Relativity Space, Inc.

The present disclosure provides methods and systems for three-dimensional (3D) printing. In an example, a system and method for maintaining a command history in 3D printing software is disclosed. In an example, a method for updating a plurality of printing instructions comprises maintaining a plurality of printing states corresponding to the plurality of printing instructions, wherein a first state corresponds to a first set of printing instructions for printing a first portion of a 3D object. The plurality of printing states may comprise a final state comprising final printing instructions. User instructions may be received to select a second state that is not the final state. A new state may be generated comprising a second set of printing instructions for printing second portion of the 3D object. The plurality of printing instructions may be updated with the second set of printing instructions to yield an updated plurality of printing instructions.

Cryogenic sources can be used for shielding in wire-based additive manufacturing. Cryogenic shielding can provide better shielding during print, as well as more efficient cooling compared to using regular room temperature shielding gas. Cryogenic shielding can extend the nozzle run time by preventing spatter build up in nozzles. Cryogenic sources also can be used for active part cooling and/or active weld puddle cooling.

The present disclosure provides methods and systems for printing a three-dimensional part. The method comprises: receiving in computer memory a digital model of said three-dimensional object; using one or more computer processors to partition said digital model of said three-dimensional part into a plurality of partitions, wherein a given partition of said plurality of partitions comprises a plurality of slices, and wherein a given slice of said plurality of slices comprises a plurality of segments; receiving, from a user, one or more parameters that specify a printing configuration for at least one segment of said plurality of segments; and generating printing instructions based at least in part on said one or more parameters, which printing instructions are usable by a print head to print said three-dimensional object.

A device may position a torch assembly relative to a workpiece. A device may initiate a pilot arc between a plasma electrode and a grounded portion of a torch assembly, the grounded portion of the torch assembly grounded using a component with a variable resistance. A device may initiate a wire arc between a first wire element and the workpiece. A device may add material to the workpiece while the torch assembly traverses the workpiece.

Systems of weldable wires, powder, and materials comprising an aluminum-magnesium-scandium alloy, and methods for additive manufacturing the alloy are described. The alloy can be additive manufactured in industrial scale. With post treatment, the additive manufactured alloys can have desired properties for aerospace applications.

Additively manufactured thrust chambers and thrust chambers with integral fluid manifolds, and hybrid additive manufacturing methods for their production, are provided. Hybrid additive manufacturing techniques may combine a variety of processes including, WAAM, PBF, cold spray and DED, for example, to produce objects with variant dimensional requirements, i.e., large overall size and small features. Hybrid additive manufacturing may be defined as provide various process layers within any manufactured object. These process layers in turn allow for the introduction of variable feature and size distribution throughout the manufactured object. Hybrid process layers according to aspects may also allow the use of a variety of materials or may use a single material across the various process layers.

A two-part coupling for use in joining sections of pipe without additional fasteners is disclosed. The two-part coupling includes integral coupling features molded by additive manufacturing technology. The two-part coupling increases reliability, reduces weight, and provides ease of manufacture. The coupling distributes a fluid load so that the coupling can withstand pressures and leak rates in accordance with stringent standards. The two-part coupling can be coupled and de-coupled using a locking and release mechanism built into the integral parts. Assembly is made easier because the geometry of the coupling is amenable to additive manufacturing. Because the two-part coupling requires a lesser degree of precision, machined parts are not required.

A valve assembly has a housing and a poppet-carrying portion. The housing includes an inlet port, an outlet port, an opening, and a assembly portion including helical grooves. The poppet-carrying portion is configured to be inserted through the opening and engage with the assembly portion. The poppet-carrying portion comprises a poppet head, a closure including protruding arms, convolutions, and a stopping portion. The convolutions extend between the poppet head and the closure and provide compliance such that the poppet head is movable relative to the closure. The stopping portion extends from the closure toward the poppet head and is spaced apart from the poppet head by a maximum compression distance. At a first fluid pressure, the protruding arms engage with the helical grooves, and the poppet head is positioned in a pre-load position that prevents the fluid from discharging through the outlet port.

Process control parameters are predicted to fabricate an object using deposition. An input design geometry is provided for the object. A training data set includes past post-build physical inspection data for a plurality of objects that comprise at least one object that is different from the object to be physically fabricated; and training data generated through a repetitive process of randomly choosing values for each of multiple process control parameters and scoring adjustments to the multiple process control parameters as leading to either undesirable or desirable outcomes, the outcomes based respectively on the presence or absence of defects detected in a fabricated object arising from the process control parameter adjustments. A machine learning algorithm is trained using the provided training data set and a predicted optimal set of the multiple process control parameters is generated for initiating and performing the deposition process to fabricate the object.

Systems and methods for localized work return path of additive manufacturing systems are described. Localized grounding connects the printed surface directly to the work return, and shortens the length of grounding and/or the return cables compared to substrate-based grounding.