VulcanForms Inc.

Additive manufacturing systems and related methods are disclosed. In some embodiments, an additive manufacturing system includes a build surface, one or more laser energy sources configured to emit laser energy, an optical phased array operatively coupled to the one or more laser energy sources, and a Risley prism assembly comprising a plurality of wedge prisms. The optical phased array includes one or more phase shifters operatively coupled to the one or more laser energy sources and configured to control a phase of the laser energy. The optical phased array is configured to direct the laser energy towards the Risley prism assembly, and the Risley prism assembly is configured to direct the laser energy towards the build surface.

An additive manufacturing system has a build surface supporting a precursor material to be fused by incident light energy. The system includes an optics assembly to direct the incident light energy along a beam path in a first direction toward the build surface, and an energy management system. The energy management system includes a beam block disposed along the beam path. The beam block has an aperture allowing the incident light energy to pass through the beam block in the first direction. The beam block also has a surface to absorb or deflect, away from the beam path, light energy traveling in a second direction different from the first direction. The energy management system also includes a heat sink to receive heat energy from at least a portion of the light energy traveling in the second direction.

A hopper for dispensing powder material for an additive manufacturing system includes a gate that is movable along a first direction to open and close a discharge slot and which is pivotable about a pivot axis transverse to the first direction. The first direction can be a horizontal direction and the pivot axis can be parallel to a vertical direction. The gate can have a portion that contacts the hopper, e.g., at a surface including the discharge slot, and is elastically deformed with movement from the open to the closed position.

Systems and methods for additive manufacturing are described. In some embodiments, a method of controlling a weld height in an additive manufacturing process includes determining a desired melt pool width based, at least in part, on a desired weld height; selectively activating one or more laser energy sources based, at least in part, on the desired melt pool width; and melting a portion of a layer of material on a build surface via exposure to laser energy from the one or more activated laser energy sources to form a melt pool on the build surface having the desired melt pool width. Systems and methods to the use of staggered laser energy sources are also described.

Systems and methods for additive manufacturing are generally described. In some embodiments, an additive manufacturing system may include at least one alignment fixture for accurately positioning one or more optical fibers. The alignment fixture may maintain a desired position and/or orientation of the fiber or endcap. In some embodiments, an additive manufacturing system may include at least one stray light baffle coupled to the alignment fixture for reducing the amount of stray light within the optical system.

System and method for dispensing powder material for an additive manufacturing system. A hopper can include a spline configured for rotation to dispense powder material from an exit opening of the hopper. A shield can be provided for one or both ends of the spline to help control powder movement at an interface with the spline, e.g., so powder that passes the interface is trapped in a space. An auger can be provided in a hopper and configured for moving powder in the hopper in two opposed directions in response to rotation of the auger in a single direction. A common drive can be used to move both an auger and spline. One or more load cells can be provided to determine a mass of powder delivered to and/or dispensed from the hopper.

Systems and methods for additive manufacturing are generally described. In some embodiments, an additive manufacturing system may include at least one mechanical fixture in the form of a resilient member for accurately positioning one or more optical fibers without the use of adhesives. The resilient member may, in some embodiments, bias each optical fiber (or similarly, an endcap coupled to a distal end of an optical fiber) against an alignment fixture to maintain a desired position and/or orientation of the fiber or endcap. In some embodiments, an additive manufacturing system may include at least one stray light baffle for reducing the amount of stray light within the optical system.

Systems and methods for additive manufacturing are generally described. According to certain aspects, endcaps optically coupled to optical fibers of additive manufacturing systems are provided. In some aspects, methods for reducing a power area density of laser energy within an endcap are provided. The endcaps described herein may be used to at least partially mitigate thermal cycling that may result from the transmission of laser energy through interfaces of an additive manufacturing system.

Systems and methods for additive manufacturing are generally described. According to certain aspects, endcaps optically coupled to optical fibers of additive manufacturing systems are provided. In some aspects, methods for reducing a power area density of laser energy within an endcap are provided. The endcaps described herein may be used to at least partially mitigate thermal cycling that may result from the transmission of laser energy through interfaces of an additive manufacturing system.

Disclosed embodiments are generally related to recoater assemblies for additive manufacturing systems. In some embodiments, a recoater blade may include a plurality of flexible portions that are configured to deflect relative to one another when moved over and past a defect on a build surface. In other embodiments, a recoater assembly may include compliant attachments that exhibit compliances that increase in an outward direction relative to a central portion of a body of the recoater assembly. In still other embodiments, a pair of scoops may be disposed on opposing end portions of a recoater blade and/or recoater assembly to help guide and collect excess powder dispensed onto a build surface.