comprising the step of removing the manipulation point.4. The method of claim 1 , further comprising the step of reorienting the part using a manipulation device before adding more powdered material.5. The method of claim 1 , further comprising the step of moving the part using the manipulation device to maneuver the part to another processing area.6. A part comprising:a printed structure formed from at least one of a metal, ceramic, plastic, glass metallic hybrid, ceramic hybrid, plastic hybrid, or glass hybrid material and substantially formed using only an additive manufacturing system including a two-dimensional patterned energy beam;wherein the printed structure has one or more manipulation points capable of being engaged by a manipulator device.7. The part of claim 6 , wherein the manipulation point is a structure projecting from the part.8. The part of claim 6 , wherein the manipulation point is a temporary structure projecting from the part that is removable with a directed energy beam.9. The part of claim 6 , wherein the ...

Multi-Functional Ingester System For Additive Manufacturing

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. 1. A method comprising the steps of:collecting a plurality of powder samples of a powdered material in real-time during a print job;performing a set of characterizations on the powder samples; anddetermining whether to modify a set of printing parameters employed during the print job or abort the print job according to a result of the set of characterizations.2. The method of claim 1 , wherein the collecting of the powder samples of the powdered material in real-time comprises collecting the powder samples of the powdered material periodically at a predetermined interval claim 1 , randomly claim 1 , or at one or more predetermined stages during claim 1 , before claim 1 , or after the print job.3. The method of claim 1 , further comprising the step of aborting the print job when an unlicensed powder is used.4. The method of claim 1 , wherein the set of printing parameters comprises one or more of:a temperature of the powder material;a intensity of an energy source incident on the powder material;a duration of the energy source incident on the powder material;a pulse shape of energy source incident on the powder material modulated over time and position on the bed;a thickness of a layer the powder material being dispensed; anda rate of dispensing a layer of the powdered material.5. The method of claim 1 , wherein the determining of whether to modify the set of printing parameters employed during the print job or abort the ...

Optical area monitoring with spot matrix illumination

An imaging sensor device is configured to illuminate a viewing field using an array of focused light spots spaced across the viewing field rather than uniformly illuminating the viewing field, thereby reducing the amount of illumination energy required to produce a given intensity of light reflected from the spots. In some embodiments, the imaging sensor device can project an array of focused light spots at two different intensities or brightness levels, such that high intensity and low intensity light spots are interlaced across the viewing field. This ensures that both relatively dark and relatively bright or reflective objects can be reliably detected within the viewing field. The intensities of the light spots can be modulated based on measured conditions of the viewing field, including but not limited to the measured ambient light or a determined dynamic range of reflectivity of objects within the viewing field.

Long And High Resolution Structures Formed By Additive Manufacturing Techniques

A method of additive manufacture suitable for large and high resolution structures is disclosed. The method may include sequentially advancing each portion of a continuous part in the longitudinal direction from a first zone to a second zone. In the first zone, selected granules of a granular material may be amalgamated. In the second zone, unamalgamated granules of the granular material may be removed. The method may further include advancing a first portion of the continuous part from the second zone to a third zone while (1) a last portion of the continuous part is formed within the first zone and (2) the first portion is maintained in the same position in the lateral and transverse directions that the first portion occupied within the first zone and the second zone. 1. A method of additive manufacture in a three-dimensional space corresponding to longitudinal , lateral , and transverse directions that are orthogonal to one another , the method comprising the steps of:sequentially advancing each portion of a continuous part in the longitudinal direction from a first zone to a second zone;amalgamating, within the first zone, selected granules of a granular material;removing, within the second zone, unamalgamated granules of the granular material; andadvancing a first portion of the continuous part from the second zone to a third zone while (1) a last portion of the continuous part is formed within the first zone and (2) the first portion is maintained in the same position in the lateral and transverse directions that the first portion occupied within the first zone and the second zone.2. The method of claim 1 , wherein the amalgamating comprises directing radiant energy at the selected granules.3. The method of claim 2 , wherein the amalgamating further comprises heating claim 2 , by the radiant energy claim 2 , the selected granules.4. The method of claim 3 , wherein the amalgamating further comprises:distributing a first layer of granules of the granular ...

METHOD AND DEVICE FOR ENHANCING SENSOR INDICATION

Devices and methods for providing sensor indication and enhancing sensor indication are disclosed. In one embodiment, a sensor indication is provided by sensing an operational status at a sensor circuit, generating a signal at the sensor circuit based on the sensed operational status, utilizing the signal to activate a light source, transmitting light into a first indicator layer with the light source, wherein the first indicator layer includes a fluorophore embedded within a substrate, and wherein the one or more fluorophores modify at least one characteristic of the transmitted light from the light source, and emitting the modified transmitted light from an end wall of the first indicator layer. 1. A sensing device with enhanced sensor indication comprising:a first indicator layer including a substrate having a top surface, a bottom surface, and end walls situated at least partially between the perimeters of the top surface and the bottom surface, wherein the first indicator layer is at least one of transparent and translucent;one or more fluorophores embedded in the indicator layer;a first light source for transmitting light into the indicator layer, wherein the transmitted light is reflected inside the indicator layer and absorbed by the fluorophores to generate enhanced light that is emitted from the end walls, wherein the enhanced light includes the light transmitted from the first light source with at least one characteristic modified by the fluorophores;a sensing circuit; anda housing for at least partially enclosing the first light source, the sensing circuit, and the first indicator layer.2. The device of further comprising claim 1 ,a recess formed in the first indicator layer for receiving at least a portion of the first light source therein.3. The device of wherein the recess includes at least one inner wall extending from the top surface towards the bottom surface and wherein light emitted from the first light source is transmitted through the at least ...

Light Recycling For Additive Manufacturing Optimization

A method and an apparatus pertaining to recycling and reuse of unwanted light in additive manufacturing can multiplex multiple beams of light including at least one or more beams of light from one or more light sources. The multiple beams of light may be reshaped and blended to provide a first beam of light. A spatial polarization pattern may be applied on the first beam of light to provide a second beam of light. Polarization states of the second beam of light may be split to reflect a third beam of light, which may be reshaped into a fourth beam of light. The fourth beam of light may be introduced as one of the multiple beams of light to result in a fifth beam of light. 1. A method , comprising the steps of:multiplexing, by a first optical assembly, multiple beams of light including at least one or more beams of light from one or more light sources;reshaping and blending, by an optical device, the multiple beams of light to provide a first beam of light;applying, by a spatial polarization valve, a spatial polarization pattern on the first beam of light to provide a second beam of light;splitting, by a polarizer, polarization states of the second beam of light to reflect a third beam of light;reshaping, by a second optical assembly, the third beam of light into a fourth beam of light; andintroducing, by the second optical assembly, the fourth beam of light to the first optical assembly as one of the multiple beams of light to result in a fifth beam of light that is emitted through and not reflected by the polarizer.2. The method of claim 1 , wherein the receiving of the multiple beams of light including at least one or more beams of light from the one or more light sources comprises receiving at least the one or more beams of light from at least a solid state laser or a semiconductor laser.3. The method of claim 1 , wherein the applying of the spatial polarization pattern on the first beam of light comprises applying the spatial polarization pattern on the first ...

LONG AND HIGH RESOLUTION STRUCTURES FORMED BY ADDITIVE MANUFACTURING TECHNIQUES

A method of additive manufacture suitable for large and high resolution structures is disclosed. The method may include sequentially advancing each portion of a continuous part in the longitudinal direction from a first zone to a second zone. In the first zone, selected granules of a granular material may be amalgamated. In the second zone, unamalgamated granules of the granular material may be removed. The method may further include advancing a first portion of the continuous part from the second zone to a third zone while (1) a last portion of the continuous part is formed within the first zone and (2) the first portion is maintained in the same position in the lateral and transverse directions that the first portion occupied within the first zone and the second zone. 1. An apparatus for additive manufacture in a three-dimensional space corresponding to longitudinal , lateral , and transverse directions that are orthogonal to one another , the apparatus comprising:a conveyor configured to sequentially advance each portion of a continuous part in the longitudinal direction from a first zone to a second zone;an energy patterning system configured to amalgamate, within the first zone, selected granules of a granular material with unamalgamated granules of the granular material removed within the second zone, wherein the conveyor is configured to advance a first portion of the continuous part from the second zone to a third zone while (1) a last portion of the continuous part is formed within the first zone and (2) the first portion is maintained in the same position in the lateral and transverse directions that the first portion occupied within the first zone and the second zone; anda processor configured to determine a current position or orientation of the continuous part by locating one or more features of a feature map in an intersecting wall that intersects two neighboring portions of the continuous part,wherein, in amalgamating the selected granules of the ...

Chamber Systems For Additive Manufacturing

A method of additive manufacture is disclosed. The method may include creating, by a 3D printer contained within an enclosure, a part having a weight greater than or equal to 2,000 kilograms. A gas management system may maintain gaseous oxygen within the enclosure atmospheric level. In some embodiments, a wheeled vehicle may transport the part from inside the enclosure, through an airlock, as the airlock operates to buffer between a gaseous environment within the enclosure and a gaseous environment outside the enclosure, and to a location exterior to both the enclosure and the airlock. 1. A method of additive manufacture , the method comprising:operating a manufacturing facility comprising a first enclosure, a first machine contained within the first enclosure, a first gas management system, and an airlock, the airlock comprising an interior, a first door interfacing between the interior of the airlock and an interior of the first enclosure, and a second door interfacing between the interior of the airlock and an area exterior to the first enclosure;creating, by the first machine during the operating, a first part via a first process comprising additive manufacture using an energy beam to amalgamate selected portions of a powder located within the first enclosure;maintaining, by the first gas management system during the creating, gaseous oxygen within the first enclosure below atmospheric levels;transporting the first part from inside the first enclosure, through the airlock as the airlock operates to buffer between a gaseous environment within the first enclosure and a gaseous environment outside the first enclosure, and to the area; andcontinuously supporting the first part during the transporting.2. The method of claim 1 , wherein:the first part has a weight; andthe continuously supporting comprises continuously supporting, by a vehicle, conveyor system, railway, or belt during the transporting, the weight of the first part from inside the first enclosure, ...

Enclosed Additive Manufacturing System

A method of additive manufacture is disclosed. The method may include restricting, by an enclosure, an exchange of gaseous matter between an interior of the enclosure and an exterior of the enclosure. The method may further include running multiple machines within the enclosure. Each of the machines may execute its own process of additive manufacture. While the machines are running, a gas management system may maintain gaseous oxygen within the enclosure at or below a limiting oxygen concentration for the interior. 1. An additive manufacturing system comprising:an enclosure restricting an exchange of gaseous matter between an interior of the enclosure and an exterior of the enclosure; a separate powder bed, and', 'a control system programmed to execute an independent process of powder bed fusion; and, 'a plurality of machines located within the enclosure, each machine of the plurality of machines comprising'}a gas management system maintaining gaseous oxygen within the enclosure below atmospheric level.2. The system of claim 1 , wherein the enclosure comprises an airlock interfacing between the interior and the exterior.3. The system of claim 2 , wherein the airlock comprises a first door claim 2 , a second door claim 2 , and a space located between the first door and the second door claim 2 , the first door claim 2 , second door claim 2 , and space being sized to enable one or more humans to pass through the airlock.4. The system of claim 2 , wherein each machine of the plurality of machines further comprises a material dispenser and one or more image relays.5. The system of claim 4 , wherein the independent process of powder bed fusion comprises:distributing, by the material dispenser, a first layer of granules of a powder over the separate powder bed; anddirecting, by the one or more image relays, radiant energy at selected granules within the first layer.6. The system of claim 1 , wherein each machine of the plurality of machines further comprises a material ...

Electron Beam Patterning System In Additive Manufacturing

A method and an apparatus involve applying a pattern on an addressable patternable cathode unit. The cathode unit is stimulated to emit an electron beam pattern. A patterned image in the electron beam pattern is positioned to a desired position such directly to as a powder bed for additive manufacturing or to an electron beam addressed light valve for controlling spatial patterns on an optical signal for powder bed manufacturing. 1. A method , comprising:applying a pattern on an addressable patternable cathode unit;stimulating the cathode unit to emit an electron beam pattern; andpositioning a patterned image in the electron beam pattern to a desired position.2. The method of claim 1 , wherein the applying of the pattern comprises applying a two-dimensional patterned image using a light projector3. The method of claim 1 , further comprising:generating the patterned image with an electrically driven imagery using an integrated emission array.4. The method of claim 2 , further comprising:generating the patterned image by emitting light from the light projector at a wavelength appropriate to stimulate a photoconductive layer.5. The method of claim 4 , wherein the photoconductive layer is stimulated by an optical field that enables individual emitters or one or more groups of emitters to produce an electron beam.6. The method in claim 1 , further comprising:focusing the electron beam pattern directly to a powder bed in an electron beam system by using an ensemble of integrated focusing grids.7. The method of claim 6 , wherein the focusing of the electron beam pattern directly to the powder bed comprises scanning the electron beam pattern in a one-dimensional (1D) or two-dimensional (2D) space across a print bed by using an ensemble of scanning grids.8. The method of claim 7 , wherein the ensemble of scanning grids are either integrated into an field emission array or are constructed separately and assembled into a system.9. The method of claim 7 , wherein the scanning ...

Integration of optical area monitoring with industrial machine control

An industrial safety system is provided that integrates optical safety monitoring with machine control. The safety system includes an imaging sensor device supporting pixel array processing functions that allow time-of-flight (TOF) analysis to be performed on selected portions of the pixel array, while two-dimensional imaging analysis is performed on the remaining portions of the array, reducing processing load and response time relative to performing TOF analysis for all pixels of the array. The portion of the pixel array designated for TOF analysis can be pre-defined through configuration of the imaging sensor device, or can be dynamically selected based on object detection and classification by the two-dimensional imaging analysis. The imaging sensor device can also implement a number of safety and redundancy functions to achieve a high degree of safety integrity.

Light Valve Cooling System

An additive manufacturing system includes a high power laser to form a laser beam directed against a light valve. An active light valve cooling system is arranged to remove heat from the light valve and a heat exchanger is connected to the active light valve cooling system. A heat exchange fluid is circulated through the active light valve cooling system and the heat exchanger.

Resonance Based Light Valve System

An additive manufacturing system includes a high power laser to form a high fluence laser beam at a first wavelength. The systems includes a 2D patternable light valve having a resonance based structure responsive to a write beam.

Large Area Arrayed Light Valves

An additive manufacturing system includes at least two photoconductor plates attached to a substrate. Each photoconductor plate can include separate the Linear Electro layers and transparent conductive oxide layers.

Phase Change Light Valve System

An additive manufacturing system includes a high power laser to form a high fluence laser beam at a first wavelength. A 2D patternable light valve having a phase change material responsive to a write beam at a second wavelength, and non-responsive at the first wavelength is used to pattern the high fluence laser beam.

Distributed Flux Array

An apparatus includes at least one laser source and a print bed. A light valve array having at least three optically addressable light valves is positioned to direct differing images at the print bed. Optics to direct multiple beams derived from the at least one laser source can be positioned to direct light toward and from the optically addressable light valves.

AUXILIARY LIGHT SOURCE ASSOCIATED WITH AN INDUSTRIAL APPLICATION

Systems and techniques for providing an auxiliary light source associated with an industrial application are presented. A luminescent label is attached to an optical assembly via a pressure sensitive adhesive. The luminescent label comprises at least a fluorophore layer configured to transform light received from a light source into output light that is projected the optical assembly. 1. A system , comprising:an optical assembly; anda luminescent label that is attached to the optical assembly via a pressure sensitive adhesive and comprises at least a fluorophore layer configured to transform light received from a light source into output light that is projected by the optical assembly.2. The system of claim 1 , wherein the fluorophore layer is applied to substrate of the luminescent label.3. The system of claim 2 , wherein the substrate of the luminescent label is a clear substrate.4. The system of claim 2 , wherein a mask layer is further applied to the substrate of the luminescent label.5. The system of claim 2 , wherein the substrate is attached to the pressure sensitive adhesive of the luminescent label.6. The system of claim 1 , wherein the substrate is a rigid substrate.7. The system of claim 1 , wherein the luminescent label is further attached to the optical assembly via a mechanical technique.8. The system of claim 1 , wherein the luminescent label is attached to an aperture of the optical assembly.9. The system of claim 1 , wherein at least the fluorophore layer is applied to a metal layer of the luminescent label.10. The system of claim 1 , wherein the light source is a light-emitting diode.11. The system of claim 1 , wherein the light source is a remote light source that transmits the light to the luminescent label via a light guide.12. The system of claim 11 , wherein the light guide further transmits the light to another luminescent label associated with an industrial indicator that comprises at least another fluorophore layer.13. The system of claim 1 ...

Chamber Systems For Additive Manufacturing

An apparatus and a method for powder bed fusion additive manufacturing involve a multiple-chamber design achieving a high efficiency and throughput. The multiple-chamber design features concurrent printing of one or more print jobs inside one or more build chambers, side removals of printed objects from build chambers allowing quick exchanges of powdered materials, and capabilities of elevated process temperature controls of build chambers and post processing heat treatments of printed objects. The multiple-chamber design also includes a height-adjustable optical assembly in combination with a fixed build platform method suitable for large and heavy printed objects. 1. An apparatus , comprising:a print head comprising an energy source, the print head comprising one or more energy patterning units configured to provide one or more two-dimensional patterned incident beams to process a powdered material;a build chamber configured to at least partially surround a build platform capable of holding a powder bed formed by the powdered material; andan optical-mechanical assembly comprising optical components arranged to receive and direct the one or more incident beams into the build chamber,a rejected energy handling unit configured to reuse beam energy rejected by the one or more energy patterning units.2. The apparatus of claim 1 , wherein the rejected energy handling unit reuses the beam energy rejected by the one or more energy patterning units by performing either or both of:recycling the rejected beam energy using beam shaping optics; anddirecting the rejected beam energy to an article processing unit for heating or further patterning.3. The apparatus of claim 1 , wherein the build platform is height adjustable.4. The apparatus of claim 1 , wherein the build chamber is configured to accommodate side removal of the build platform.5. The apparatus of claim 1 , wherein the build chamber further comprises a thermal regulation system claim 1 , wherein the thermal ...

Multi-Functional Ingester System For Additive Manufacturing

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. 1. A method comprising the steps of:collecting a plurality of powder samples of a powdered material in real-time during a print job;performing a set of characterizations on the powder samples; andpackaging the powder samples in a plurality of sample canisters, with a second atmosphere in the sample canisters substantially equivalent to a first atmosphere utilized during the print job.2. The method of claim 1 , wherein the collecting of the powder samples of the powdered material in real-time comprises collecting the powder samples of the powdered material periodically at a predetermined interval claim 1 , randomly claim 1 , or at one or more predetermined stages during claim 1 , before claim 1 , or after the print job.3. The method of claim 1 , further comprising the step of aborting the print job when an unlicensed powder is used.4. The method of claim 1 , wherein the first atmosphere or the second atmosphere comprises air or an inert gas.5. The method of claim 4 , wherein the inert gas comprises nitrogen claim 4 , carbon dioxide claim 4 , argon claim 4 , helium claim 4 , or other noble gas.6. A method comprising the steps of:collecting a plurality of powder samples of a powdered material in real-time during a print job;performing a set of characterizations on the powder samples;determining whether to modify a set of printing parameters employed during the print job or abort the print job according to a result of the set of ...

Switchyard Beam Routing Of Patterned Light For Additive Manufacturing

A method and an apparatus for additive manufacturing pertaining to high efficiency, energy beam patterning and beam steering to effectively and efficiently utilize the source energy. In one embodiment recycling and reuse of unwanted light includes a source of multiple light patterns produced by one or more light valves, with at least one of the multiple light patterns being formed from rejected patterned light. An image relay is used to direct the multiple light patterns, and a beam routing system receives the multiple light patterns and respectively directs them toward defined areas on a powder bed. 1. An additive manufacturing method , the method comprising:distributing at least one layer of granular material;routing a first energy beam along a first route through a switchyard comprising a plurality of energy-switching units;directing, after the routing along the first route, the first energy beam at a first portion of the at least one layer;routing a second energy beam along a second route through the switchyard, wherein the second route is different from the first route; anddirecting, after the routing along the second route, the second energy beam at a second portion of the at least one layer, wherein the second portion is different from the first portion.2. The method of claim 1 , further comprising amalgamating claim 1 , as a result of the directing the first energy beam claim 1 , at least a portion of the granular material corresponding to the first portion.3. The method of claim 2 , further comprising amalgamating claim 2 , as a result of the directing the second energy beam claim 2 , at least a portion of the granular material corresponding to the second portion.4. The method of claim 3 , wherein:the at least one layer comprises a first layer of the granular material located in a first powder bed; andthe first portion forms part of the first layer.5. The method of claim 4 , wherein the second portion forms part of the first layer.6. The method of claim 4 , ...

Variable Print Chamber Walls For Powder Bed Fusion Additive Manufacturing

Additive manufacturing can involve dispensing a powdered material to form a layer of a powder bed on a support surface of a build platform. A portion of the layer of the powder bed may be selectively melted or fused to form one or more temporary walls out of the fused portion of the layer of the powder bed to contain another portion of the layer of the powder bed on the build platform 1. A method , comprising:dispensing a powdered material to form a first layer of a powder bed on a support surface of a build platform; andselectively fusing a portion of the first layer of the powder bed to form one or more first walls out of the fused portion of the first layer of the powder bed such that the one or more first walls contain another portion of the first layer of the powder bed on the build platform.2. The method of claim 1 , wherein the one or more first walls comprise multiple walls surrounding an area interior of the build platform to create a region devoid of the powdered material.3. The method of claim 1 , further comprising:dispensing the powdered material to form a second layer of the powder bed on the first layer of the powder bed; andselectively fusing a portion of the second layer of the powder bed to form one or more second walls out of the fused portion of the second layer of the powder bed such that the one or more second walls contain another portion of the second layer of the powder bed.4. The method of claim 3 , wherein the one or more first walls comprise multiple first walls surrounding the another portion of the first layer of the powder bed over a first area of the build platform claim 3 , wherein the one or more second walls comprise multiple second walls surrounding the another portion of the second layer of the powder bed over a second area of the first layer of the powder bed claim 3 , and wherein the second area is smaller than the first area.5. The method of claim 1 , wherein the one or more first walls comprise at least one wall along at ...

WAVEFORM RECONSTRUCTION IN A TIME-OF-FLIGHT SENSOR

A time-of-flight (TOF) sensor device is provided that is capable of accurately recovering waveforms of reflected light pulses incident on the sensor's photo-receiver array using a low sampling rate. A number of samples for a received light pulse incident on a given photo-receiver are obtained by emitting a light pulse to the viewing field, integrating the electrical output generated by the photo receiver over an integration period, and adding the integral values for respective integration cycles to yield an accumulation value. This process is repeated for multiple accumulation cycles; however, for each consecutive accumulation cycle the start of the integration period is delayed relative the start time of the integration period for the previous cycle by a delay period. Sampled values for the waveform are obtained by determining the difference values between consecutive accumulation values for the respective accumulation cycles.

OPTICAL AREA MONITORING WITH SPOT MATRIX ILLUMINATION

An imaging sensor device is configured to illuminate a viewing field using an array of focused light spots spaced across the viewing field rather than uniformly illuminating the viewing field, thereby reducing the amount of illumination energy required to produce a given intensity of light reflected from the spots. In some embodiments, the imaging sensor device can project an array of focused light spots at two different intensities or brightness levels, such that high intensity and low intensity light spots are interlaced across the viewing field. This ensures that both relatively dark and relatively bright or reflective objects can be reliably detected within the viewing field. The intensities of the light spots can be modulated based on measured conditions of the viewing field, including but not limited to the measured ambient light or a determined dynamic range of reflectivity of objects within the viewing field.

INTEGRATION OF OPTICAL AREA MONITORING WITH INDUSTRIAL MACHINE CONTROL

An industrial safety system is provided that integrates optical safety monitoring with machine control. The safety system includes an imaging sensor device supporting pixel array processing functions that allow time-of-flight (TOF) analysis to be performed on selected portions of the pixel array, while two-dimensional imaging analysis is performed on the remaining portions of the array, reducing processing load and response time relative to performing TOF analysis for all pixels of the array. The portion of the pixel array designated for TOF analysis can be pre-defined through configuration of the imaging sensor device, or can be dynamically selected based on object detection and classification by the two-dimensional imaging analysis. The imaging sensor device can also implement a number of safety and redundancy functions to achieve a high degree of safety integrity.

OPTICAL SAFETY MONITORING WITH SELECTIVE PIXEL ARRAY ANALYSIS

An imaging sensor device includes pixel array processing functions that allow time-of-flight (TOF) analysis to be performed on selected portions of the pixel array, while two-dimensional imaging analysis is performed on the remaining portions of the array, reducing processing load and response time relative to performing TOF analysis for all pixels of the array. The portion of the pixel array designated for TOF analysis can be pre-defined through configuration of the imaging sensor device. Alternatively, the imaging sensor device can dynamically select the portions of the pixel array on which TOF analysis is to be performed based on object detection and classification by the two-dimensional imaging analysis. Embodiments of the imaging sensor device can also implement a number of safety and redundancy functions to achieve a high degree of safety integrity, making the sensor suitable for use in various types of safety monitoring applications.

Switchyard Beam Routing Of Patterned Light For Additive Manufacturing

A method and an apparatus for additive manufacturing pertaining to high efficiency, energy beam patterning and beam steering to effectively and efficiently utilize the source energy. In one embodiment recycling and reuse of unwanted light includes a source of multiple light patterns produced by one or more light valves, with at least one of the multiple light patterns being formed from rejected patterned light. An image relay is used to direct the multiple light patterns, and a beam routing system receives the multiple light patterns and respectively directs them toward defined areas on a powder bed. 1. A switchyard beam routing system for additive manufacturing , comprising:an energy beam;a beam patterning unit to generate a two-dimensional patterned energy beam from the energy beam;a plurality of energy switching units to direct two-dimensional patterned energy beams;a plurality of energy steering units to receive and direct the two-dimensional patterned energy beams, andat least one powder bed to receive at least a portion of the directed two-dimensional patterned energy beam from at least one of the plurality of energy steering units.2. The system of claim 1 , wherein the two-dimensional patterned energy beam preserves greater than 50% of angular power density and 75% of spatial etendue content of a two-dimensional patterned image generated at the beam patterning unit and received at the least one powder bed.3. The system of claim 1 , wherein at least one of the plurality of energy switching units can direct the two-dimensional patterned energy beam to at least two energy switching units claim 1 , forming a switching hierarchy.4. The system of claim 1 , wherein at least some of the plurality of energy switching units are arranged in a switching hierarchy claim 1 , and wherein at least two of the plurality of energy switching units can direct a two-dimensional patterned energy beams therebetween5. The system of claim 1 , wherein the energy beam comprises a laser ...

Solid State Routing Of Patterned Light For Additive Manufacturing Optimization

A solid state beam routing apparatus includes a controller and a spatial angular light valve arranged to direct a two-dimensional patterned light beam through a predetermined angle in response to an applied voltage. A bed is arranged to receive the two-dimensional patterned light beam as a succession of tiles. In some embodiments, one or more solid state galvo mechanisms are used to direct the two-dimensional patterned light beams formed by the light valve to the multiple powder bed chambers. 1. A solid state beam routing apparatus , comprisinga controller;a spatial angular light valve connected to the controller, the spatial angular light valve being arranged to direct a two-dimensional patterned light beam through a predetermined angle; anda bed arranged to receive the two-dimensional patterned light beam as a succession of tiles.2. The solid state beam routing apparatus of wherein the spatial angular light valve is further arranged to direct the two-dimensional patterned light beam through a predetermined angle in response to an applied optical address pattern and a stimuli selected to be at least one of voltage claim 1 , current claim 1 , heat claim 1 , sound claim 1 , light claim 1 , electric field claim 1 , magnetic field claim 1 , chemical reaction claim 1 , quantum spin change claim 1 , energy claim 1 , or mechanical.3. The solid state beam routing apparatus of wherein the spatial angular light valve modifies the pattern of the two-dimensional patterned light beam.4. The solid state beam routing apparatus of claim 2 , wherein the spatial angular light valve defines multiple discrete zones arranged to redirect light in different directions in response to stimuli.5. The solid state beam routing apparatus of claim 2 , wherein the spatial angular light valve defines multiple discrete zones arranged to pattern and redirect light in different directions in response to the applied optical address pattern wherein the pattern is one of a superposition of linear ...

Additive Manufacturing System And Method

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved optical systems supporting beam combining, beam steering, and both patterned and unpatterned beam recycling and re-use are described.

Grayscale Area Printing for Additive Manufacturing

An additive manufacturing system includes one or more light sources and one or more light valves that can be written with two-dimensional gray scale patterns that the light valves impose on beams from the one or more light sources to obtain one or more patterned beams. The one or more patterned beams are steered to each area of a plurality of areas on a layer of powder. The two-dimensional gray scale patterns are selected to achieve desired material properties at each pixel position of the patterned beam incident on the layer of powder. The light valves may modulate one or more of amplitude, phase, or coherence. The material properties may include one or more of Young's modulus, porosity, grain size, and crystalline microstructure.

Dynamic Optical Assembly For Laser-Based Additive Manufacturing

A method and an apparatus of a powder bed fusion additive manufacturing system that enables a quick change in the optical beam delivery size and intensity across locations of a print surface for different powdered materials while ensuring high availability of the system. A dynamic optical assembly containing a set of lens assemblies of different magnification ratios and a mechanical assembly may change the magnification ratios as needed. The dynamic optical assembly may include a transitional and rotational position control of the optics to minimize variations of the optical beam sizes across the print surface.

Safety arrangement

A safety arrangement for use with a piece of equipment. The safety arrangement includes a signal generating unit for generating an optical signal, an elongate element, and a signal detecting unit. The elongate element is disposed along, about, around or through the piece of equipment and is capable of transmitting an optical signal. The signal detecting unit detects an optical signal. The signal generating unit is connected to the signal detecting unit by the elongate element such that the signal detecting unit is in optical communication with the signal detecting unit. The signal detecting unit is arranged to detect a change in the optical signal transmitted by the elongate element as a consequence of movement of the elongate element and, upon detection of the change in the signal, the detecting unit is configured to effect a change in the operation of the piece of equipment.

Additive manufacturing with photo-acoustic tomography defect testing

An additive manufacturing method supporting layer by layer testing includes a layer test including generating a hammer beam using laser light having a first wavelength, generating a read-out beam using laser light having a second wavelength, directing the generated hammer beam toward a first layer on a part to provide an acoustic hammer pulse that induces surface movement of the part, and reading the surface movement of the part using the read-out beam directed to a second position on the part. Layers can be added and the layer test repeated.

Optical safety monitoring with selective pixel array analysis

Polarization combining system in additive manufacturing

A method and an apparatus pertaining to polarization combining in additive manufacturing may involve emitting two or more beams of light with a first intensity. Each of the two or more beams of light may be polarized and may have a majority polarization state and a minority polarization state. A respective polarization pattern may be applied on the majority polarization state of each of the two or more beams of light. The two or more beams of light may be combined to provide a single beam of light.

Safety arrangement

Modular architecture for additive manufacturing

A print engine of an additive manufacturing system includes a print station configured to hold a removable cartridge. A laser engine including a frame can be positioned to hold at least one removable field replaceable unit that includes at least some laser optics or patterning optics. An optical alignment system can be attached to at least one of the print station or the laser engine to align the field replaceable unit with respect to the removable cartridge.

Laser damage hardening of light modulator components for use with high optical fluence systems

An apparatus with first and second transparent conductive oxide layers is described. A photoconductive layer can be positioned between the first and a second transparent conductive oxide layers. The photoconductive layer can be a crystalline layer that can include bismuth silicate or other suitable materials. An electro-optical layer is positioned in contact with the photoconductive layer. In some embodiments the photoconductive layer is positionable to receive a write beam that defines a two-dimensional spatial pattern.

Additive manufacturing system and method

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved structure formation, part creation and manipulation, use of multiple additive manufacturing systems, and high throughput manufacturing methods suitable for automated or semi-automated factories are also disclosed.

Additive manufacturing with photo-acoustic tomography defect testing

An additive manufacturing method supporting layer by layer testing includes a layer test including generating a hammer beam using laser light having a first wavelength, generating a read-out beam using laser light having a second wavelength, directing the generated hammer beam toward a first layer on a part to provide an acoustic hammer pulse that induces surface movement of the part, and reading the surface movement of the part using the read-out beam directed to a second position on the part. Layers can be added and the layer test repeated.

Light recycling for additive manufacturing optimization

A method comprising generating an energy beam (112); directing the energy beam towards beam shaping optics (114) that shape the energy beam to provide a shaped energy beam; patterning the shaped energy beam two-dimensionally using an energy patterning unit ( 230) ; and handling a rejected patterned energy from the energy patterning unit (230) using an energy handling unit(222).

Additive Manufacturing With Photo-Acoustic Tomography Defect Testing

An additive manufacturing method supporting layer by layer testing includes a layer test including generating a hammer beam using laser light having a first wavelength, generating a read-out beam using laser light having a second wavelength, directing the generated hammer beam toward a first layer on a part to provide an acoustic hammer pulse that induces surface movement of the part, and reading the surface movement of the part using the read-out beam directed to a second position on the part. Layers can be added and the layer test repeated.

Additive manufacturing system and method

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved optical systems supporting beam combining, beam steering, and both patterned and unpatterned beam recycling and re-use are described.

Light recycling for additive manufacturing optimization

Optical safety monitoring with selective pixel array analysis

An imaging sensor device includes pixel array processing functions that allow time-of-flight (TOF) analysis to be performed on selected portions of the pixel array, while two-dimensional imaging analysis is performed on the remaining portions of the array, reducing processing load and response time relative to performing TOF analysis for all pixels of the array. The portion of the pixel array designated for TOF analysis can be pre-defined through configuration of the imaging sensor device. Alternatively, the imaging sensor device can dynamically select the portions of the pixel array on which TOF analysis is to be performed based on object detection and classification by the two-dimensional imaging analysis. Embodiments of the imaging sensor device can also implement a number of safety and redundancy functions to achieve a high degree of safety integrity, making the sensor suitable for use in various types of safety monitoring applications.

Phase change light valve system

An additive manufacturing system includes a high power laser to form a high fluence laser beam at a first wavelength. A 2D pattemable light valve having a phase change material responsive to a write beam at a second wavelength, and non-responsive at the first wavelength is used to pattern the high fluence laser beam.

Print cartridge for additive manufacturing

Grayscale area printing for additive manufacturing

An additive manufacturing system includes one or more light sources and one or more light valves that can be written with two-dimensional gray scale patterns that the light valves impose on beams from the one or more light sources to obtain one or more patterned beams. The one or more patterned beams are steered to each area of a plurality of areas on a layer of powder. The two-dimensional gray scale patterns are selected to achieve desired material properties at each pixel position of the patterned beam incident on the layer of powder. The light valves may modulate one or more of amplitude, phase, or coherence. The material properties may include one or more of Young's modulus, porosity, grain size, and crystalline microstructure.

Photo-acoustic tomography defect testing system and method

Recycling powdered material for additive manufacturing

A method and an apparatus for collecting a powdered material after a print job in powder bed fusion additive manufacturing may involve a build platform supporting a powder bed capable of tilting, inverting, and shaking to separate the powder bed substantially from the build platform in a hopper. The powdered material may be collected in a hopper for reuse in later print jobs. The powder collecting process may be automated to increase efficiency of powder bed fusion additive manufacturing.

Additive manufacturing with photo-acoustic tomography defect testing

Long and high resolution structures formed by additive manufacturing techniques

A method of additive manufacture suitable for large and high resolution structures is disclosed. The method may include sequentially advancing each portion of a continuous part in the longitudinal direction from a first zone to a second zone. In the first zone, selected granules of a granular material may be amalgamated. In the second zone, unamalgamated granules of the granular material may be removed. The method may further include advancing a first portion of the continuous part from the second zone to a third zone while (1) a last portion of the continuous part is formed within the first zone and (2) the first portion is maintained in the same position in the lateral and transverse directions that the first portion occupied within the first zone and the second zone.

Dynamic optical assembly for laser-based additive manufacturing

A method and an apparatus of a powder bed fusion additive manufacturing system that enables a quick change in the optical beam delivery size and intensity across locations of a print surface for different powdered materials while ensuring high availability of the system. A dynamic optical assembly containing a set of lens assemblies of different magnification ratios and a mechanical assembly may change the magnification ratios as needed. The dynamic optical assembly may include a transitional and rotational position control of the optics to minimize variations of the optical beam sizes across the print surface.

Dynamic optical assembly for laser-based additive manufacturing

A method and an apparatus of a powder bed fusion additive manufacturing system that enables a quick change in the optical beam delivery size and intensity across locations of a print surface for different powdered materials while ensuring high availability of the system. A dynamic optical assembly containing a set of lens assemblies of different magnification ratios and a mechanical assembly may change the magnification ratios as needed. The dynamic optical assembly may include a transitional and rotational position control of the optics to minimize variations of the optical beam sizes across the print surface.

Long and high resolution structures formed by additive manufacturing techniques

A method of additive manufacture suitable for large and high resolution structures is disclosed. The method may include sequentially advancing each portion of a continuous part in the longitudinal direction from a first zone to a second zone. In the first zone, selected granules of a granular material may be amalgamated. In the second zone, unamalgamated granules of the granular material may be removed. The method may further include advancing a first portion of the continuous part from the second zone to a third zone while (1) a last portion of the continuous part is formed within the first zone and (2) the first portion is maintained in the same position in the lateral and transverse directions that the first portion occupied within the first zone and the second zone.

Enclosed Additive Manufacturing System

A method of additive manufacture is disclosed. The method may include restricting, by an enclosure, an exchange of gaseous matter between an interior of the enclosure and an exterior of the enclosure. The method may further include running multiple machines within the enclosure. Each of the machines may execute its own process of additive manufacture. While the machines are running, a gas management system may maintain gaseous oxygen within the enclosure at or below a limiting oxygen concentration for the interior.

Chamber Systems For Additive Manufacturing

An apparatus and a method for powder bed fusion additive manufacturing involve a multiple-chamber design achieving a high efficiency and throughput. The multiple-chamber design features concurrent printing of one or more print jobs inside one or more build chambers, side removals of printed objects from build chambers allowing quick exchanges of powdered materials, and capabilities of elevated process temperature controls of build chambers and post processing heat treatments of printed objects. The multiple-chamber design also includes a height-adjustable optical assembly in combination with a fixed build platform method suitable for large and heavy printed objects.

Additive Manufacturing System And Method

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved structure formation, part creation and manipulation, use of multiple additive manufacturing systems, and high throughput manufacturing methods suitable for automated or semi-automated factories are also disclosed.

Part Manipulation Using Printed Manipulation Points

A manipulator device such as a robot arm that is capable of increasing manufacturing throughput for additively manufactured parts, and allows for the manipulation of parts that would be difficult or impossible for a human to move is described. The manipulator can grasp various permanent or temporary additively manufactured manipulation points on a part to enable repositioning or maneuvering of the part.

Waveform reconstruction in a time-of-flight sensor

Resonance based light valve system

An additive manufacturing system includes a high power laser to form a high fluence laser beam at a first wavelength. The systems includes a 2D patternable light valve having a resonance based structure responsive to a write beam.

High Speed Light Valve System

An additive manufacturing system includes a high power laser to form a high fluence laser beam. A 2D patternable light valve having a structure responsive to electron emission is positioned to receive and pattern light received from the high power laser.

Distributed flux array

An apparatus includes at least one laser source and a print bed. A light valve array having at least three optically addressable light valves is positioned to direct differing images at the print bed. Optics to direct multiple beams derived from the at least one laser source can be positioned to direct light toward and from the optically addressable light valves.

Light valve cooling system

An additive manufacturing system includes a high power laser to form a laser beam directed against a light valve. An active light valve cooling system is arranged to remove heat from the light valve and a heat exchanger is connected to the active light valve cooling system. A heat exchange fluid is circulated through the active light valve cooling system and the heat exchanger.

Light valve cooling system

An additive manufacturing system includes a high power laser to form a laser beam directed against a light valve. An active light valve cooling system is arranged to remove heat from the light valve and a heat exchanger is connected to the active light valve cooling system. A heat exchange fluid is circulated through the active light valve cooling system and the heat exchanger.

Multi-functional ingester system for additive manufacturing

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.

Additive manufacturing method using switchyard beam routing of patterned light

A method and an apparatus for additive manufacturing pertaining to high efficiency, energy beam patterning and beam steering to effectively and efficiently utilize the source energy. In one embodiment recycling and reuse of unwanted light includes a source of multiple light patterns produced by one or more light valves, with at least one of the multiple light patterns being formed from rejected patterned light. An image relay is used to direct the multiple light patterns, and a beam routing system receives the multiple light patterns and respectively directs them toward defined areas on a powder bed.

Light recycling for additive manufacturing optimization

A method and an apparatus pertaining to recycling and reuse of unwanted light in additive manufacturing can multiplex multiple beams of light including at least one or more beams of light from one or more light sources. The multiple beams of light may be reshaped and blended to provide a first beam of light. A spatial polarization pattern may be applied on the first beam of light to provide a second beam of light. Polarization states of the second beam of light may be split to reflect a third beam of light, which may be reshaped into a fourth beam of light. The fourth beam of light may be introduced as one of the multiple beams of light to result in a fifth beam of light.

Light valve cooling system

An additive manufacturing system includes a high power laser to form a laser beam directed against a light valve. An active light valve cooling system is arranged to remove heat from the light valve and a heat exchanger is connected to the active light valve cooling system. A heat exchange fluid is circulated through the active light valve cooling system and the heat exchanger.

Distributed Flux Array

An apparatus includes at least one laser source and a print bed. A light valve array having at least three optically addressable light valves is positioned to direct differing images at the print bed. Optics to direct multiple beams derived from the at least one laser source can be positioned to direct light toward and from the optically addressable light valves.

Switchyard Beam Routing Of Patterned Light For Additive Manufacturing

A method and an apparatus for additive manufacturing pertaining to high efficiency, energy beam patterning and beam steering to effectively and efficiently utilize the source energy. In one embodiment recycling and reuse of unwanted light includes a source of multiple light patterns produced by one or more light valves, with at least one of the multiple light patterns being formed from rejected patterned light. An image relay is used to direct the multiple light patterns, and a beam routing system receives the multiple light patterns and respectively directs them toward defined areas on a powder bed.

Grayscale area printing for additive manufacturing

An additive manufacturing system includes one or more light sources and one or more light valves that can be written with two-dimensional gray scale patterns that the light valves impose on beams from the one or more light sources to obtain one or more patterned beams. The one or more patterned beams are steered to each area of a plurality of areas on a layer of powder. The two-dimensional gray scale patterns are selected to achieve desired material properties at each pixel position of the patterned beam incident on the layer of powder. The light valves may modulate one or more of amplitude, phase, or coherence. The material properties may include one or more of Young's modulus, porosity, grain size, and crystalline microstructure.

High speed light valve system

An additive manufacturing system includes a high power laser to form a high fluence laser beam. A 2D patternable light valve having a structure responsive to electron emission is positioned to receive and pattern light received from the high power laser.

Powder production and recycling

A print engine of an additive manufacturing system includes a print station configured to hold a removable cartridge containing powder. A laser engine is positioned to direct a one or two dimensional patterned laser beam into the removable cartridge. In some embodiments powder is produced at least in part with a magnetohydrodynamic system.

Speckle reduction for an additive printing system

An additive manufacturing system can include at least one laser source and a speckle reduction system that receives light from the at least one laser source. The speckle reduction system provides laser light to an optical homogenizer that increases uniformity of laser light and can provide the light to an area patterning system.

Recycling powdered material for additive manufacturing

A method and an apparatus for collecting a powdered material after a print job in powder bed fusion additive manufacturing may involve a build platform supporting a powder bed capable of tilting, inverting, and shaking to separate the powder bed substantially from the build platform in a hopper. The powdered material may be collected in a hopper for reuse in later print jobs. The powder collecting process may be automated to increase efficiency of powder bed fusion additive manufacturing.

Phase change light valve system

An additive manufacturing system includes a high power laser to form a high fluence laser beam at a first wavelength. A 2D patternable light valve having a phase change material responsive to a write beam at a second wavelength, and non-responsive at the first wavelength is used to pattern the high fluence laser beam.

Polarization combining system in additive manufacturing

Large Area Arrayed Light Valves

An additive manufacturing system includes at least two photoconductor plates attached to a substrate. Each photoconductor plate can include separate the Linear Electro layers and transparent conductive oxide layers.

Large area arrayed light valves

An additive manufacturing system includes at least two photoconductor plates attached to a substrate. Each photoconductor plate can include separate the Linear Electro layers and transparent conductive oxide layers.

Spatially variable filter laser wavelength monitoring/control

A feedback controlled laser diode communication device is disclosed that, as is common, has a laser diode that is modulated in response to an input signal to generate an optical signal, encoding the input signal. Spatially variable passband filter material, however, is arranged to receive at least a portion of the optical signal generated by the laser diode, preferably from the rear facet, and at least one detector is used to detect the thus filtered optical signal. Control circuitry then controls a wavelength of the laser diode based upon the response of the detector(s) to thus provide feedback control. As such, the device is particularly applicable to maintaining the tight channel spacings found in wavelength division multiplexed systems.

Phase managed additive printing system

An additive manufacturing system includes at least two high power lasers to generate beams. A phase patterning unit is used to receive and alter phase of a beam from at least one of the two high power lasers. At least one phase patterned beam can be mixed with another beam at a print the print bed. In some embodiments, beams are moved with respect to the print bed by changes in phase patterns from the phase patterning unit. In other embodiments, phase patterns from the phase patterning unit can be used for simultaneous printing of multiple layers.

Phase managed additive printing system

An additive manufacturing system includes at least two high power lasers to generate beams. A phase patterning unit is used to receive and alter phase of a beam from at least one of the two high power lasers. At least one phase patterned beam can be mixed with another beam at a print the print bed. In some embodiments, beams are moved with respect to the print bed by changes in phase patterns from the phase patterning unit. In other embodiments, phase patterns from the phase patterning unit can be used for simultaneous printing of multiple layers.

Light Recycling For Additive Manufacturing Optimization

A method and an apparatus pertaining to recycling and reuse of unwanted light in additive manufacturing can multiplex multiple beams of light including at least one or more beams of light from one or more light sources. The multiple beams of light may be reshaped and blended to provide a first beam of light. A spatial polarization pattern may be applied on the first beam of light to provide a second beam of light. Polarization states of the second beam of light may be split to reflect a third beam of light, which may be reshaped into a fourth beam of light. The fourth beam of light may be introduced as one of the multiple beams of light to result in a fifth beam of light.

Light Valve Cooling System

An additive manufacturing system includes a high power laser to form a laser beam directed against a light valve. An active light valve cooling system is arranged to remove heat from the light valve and a heat exchanger is connected to the active light valve cooling system. A heat exchange fluid is circulated through the active light valve cooling system and the heat exchanger.

Long and high resolution structures formed by additive manufacturing techniques

A method of additive manufacture suitable for large and high resolution structures is disclosed. The method may include sequentially advancing each portion of a continuous part in the longitudinal direction from a first zone to a second zone. In the first zone, selected granules of a granular material may be amalgamated. In the second zone, unamalgamated granules of the granular material may be removed. The method may further include advancing a first portion of the continuous part from the second zone to a third zone while (1) a last portion of the continuous part is formed within the first zone and (2) the first portion is maintained in the same position in the lateral and transverse directions that the first portion occupied within the first zone and the second zone.

Variable print chamber walls for powder bed fusion additive manufacturing

Additive manufacturing can involve dispensing a powdered material to form a layer of a powder bed on a support surface of a build platform. A portion of the layer of the powder bed may be selectively melted or fused to form one or more temporary walls out of the fused portion of the layer of the powder bed to contain another portion of the layer of the powder bed on the build platform.

Powder bed measurement for additive manufacturing

A print engine of an additive manufacturing system that supports powder measurement systems includes a print bed able to hold powder of varying sizes. A laser energy patterning system is made to be directable against the print bed and a backscatter detection system is situated to evaluate scattered light distribution from powder on the print bed and determine powder size.

High speed light valve system

An additive manufacturing system includes a high power laser to form a high fluence laser beam. A 2D patternable light valve having a structure responsive to electron emission is positioned to receive and pattern light received from the high power laser.

Resonance based light valve system

An additive manufacturing system includes a high power laser to form a high fluence laser beam at a first wavelength. The systems includes a 2D patternable light valve having a resonance based structure responsive to a write beam.