Freeform Future Corp.

Derek Schmuland

Thomas J Ronacher

Erik Palitsch

Daniel Roszhart Zehr

Tasso Lappas

A metal additive manufacturing system includes a powder bed for powdered metal, a plurality of lasers to generate a plurality of laser beams, and a plurality of scanners to independently steer respective laser beams of the plurality of laser beams into laser-beam clusters on selected portions of a surface of the powder bed. A method of metal additive manufacturing includes generating a plurality of laser beams and independently steering respective laser beams of the plurality of laser beams, using a plurality of scanners, to form laser-beam clusters on selected portions of a surface of a powder bed of powdered metal. Each scanner of the plurality of scanners independently steers a respective laser beam of the plurality of laser beams.

Independent laser-beam steering for laser beamforming in metal additive manufacturing using powder-bed fusion

A 3D printing system uses lasers for manufacturing parts in metal additive manufacturing, such as powder-bed fusion. The lasers may be arranged on a dome-shaped structure, vertically above powdered metal. The dome-shaped structure, and arrangement of the lasers on the dome-shaped structure, permits a higher density of the lasers to be packaged onto the 3D printing system and increases a utilization of the lasers during manufacturing. Mirror(s) allow the lasers to be selectively, and individually, steered towards particular locations within the powdered metal in which the parts are manufactured. Lens(es) may actuate to adjust a spot size of laser beams emitted by the lasers. Imaging sensor(s) may also monitor the powdered metal, such as a melt pool of the powdered metal, for feedback and use in driving and steering the lasers.

Lasing module for 3D printing system

A method of metal additive manufacturing includes generating a plurality of laser beams and directing the plurality of laser beams to selected portions of a surface of a powder bed of powdered metal. The method also includes monitoring the powder bed while performing the generating and directing, and adjusting at least one of the generating or directing based on the monitoring.

Process monitoring and feedback for metal additive manufacturing using powder-bed fusion

A 3D printing system uses heat sources, such as lasers, for manufacturing parts in metal additive manufacturing, such as powder-bed fusion, on one or more movable build modules. The build modules may be moved (e.g., by a conveyor system) into and out of a lasing module. Parts may be manufactured on multiple build modules simultaneously and/or sequentially, in some cases while the build module(s) are moving relative to the heat sources. Sensor(s) are arranged to determine a position, orientation, and/or movement of the build modules and feedback from the sensor(s) may be used to control the heat sources to compensate for motion of the build modules.

3D printing system with moving build module

A metal additive manufacturing system includes a powder bed for powdered metal, a plurality of lasers to generate a plurality of laser beams, and a scanner to steer the plurality of laser beams onto selected portions of a surface of the powder bed. A method of metal additive manufacturing includes generating a plurality of laser beams and steering the plurality of laser beams, using a scanner, onto selected portions of a surface of a powder bed of powdered metal.

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El Segundo, CA, United States of America

Derek Schmuland