Additive manufacturing system and method

Abstract

This application relates to additive manufacturing systems and methods. An additive manufacturing system includes one or more processors configured to determine one or more geometric features of each segment of a plurality of segments of a build part at a candidate position relative to an additive manufacturing tool. The one or more geometric features include an angle of incidence between a beam line extending from a beam source and a surface normal of a respective skin of the corresponding segment adjacent to the beam line. The one or more processors are configured to control the additive manufacturing tool to direct a focused energy beam from a first direction relative to the build part to form a first segment of the segments of the build part and to direct the focused energy beam from a second direction relative to the build part to form a second segment of the segments of the build part based on the one or more geometric features.

Description

Technical Field

[0001] The embodiments of this disclosure generally relate to additive manufacturing of three-dimensional building parts. Background Technology

[0002] Additive manufacturing refers to any process that manufactures three-dimensional building parts in which continuous layers of base material are deposited under computer control. The deposited layers are selectively fused together by the application of a focused energy beam (such as a laser), which heats and bonds the material. The size and shape of the building part can be based on a three-dimensional computer model or another electronic data source. Additive manufacturing can be used to create objects with complex structures and shapes. Compared to conventional metal manufacturing techniques such as die casting, extrusion, etc., additive manufacturing techniques for manufacturing metal building parts allow for greater design freedom and produce more accurate and repeatable finished products.

[0003] The setup for the additive manufacturing build process includes selecting the design of the build part to be built, specifying the position of the build part on the build platform, and generating a build plan for constructing the build part based on the selected design and the specified position relative to the platform. Positioning can refer to the location of the build part relative to the build platform, such as relative to the center and / or edge of the platform, and the planned orientation of the build part relative to the platform, such as the direction of rotation and / or angular direction (e.g., tilt or ramp) about the vertical axis of the build part. The build plan controls the performance of the additive manufacturing tooling during the build process. The build plan can specify a series of actions performed by the tooling, and can also specify parameters and settings. For a focused energy source, the build plan can provide a path along which the emitted energy beam is aimed, along with parameters of the energy beam, such as energy intensity, beam width, or diameter.

[0004] Typically, the location and build schedule of build parts are determined without considering how the positioning of the build part relative to the focused energy source affects the surface and subsurface quality of the build part (e.g., surface roughness and porosity of the component). After the additive manufacturing build process, various finishing tasks can be performed on the manufactured build part, for example, to smooth rough surfaces. Grinding rough surfaces and other finishing tasks to improve the surface quality of the part can be expensive, difficult, time-consuming, and / or labor-intensive, thus reducing manufacturing efficiency and increasing production costs. Additionally, for parts with inaccessible areas, typical post-processing may be ineffective or impossible, and current methods may be insufficient. Furthermore, if the surface quality, subsurface quality, or dimensional accuracy of the build part is sufficiently reduced during additive manufacturing, it may be necessary to scrap the entire build part, which is a waste of time and resources. Summary of the Invention

[0005] In one or more embodiments, an additive manufacturing system is provided, including one or more processors configured to determine one or more geometric features for each of a plurality of segments of a build part at candidate locations relative to an additive manufacturing tool. The one or more geometric features include an angle of incidence between a beamline extending from a source of a focused energy beam and a surface normal of the respective skin of a corresponding segment adjacent to the beamline. The one or more processors are configured to control the additive manufacturing tool based on the one or more geometric features to guide the focused energy beam from a first direction relative to the build part to form a first segment of the build part and to guide the focused energy beam from a second direction relative to the build part to form a second segment of the build part.

[0006] In one or more embodiments, a method (e.g., for additively manufacturing a component) is provided. The method includes determining one or more geometric features of each segment of a plurality of segments of the component at candidate locations relative to an additive manufacturing tool prior to additively manufacturing the component. The one or more geometric features include an angle of incidence between a beamline extending from a source of a focused energy beam and a surface normal of the respective skin of a corresponding segment adjacent to the beamline. The method also includes controlling the additive manufacturing tool based on the one or more geometric features to guide the focused energy beam from a first direction relative to the component to form a first segment of the components, and controlling the additive manufacturing tool based on the one or more geometric features to guide the focused energy beam from a second direction relative to the component to form a second segment of the components.

[0007] In one or more embodiments, an additive manufacturing system is provided, including an additive manufacturing tool and one or more processors. The additive manufacturing tool includes a platform and one or more beam emitters configured to emit focused energy beams from multiple different source locations relative to the platform. The one or more processors are configured to determine one or more geometric features for each of a plurality of segments of a build part at candidate locations relative to the additive manufacturing tool. The one or more geometric features include an angle of incidence between a beamline extending from a corresponding source location in one of the source locations and a surface normal of a respective skin of a corresponding segment adjacent to the beamline. The one or more processors are configured to control one or more beam emitters based on the one or more geometric features to guide the focused energy beam from a first source location relative to the platform to form a first segment of the build part and to guide the focused energy beam from a second source location relative to the platform to form a second segment of the build part. Attached Figure Description

[0008] These and other features, aspects, and advantages of this disclosure will be better understood when the following detailed description is read with reference to the accompanying drawings, in which like reference numerals denote like parts throughout the drawings, wherein:

[0009] Figure 1 This is a schematic diagram of an additive manufacturing system according to an embodiment of the present disclosure;

[0010] Figure 2 A schematic diagram of an additive manufacturing tool within an additive manufacturing system according to an embodiment is shown;

[0011] Figure 3 It shows Figure 2 A close-up of the first sample shown;

[0012] Figure 4 A schematic diagram of an additive manufacturing tool is shown during the first stage of the construction of a single specimen according to an embodiment of the present disclosure;

[0013] Figure 5 It shows in Figure 4 A schematic diagram of the additive manufacturing tooling during the second stage of the construction of the specimen shown;

[0014] Figure 6 It shows in Figure 4 and Figure 5 A schematic diagram of the additive manufacturing tooling in the third stage of the construction of the sample shown;

[0015] Figure 7 A schematic diagram of an additive manufacturing tool according to another embodiment of the present disclosure is shown;

[0016] Figure 8 It shows that according to Figure 1 A schematic diagram of the additive manufacturing tooling of the illustrated embodiment;

[0017] Figure 9 A schematic diagram of an additive manufacturing tool according to another embodiment of the present disclosure is shown;

[0018] Figure 10 A schematic diagram of an additive manufacturing tool according to another embodiment of the present disclosure is shown;

[0019] Figure 11 An additive manufacturing tool according to another embodiment is shown that utilizes optical components to change the orientation of a focused energy beam relative to a building component;

[0020] Figure 12 An additive manufacturing tool according to another embodiment is shown, which utilizes optical components to change the orientation of a focused energy beam relative to a building component; and

[0021] Figure 13This is a flowchart of a method for additively manufacturing a build component during a build process by guiding a focused energy beam in a plurality of different beam directions relative to the build component, according to embodiments of the present disclosure. Detailed Implementation

[0022] The foregoing overview and the following detailed description of certain embodiments will be better understood when read in conjunction with the accompanying drawings. As used herein, elements or steps stated in the singular and preceding the words “a” or “an” should be understood to not necessarily exclude multiple elements or steps. Furthermore, the reference to “an embodiment” is not intended to exclude the existence of additional embodiments that also include the described features. Moreover, unless explicitly stated to the contrary, embodiments that “comprise” or “have” one or more elements having a particular characteristic may include other elements that do not have that characteristic.

[0023] Considering the cost, time, and labor involved in performing surface treatments after the additive manufacturing process, additive manufacturing techniques for building parts offer numerous advantages. These techniques inherently improve surface quality, near-surface quality, and geometric accuracy, thereby eliminating or at least accelerating post-build surface treatments. Embodiments of this disclosure provide systems (e.g., additive manufacturing systems) and methods for controlling the formation of additively manufactured building parts using multiple beam directions relative to the building part. The geometry of the building part and the relative position of the beam sources can affect a stable window of process parameters and thus the quality of the resulting product.

[0024] For example, an additive manufacturing tool is controlled to guide (e.g., emit, reflect, etc.) a focused energy beam from a first source location toward a build component on a platform to form a first segment or portion of the build component, and the additive manufacturing tool is controlled to guide a focused energy beam from a second source location spaced apart from the first source location toward the build component to form a second segment or portion of the build component. In one embodiment, a first beam emitter (e.g., a laser) positioned at the first source location emits a focused energy beam to form the first segment of the build component, and a second beam emitter positioned at the second source location emits a focused energy beam to form the second segment of the build component. In another embodiment, a single beam emitter is configured to move between the first and second source locations such that the same beam emitter emits focused energy beams from multiple different locations relative to the build component to form the first and second segments of the build component. In yet another embodiment, instead of or in addition to moving the beam emitter, the build component is moved relative to the beam emitter and other optical components. Optionally, optical components such as optical mirrors, prisms, etc., may be used to provide additional beam source locations, as the optical components guide the received beam toward the build component.

[0025] By altering the geometric relationship between an energy beam and the geometry of the build part to be manufactured during the build process, the geometric accuracy and surface and near-surface quality of the build part can be improved, relative to maintaining a fixed geometric relationship between the energy beam and the geometry of the build part throughout the build process. In one or more embodiments described herein, the additive manufacturing system determines multiple geometric locations, such as beam source locations, and / or which segments of the build part form from each of multiple beam source locations, based on one or more geometric features of segments of the build part. As described in more detail herein, geometric features may include the angle of incidence of a segment of the build part, the orientation of the segment relative to the upper surface of the platform, etc. The angle of incidence is the angle between a line extending from the beam emitter (e.g., a laser path) to the segment and the surface normal of the skin or side surface of that segment of the build part exactly below the layer to be deposited. The skin used to determine the angle of incidence is defined by the edge of the most recently deposited layer. The system and method can analyze the design of the build part among candidate locations of the build part on the platform to determine one or more geometric features of individual segments or features of the build part. Known additive manufacturing systems do not emit focused energy beams from multiple distinct geometric locations during the build process to form different segments of the build part based on analysis of its geometry, thereby improving part accuracy and quality. These systems do not consider the angle of incidence defined between the beam emitter and the vertical line of the skin just below the top layer of the build part (e.g., the layer to be deposited or the most recently deposited layer). As mentioned above, improving surface quality during the build process can increase manufacturing efficiency and reduce costs by eliminating or at least accelerating post-build surface finishing processes. Another benefit is the ability to form build parts with smoother surfaces (with or without post-processing).

[0026] The build parts described herein refer to both virtual objects designed for additive manufacturing and physical objects produced via the additive manufacturing build process. The location or orientation of a build part within an additive manufacturing tool refers to its position and orientation. For example, location refers to a specific area of ​​the build platform of the additive manufacturing tool, on which build parts are constructed layer by layer. Typically, multiple build parts are built in a common build process, and these build parts are arranged in different locations along the upper surface of the build platform. The orientation of a build part typically refers to the direction in which the build part (to be built) faces and the tilt or ramp of the build part. For example, a build part may be oriented about a longitudinal axis. Orientation may include rotation of the build part about the longitudinal axis. Orientation may also include the tilt or ramp of the longitudinal axis relative to a vertical axis.

[0027] The surface quality of a given surface can refer to surface roughness, the porosity content of the walls defining the given surface, the uniformity of the wall structure and / or composition, etc. Generally, higher quality surfaces of additively manufactured build parts have fewer pores, smaller pores, and are smoother (e.g., less rough) compared to lower quality surfaces. One or more embodiments described herein are configured to produce build parts with desired and / or satisfactory surface and subsurface quality and dimensional accuracy to reduce scrap rates and reduce surface finishing work in post-processing after the build process.

[0028] Figure 1 This is a schematic diagram of an additive manufacturing system 100 according to one embodiment. The additive manufacturing (AM) system 100 includes an additive manufacturing (AM) tool 101, a control unit 108, an input device 134, and a display device 136. The control unit 108 can control the operation of the AM tool 101. The input device 134 and / or the display device 136 are optional components. The AM tool 101 includes a build platform (or plate) 102, a housing 104, a beam emitter 106, and a source material coater 117. The platform 102 is a plane of the AM tool 101 and can be represented by a plate, the lower wall of the housing 104, etc. The AM tool 101 performs an additive manufacturing build process to form three-dimensional build parts 116. Each build part 116 is built from the upper surface 110 of the platform 102 by selectively depositing source material 111 in successive layers 114 and fusing the source material 111 at designated locations according to a build plan 132. Each layer 114 can be relatively thin, for example, no more than 0.5mm, no more than 0.25mm, no more than 0.1mm, etc.

[0029] Figure 1 The AM system 100 can be used to perform a variety of additive manufacturing processes. Suitable additive manufacturing processes can include, for example, material extrusion (e.g., fused wire deposition modeling), barrel photopolymerization (e.g., stereolithography, digital light processing, continuous digital light processing, light-emitting diodes, etc.), powder bed fusion (e.g., multi-jet fusion, selective laser sintering, etc.), material jetting (e.g., material jetting, nanoparticle jetting, on-demand dripping, etc.), selective laser melting, and binder jetting. All of these processes involve depositing a layer of material on a build surface and fusing selective portions of the material using an energy and / or polymer binder (based on a CAD pattern scanned surface).

[0030] Source material 111 may be in powder form. In a non-limiting example, the powder includes one or more metal particles, flakes, etc. The powder may also optionally include a non-metallic filler material mixed with the metallic material. The metallic material may include various metal types, such as aluminum, stainless steel, copper, nickel, cobalt, titanium, etc., and alloys of various metal types. Possible non-metallic fillers in the powder may include ceramics, polymers (e.g., plastics), silica, etc. The powder deposited but not fused to form part of the build component 116 defines a powder bed 122 of unused material 111 contained within the walls 112A, 112B of the housing 104. In an embodiment, the build component 116 is encapsulated within the powder bed 122 during the build process. In an alternative embodiment, source material 111 does not contain metal.

[0031] The build member 116 is gradually formed or constructed by accumulating a surface layer 114 along the build axis 126 in the build direction 124. The build member 116 grows in the build direction 124 as material 111 is successively added to the top of the build member 116 each time. The build direction 124 extends away from the platform 102. In the illustrated embodiment, the build axis 126 is orthogonal to the plane of the upper surface 110 of the platform 102.

[0032] AM system 100 creates new layers of build component 116 by dispersing a thin layer or layer of powder material 111 over the top of the build component 116. For example, the source material coater 117 of AM system 100 deposits each layer 114 of material 111. The source material coater 117 includes or represents a spreader or recoater device that uniformly disperses a thin layer of material 111, an injector for injecting material 111, etc. Material 111 can be stored in a reservoir before use. The source material application 117 is controlled by control unit 108.

[0033] The beam emitter 106 is then controlled by the control unit 108 to emit a focused energy beam toward the source material 111 in the top surface layer 114. The high-energy beam delivers energy to a designated portion of the material 111 struck by the beam, causing that designated portion to fuse (e.g., melt and adhere) into a solidified mass of the build part 116. The result is the formation of a new surface layer or portion of the build part 116. The focused energy beam is electromagnetic energy. For example, the beam emitter 106 could be a laser device that generates a high-energy laser beam. The beam emitter 106 can be suspended above the top of the powder bed 122, for example, about 0.5 meters (m) above the upper surface 110 of the platform 102. The focused energy beam emitted from the beam emitter 106 is aimed and / or directed to different locations on the powder bed 122 to fuse different selected portions of the top surface layer 114 to the build part 116. The beam emitter 106 may include a scanning head 142 capable of directing the beam to different locations within a designated coverage area without requiring movement (e.g., repositioning) of the beam emitter 106 relative to other components of the AM tool 101. The orientation of the scanning head and parameters of the energy beam (e.g., timing, energy intensity, beam width, etc.) can be controlled via control signals through a control unit 108. This process is repeated continuously according to the instructions in the build plan 132 until the build piece 116 is fully formed.

[0034] AM tool 101 is configured such that a focused energy beam can be emitted toward build component 116 from multiple different source locations relative to build component 116 on platform 102. Figure 1 In this embodiment, only one beam emitter 106 is shown, and the beam emitter 106 is movable (e.g., translateable) relative to the build member 116 and the platform 102 to change the beam source position. The beam emitter 106 may be mechanically connected to an actuator 140 and mounted to a rail or frame 144 defining a track. The actuator 140 may be controlled by a control unit 108 to selectively position the beam emitter 106 at different locations along the length of the track. For example, the actuator 140 may cause the beam emitter 106 to move along the track or frame 144 toward a first wall 112A and / or toward a second wall 112B of the housing 104. The movement of the beam emitter 106 along the track or frame 144 is independent of the operation of the scanning head 142 of the beam emitter 106. In this embodiment, the AM tool 101 has only one beam emitter 106, and the movement of the beam emitter 106 enables the formation of different segments of the build member 116 from different beam source positions. In an alternative embodiment, AM tool 101 includes one or more reflective surfaces that serve as relay components. These reflective surfaces may be spaced apart from beam emitter 106 to redirect a focused energy beam striking it to platform 102, effectively altering the source position of the energy beam relative to build-up component 116.

[0035] In one or more alternative embodiments, the AM tool 101 has a plurality of beam emitters 106. In a first alternative embodiment, each of the plurality of beam emitters 106 is fixed in a different fixed position (e.g., non-translatable), and the control unit 108 selectively controls the beam emitters 106 to provide focused energy beams from different source locations. For example, in the first alternative embodiment, the AM tool 101 may lack the actuator 140 and the track or frame 144. In a second alternative embodiment, similar to... Figure 1 The beam emitter 106 shown is at least one of the plurality of beam emitters 106 that is translational relative to other components of the AM tool 101. For example, the AM tool 101 may include at least one translational beam emitter 106 and at least one non-translatable beam emitter 106, or it may include a plurality of translational beam emitters 106 without any non-translatable beam emitters 106.

[0036] The AM tool 101 can be controlled to form one or more external supports 120 during the build process to structurally support the overhanging features of the build component 116. The one or more external supports 120 are additively formed in the same build process as the build component 116. For example, both the build component 116 and the external supports 120 consist of a series of stacked material layers fused together during the additive manufacturing process. Optionally, the internal structure (e.g., density, lattice, etc.) and / or material composition of the external supports 120 may differ from that of the build component 116. For example, the structure of the external supports 120 may be less dense than that of the build component 116.

[0037] Control unit 108 represents hardware circuitry that includes or is connected to one or more processors 118 (e.g., one or more microprocessors, integrated circuits, microcontrollers, field-programmable gate arrays, etc.) that perform the operations described in connection with control unit 108. The one or more processors 118 may operate based on programming instructions. The term "processor" in this document refers to one or more processors, which may include a single processor or multiple processors, without limiting the scope to the requirement of multiple processors 118. Control unit 108 also includes a tangible and non-transitory computer-readable storage medium (e.g., memory) 130. Memory 130 may store programming instructions (i.e., software) instructing the operation of processor 118. For example, memory 130 stores a build plan 132 associated with a build component 116 being manufactured.

[0038] The memory 130 may also store a component design 138 file for the building component 116. The component design 138 file may be a computer-aided design (CAD) file or another data file describing the physical characteristics of the building component 116, such as its shape, dimensions, and / or composition. A build plan 132 may be generated based on the component design 138 file. The build plan 132 may be a data file instructing the AM tool 101 on parameters, conditions, settings, and / or operations to generate the physical building component 116, which is a copy or match of the virtual component defined by the component design 138 file. One or more parameters or settings characterized by the build plan 132 may include the positioning of the building component 116 on the platform 102, a series of actions taken by the AM tool 101 for the building component 116, the position of the support 120, etc. As specified in build plan 132, a series of actions taken by AM tool 101 may include when and where actuator 140 moves beam emitter 106 (if beam emitter is translational) and / or platform 102 (if platform is translational), a specified scan path along which scan head 142 of each emitter 106 will guide a focused energy beam from each corresponding beam source location, and parameters of the focused energy beam (e.g., timing, energy intensity, beam width, etc.). Additional parameters specified in build plan 132 may include settings such as offset, layer thickness, airflow parameters, etc. Control unit 108 (e.g., its processor 118) controls the operation of one or more beam emitters 106, source material coater 117, and / or other components, according to build plan 132, to generate build part 116 at selected locations on platform 102 according to the proposed design.

[0039] The processor 118 of the control unit 108 can be communicatively connected to the input device 134 and the display device 136. The input device 134 may include a touchpad, touchscreen, keyboard, mouse, physical buttons, joystick, etc. The input device 134 enables the operator to provide commands to the AM system 100. In a non-limiting example, the operator can use the input device 134 to select a part design 138 file, select candidate locations for building part 116 on platform 102 to initiate a build process, and / or select or adjust other settings and parameters of the AM tool 101. The display device 136 includes a display screen configured to display a graphical user interface. Optionally, the input and display devices 134, 136 may be integrated on devices such as laptops, desktop computers, workstations, tablets, mobile phones, handheld computing devices (e.g., smartphones), etc. The processor 118 can be operatively connected to the input device 134 and / or the display device 136 via a wired or wireless communication path.

[0040] In one embodiment, the processor 118 of the control unit 108 is configured to generate a build plan 132. For example, the processor 118 may access a component design 138 file stored in memory 130. The component design 138 file may be generated from a remote computing device or via local input by an operator on input device 134. The processor 118 may receive user input selecting candidate locations for the build component 116 on platform 102. The processor 118 may generate the build plan 132 based on the design of the build component 116 and the selected location of the build component 116. In an alternative embodiment, instead of generating the build plan 132, the processor 118 implements remote control instructions generated by the AM tool 101. For example, machine instructions may be processed externally by a computer or processing unit and transmitted to the AM tool 101 for execution by the AM tool 101.

[0041] Figure 2 A schematic diagram of an AM tool 101 according to an embodiment is shown. Figure 2 A first specimen 202, a second specimen 204, and a third specimen 206, additively manufactured on the upper surface 110 of platform 102, are shown. Specimens 202, 204, and 206 are discrete and spaced apart from each other, but can represent a single building block (e.g., Figure 1 Different segments of the building block 116 shown will subsequently be joined during the building process. In the illustrated embodiment, specimens 202, 204, and 206 have the same dimensions, shape, and orientation relative to platform 102. Furthermore, specimens 202, 204, and 206 are formed using the same material and parameters as beam emitter 106. Specimens 202, 204, and 206 are encapsulated within powder bed 122. The only difference between specimens 202, 204, and 206 is their positioning relative to AM tool 101 (e.g., beam emitter 106 and platform 102).

[0042] The positioning of specimens 202, 204, and 206 can refer to the position and orientation of specimens 202, 204, and 206 relative to the beam emitter 106. More specifically, positioning can refer to the position and orientation of each of several different segments or layers of specimens 202, 204, and 206 relative to the beam emitter 106. Positioning is characterized by the angle of incidence of each segment of specimens 202, 204, and 206 relative to the beam emitter 106, also known as the angle of incidence at the laser point relative to the normal to the component surface.

[0043] The incident angle 208 is the angle between beamline 210 and line 212, where line 212 represents the surface normal of the surface of each sample segment at the intersection of beamline 210 and the surface. Beamline 210 represents the path of a laser beam or other focused energy beam emitted or to be emitted from beam emitter 106 to the top or surface layer 216 of the corresponding sample segment to create surface layer 216. Surface layer 216 is the most recently formed layer at the top (e.g., end) of a layer stack at a given time. The surface normal is a vector extending orthogonally from a plane tangent to the surface of the segment at the point of impact of the energy beam. The surface normal extends outward from the point of impact. If the surface at the point of impact is horizontal, the plane tangent to that surface is vertical, and the surface normal extends parallel to the horizontal direction from the point of impact. Skin 214 may represent one or more sides or edges of the corresponding sample immediately below surface layer 216 and adjacent to beamline 210. If skin 214 is curved (e.g., non-planar), then line 212 can be perpendicular to the tangent of the curved skin 214 at a location directly below surface layer 216. Since the build-in component is three-dimensional, line 212 of different skin segments of the same or different parts can have different vertical, lateral, and / or longitudinal or depth components relative to beam emitter 106. As described herein, the incident angle 208 is based on the positioning (e.g., position and orientation) of a given segment of the build-in component relative to beam emitter 106. For example, surface normal 212 is influenced by the orientation of skin 214, while beam line 210 is influenced by the position of the segment (e.g., skin 214) relative to beam emitter 106.

[0044] Figure 2 The three specimens 202, 204, and 206 have the same size, shape, and orientation relative to platform 102. In the illustrated embodiment, the first, second, and third specimens 202, 204, and 206 are protruding objects. Each specimen 202, 204, and 206 includes a corresponding lower skin 218 generally facing platform 102 and an upper skin 220 opposite to the lower skin 218. The upper skin 220 generally faces upward away from platform 102. The upper skin 218 and lower skin 220 of each specimen 202, 204, and 206 represent an inclined skin 214, so that the normal 212 is perpendicular to the area or portion of the lower skin 218 and upper skin 220 near surface layer 216.

[0045] The three specimens 202, 204, and 206 have different positions relative to the beam emitter 106, indicated by different incident angles 208. For example, the first specimen 202 defines a first incident angle 208A between a line 212A perpendicular to each of the lower skins 218 and a first beam line 210A. The first specimen 202 defines a second incident angle 208B between a line 212B perpendicular to each of the upper skins 220 and a second beam line 210B. The second specimen 204 defines a third incident angle 208C between a line 212C perpendicular to each of the lower skins 218 and a third beam line 210C. The second specimen 204 defines a fourth incident angle 208D between a line 212D perpendicular to each of the upper skins 220 and a fourth beam line 210D. The third specimen 206 defines a fifth incident angle 208E between a line 212E perpendicular to each of the lower skins 218 and a fifth beam line 210E. The third specimen 206 defines a sixth incident angle 208F between a line 212F perpendicular to each of the upper skins 220 and a sixth beam line 210F. In the illustrated embodiment, the first, third, and sixth incident angles 208A, 208C, and 208F are obtuse angles (e.g., greater than 90 degrees). For reasons provided below, the skin 214 associated with the obtuse incident angle is referred to herein as the outer skin. The second and fifth incident angles 208B and 208E are acute angles (e.g., less than 90 degrees). The skin 214 associated with the acute incident angle is referred to herein as the inner skin. The fourth incident angle 208D is a right angle (e.g., 90 degrees). The skin 214 associated with the right incident angle represents the inflection point or transition zone between the outer and inner skins.

[0046] The orientation of the skin 214 of specimens 202, 204, and 206 relative to platform 102 represents another geometric feature, which can optionally be used to determine one or more source locations of the focused energy beam during the construction process. The orientation of each skin 214 relative to platform 102 can refer to the tilt angle defined between the skin 214 (or a tangent extending from the curved skin 214) and the upper surface 110 of platform 102 (on which specimens 202, 204, and 206 are constructed). The lower skin 218 of the first, second, and third specimens 202, 204, and 206 are all relative to... Figure 2 The platforms 102 in the samples have the same orientation, and the upper skins 202 of the samples 202, 204, and 206 are also relative to each other. Figure 2 Platform 102 in the middle has the same orientation.

[0047] Experimental tests show that the incident angle 208 between beamline 210 and line 212 perpendicular to skin 214 can significantly affect the formation of the constructed part, such as surface quality, near-surface quality, porosity, and dimensional accuracy. For example, in similar... Figure 2In the experimental setup shown, even with all test parameters being the same, the properties of the outer skin with an incident angle of 208 greater than 90 degrees (e.g., surface and near-surface quality, porosity, and dimensional accuracy) were much worse than those of the inner skin with an incident angle of 208 less than 90 degrees. Figure 2 The outer skin shown includes the lower skin 218 of the first sample 202, the lower skin 218 of the second sample 204, and the upper skin 220 of the third sample 206. Figure 2 The inner skin shown includes the upper skin 220 of the first sample 202 and the lower skin 218 of the third sample 206. These results indicate that some lower skin surfaces 218 can be inner skins (e.g., the lower skin 218 of the third sample 206), while other lower skin surfaces 218 can be outer skins (e.g., the lower skins 218 of the first and second samples 202, 204), which have decreased performance relative to the inner skin. Similarly, some upper skin surfaces 220 can be inner skins (e.g., the upper skin 220 of the first sample 202), while other upper skin surfaces 220 can be outer skins (e.g., the upper skin 220 of the third sample 206).

[0048] As suggested in S. Kleistchensky, A. Radwig, K. Friedberger, J. Zuljakum, D. Melhoff, and G. Witte (2015), “Positional Dependence of Surface Roughness of Components in Laser Beam Melting Systems,” 26th International Symposium on Solid Amorphous Machining (SFF), USA, pp. 360-370 (the entire contents of which are incorporated herein by reference), a possible explanation for this phenomenon is that the local absorption of focused beam energy differs due to the varying angle of incidence of the laser beam relative to the geometry of the near-end portion. For example, when forming a surface layer 216 along or near the outer skin surface (e.g., which defines an incident angle 208 greater than 90 degrees), some of the focused beam energy may be absorbed into the underlying powder within the powder bed 122, affecting the molten pool.

[0049] Figure 3 It shows Figure 2 A close-up of the first sample 202 is shown. A laser beam 226 approaches the lower skin 218 of the sample 202 and irradiates the surface layer 216. (As shown) Figure 2 As shown, because the incident angle 208A between the laser beam 226 and the line 212A perpendicular to the lower skin 218 is greater than 90 degrees, the lower skin 218 is classified as the outer skin. The high-energy laser beam 226 melts the source material, forming a molten pool 228. The shape of the molten pool 228 may not accurately fit the part dimensions, at least in the region near the outer skin. For example, Figure 3The molten pool 228 penetrates to a depth 231 exceeding the desired lower skin edge 232 of the sample 202, causing the energy of the beam 226 to be expelled into the powder bed 122. As the material cools and solidifies, the energy absorbed by the powder can cause additional unwanted material to form along the lower skin surface 218, referred to herein as melt extension 230. Melt extension 230 can increase surface roughness (e.g., reduce surface quality), increase porosity, and dimensional errors. Dimensional errors refer to the increase in thickness or lateral width of the lower skin 218 relative to the thickness / lateral width defined by the desired lower skin edge 232. Note that, at least at the current time during the construction process, the topmost layer(s) including surface layers 216 can be dimensionally accurate. Laser penetration causes the growth of previously formed layers beneath the topmost layer. For example, in Figure 3 In the process, the molten pool 228 causes the melt extension 230 to grow along the layers 234 of the two layers below the surface layer 216. As the additional material layer is formed, the melt extension 230 aggregates during the additive manufacturing process.

[0050] Continue to refer to Figure 2 The incident angle 208B at the upper skin 220 of the first specimen 202 is completely different from the incident angle 208A at the lower skin 218 of the first specimen 202. The incident angle 208B is an acute angle, indicating that the upper skin 220 of the first specimen 202 represents the inner skin. Compared to the outer skin, the inner skin is associated with improved quality characteristics, such as surface quality, near-surface quality, porosity, and dimensional accuracy. The change in quality can be attributed to the geometry of the build-up component beneath the newly deposited surface layer 216. For example, along the laser beam 236... Figure 2 The energy directed by the beam line 210B shown can be absorbed by the partially solidified or consolidated material beneath the first sample 202, resulting in less energy being directed beyond the boundary of the upper skin 220 and into the powder bed 122 (compared to the lower skin 218). Due to the angle of the beam 236 relative to the geometry of the sample 202, the molten pool 238 formed by the laser beam 236 may not penetrate the boundary of the upper skin 220. For example, the molten pool 238 extends at least partially inward toward the lateral center of the sample 202. Essentially, the partially solidified underlying material of the sample 202 is used to absorb more energy from the beam 236 than from the beam 226. As a result, the powder bed 122 along the upper skin 220 is heated less than the powder bed 122 along the lower skin 218, thus resulting in less melt extension and other inhomogeneities along the upper skin surface 220, thereby improving surface and near-surface quality, dimensional accuracy, and porosity relative to the lower skin 218.

[0051] like Figure 2As shown, the incident angle 208D at the upper skin 220 of the second specimen 204 is a right angle, indicating that the beam line 210D is angularly collinear with the upper skin 220, which is located directly beneath the material layer to be deposited or recently deposited. The upper skin 220 of the second specimen 204 represents the critical point or inflection point region between the inner and outer skins. For example, the curved region can represent an angular range between the inner and outer skins. The system disclosed herein can treat the skin in the curved region differently than the inner and outer skins. The curved region can be within a range centered on the inflection point, for example, but not limited to 90 degrees. For example, the curved region can be between 70 and 110 degrees, between 80 and 100 degrees, etc.

[0052] In additive manufacturing, material layers are continuously deposited in a stack according to a specified build geometry, and the angle of incidence of a given skin of the build part relative to a beam emitter can vary over time. For example, Figures 4-6 The diagram illustrates three distinct stages in the construction of a single specimen 240 using the AM tool 101 over time, according to an embodiment. These stages are arranged chronologically, therefore... Figure 4 The stage shown is located in Figure 5 and 6 Before the stage shown, and Figure 5 The stage shown is located in Figure 6 Before the stage shown. Figures 4-6 The effect of constructing a component using platform 102 is shown, which gradually descends (e.g., moves away from beam emitter 106) as additional material layers are deposited. Beam emitter 106 is positioned in the same location at each of the three illustrated stages of the construction process, such that beam emitter 106 does not move. Figure 4-6 The specimen 240 of the building component has a rhomboid shape with parallel linear upper skin 242 and lower skin 244 surfaces.

[0053] The incident angle 246 relative to the beam emitter 106 varies over time based on the geometry of the component on the upper skin 242. As described above, the relevant incident angle 246 is defined between the beam line 248 from the beam emitter 106 and a line 250 perpendicular to the upper skin 242 and close to the current surface layer 252 of the sample 240. Figure 4 In this context, the incident angle 246 is an obtuse angle (e.g., greater than 90 degrees), indicating that the upper skin 242 has an outer skin classification. The quality and / or accuracy of sections of the specimen 240 formed on or near the skin 242 may be reduced, which requires additional finishing steps after manufacturing to increase smoothness and / or provide proper dimensional alignment.

[0054] Figure 5 This shows that platform 102 has been moved, and... Figure 4 Following the stage shown, an additional portion 254 of the specimen 240 has been formed. The additional portion 254 extends from the previous surface layer 252 to the current surface layer 256. In the stage shown, the incident angle 246 based on the upper skin 242 is a right angle, indicating that the upper skin 242 is at an inclination or inflection point between the outer and inner skin classifications. Due to the difference in incident angle 246, the segment of the specimen 240 formed at or near the upper skin 242 at surface layer 256 is expected to have better quality and / or precision than the upper skin 242 at the previous surface layer 252.

[0055] Figure 6 The distance traveled by platform 102 is shown. Figure 5 The fixed beam emitter 106 shown is further away, and... Figure 5 Following the stage shown, an additional portion 260 of the specimen 240 is formed. The additional portion 260 extends from the previous surface layer 256 to the current surface layer 262. In the stage shown, the incident angle 246 based on the upper skin 242 is an acute angle (e.g., less than 90 degrees), indicating that the upper skin 242 has an inner skin classification. Due to the difference in incident angle 246, the segment of the specimen 240 formed at or near the upper skin 242 at surface layer 262 is expected to have better quality and / or accuracy than the upper skin 242 at the previous surface layers 256, 252. Figures 4-6 As shown, as the rhomboid specimen 240 becomes taller and the position of the surface layer changes relative to the beam emitter 106, the upper skin 242 can transition from representing the outer skin to the inner skin, and vice versa. Therefore, the geometry and design of the build component are evaluated across multiple layers to determine the effect of the incident angle on the build component. Optionally, each layer of the build component geometry along the skin surface is evaluated to classify it as an outer skin, inner skin, or inflection point.

[0056] Figure 7 A schematic diagram of an additive manufacturing (AM) tool 101 according to a second embodiment of the present disclosure is shown. The AM tool 101 is in the process of additively manufacturing a build part 302 on a platform 102. In the illustrated embodiment, the build part 302 has an asymmetrical shape. The build part 302 is formed according to the systems and methods described herein, taking into account the geometry of the build part relative to a beam source, to determine multiple relative positions of the build part 302 relative to one or more beam emitters during the building process.

[0057] In the illustrated embodiment, the AM tool 101 includes a first beam emitter 106A and a second beam emitter 106B. The beam emitters 106A and 106B are spaced apart from each other. The first beam emitter 106A is located at a first source position 314, and the second beam emitter 106B is located at a second source position 316. For example, the beam emitters 106A and 106B are located near corresponding first and second walls 112A and 112B of the housing 104. The beam emitters 106A and 106B may be located on or near opposite sides or corners of the three-dimensional AM tool 101. For example, the first beam emitter 106A may be located at or near a corner of the housing 104, while the second beam emitter 106B may be located at or near a diagonal of the housing 104. In this embodiment, the coverage areas of the beam emitters 106A and 106B overlap. The coverage area of ​​a beam emitter refers to the area where the individual scanning heads of the beam emitters can guide a focused energy beam to any location. The coverage area is based on the position of the beam emitter and the function of the scanning head and other beam control elements. Optionally, the coverage area of ​​the first beam emitter 106A may substantially overlap with the coverage area of ​​the second beam emitter 106B, such that the overlapping portion represents at least a majority of each coverage area. In the illustrated embodiment, the first and second beam emitters 106A, 106B are non-translatable relative to the platform 102, such that the beam emitters 106A, 106B are fixedly fixed at their respective source positions 314, 316. Alternatively, at least one of the beam emitters 106A, 106B may be controllably translated relative to the platform 102. Optionally, the platform 102 may be translational. For example, similar to... Figures 4-6 The mobile platform 102 described herein can be controlled to move away from the beam emitters 106A and 106B.

[0058] In one or more embodiments, the control unit 108 (in) Figure 1 The processor 118 (shown in the diagram) is configured to analyze the geometry (e.g., geometric design) of the build part 302 and select locations of the build part 302 on the platform 102 to determine the geometric features of the individual segments of the build part 302. The geometry and / or location can be provided in a part design 138 file accessible to the processor 118. Alternatively, an operator can use a user input device 134 to select the location. Although... Figure 7 The build component 302 is shown to be at least partially formed on platform 102, but the analysis process described herein can be performed by processor 118 before the additive manufacturing build process begins.

[0059] Processor 118 is configured to determine one or more geometric features of each of a plurality of segments or sections of build part 302 based on the geometry of build part 302 relative to AM tool 101 and the selected location, to determine which source locations 314, 316 are used to form the specified segments during the build process. The purpose of the analysis is to select the beam source location that is expected to provide improved (or at least satisfactory) quality and accuracy of the resulting segments of the build part. One or more geometric features include the beam source location that emits a focused energy beam and the angle of incidence of a line perpendicular to the skin (exactly below the surface layer of the segment (within a specified number of layers)). The system described herein is configured to select the beam source location based on the angle of incidence, which is expected to provide improved quality and accuracy compared to using only a single beam source location or using multiple beam source locations without considering the angle of incidence.

[0060] Based on the geometry of the build component 302, one or more processors 118 can divide the build component 302 into different constituent segments. In the illustrated embodiment, the build component 302 is divided into multiple contour segments 304, 306, 308, 310 and fill segments 312, which in Figure 7 The sections are defined by dashed lines. A first section 304 includes a vertically oriented skin. A second section 306 is formed on top of the first section 304 and includes an upper skin. A third section 308 defines a lower skin intersecting the second section 306. A fourth section 310 defines an upper skin below the third section 308, such that the third section 308 is formed on top of the fourth section 310. A filler section 312 is laterally disposed between the first and fourth sections 304, 310 and between the second and third sections 306, 308. The filler section 312 may be filled with a bulk material having properties different from the material deposited to form the contour sections 304, 306, 308, 310. Optionally, the mechanical structure of the filler section 312, such as a mesh structure, may differ from the mechanical structure of the contour sections 304, 306, 308, 310, regardless of whether the material properties of the filler section and the contour section are the same. Note that contour segments 304, 306, 308, and 310 define different outer surfaces of the building component 302. Although the outer surfaces are... Figure 7 The middle part is linear, but the building part 302 can have a curved skin / surface.

[0061] In an embodiment, processor 118 can analyze the angle of incidence defined between each segment of the build component and each potential beam source location to select which beam source location to use to emit a focused energy beam to the segment to form one or more layers on the segment. For example, processor 118 can calculate the angle of incidence between a first beam source location 314 and a first segment 304, and between a second beam source location 316 and the first segment 304. Processor 118 can select which beam source location 314, 316 to use to form the first segment 304 based at least in part on the comparison of the angles of incidence. In an embodiment, because the inner skin has been determined to provide the desired surface and near-surface quality, porosity, and dimensional accuracy, processor 118 can select a beam source location associated with an angle of incidence less than 90 degrees as the location to be used during the build process. In an embodiment, if both angles of incidence at the first and second source locations 314, 316 are less than 90 degrees, such that both skin surfaces would be classified as inner skin, processor 118 can select the beam source location with the smallest angle of incidence. A smaller incident angle may result in less energy being directed from the surface layer into the surrounding powder bed, thus improving surface quality compared to laser beams emitted from other beam source locations.

[0062] The processor 118 can be configured to consider secondary factors in addition to the angle of incidence to determine the beam source location for forming a corresponding segment (e.g., without needing to select the source location solely based on the angle of incidence). Secondary factors may include the respective efficiencies of the different beam emitters 106A, 106B, the respective workload and / or capability of the beam emitters 106A, 106B, the presence of any intervening gas clouds or other potential interferences, etc. For example, secondary factors can be used as a deciding factor when selecting among multiple source locations with similar angles of incidence. For instance, if the angle of incidence associated with the first beam emitter 106A is 60 degrees and the angle of incidence associated with the second beam emitter 106B is 45 degrees, then even if the angle of incidence is greater than that of the second beam emitter 106B, if the secondary factors favor the first beam emitter 106A, the first beam emitter 106A can be selected to form a given segment.

[0063] In the illustrated embodiment, as a result of analysis, processor 118 may select a first beam emitter 106A at a first source location 314 to form a first segment 304 of the building member 302. For example, since the incident angle 318 at the first source location 314 is an acute angle, the vertically oriented skin of the first segment represents the inner skin. Although not shown, the incident angle at a second source location 316 will be an obtuse angle, indicating that the skin of the first segment will represent the outer skin. Therefore, selecting the first beam emitter 106A to emit a focused energy beam toward the first segment 304 is expected to improve surface and near-surface quality, porosity, dimensional accuracy, etc., compared to forming the first segment 304 by emitting an energy beam from a second beam emitter 106B. Based on the incident angle analysis, processor 118 may select the first beam emitter 106A to form a second segment 306 of the building member 302, and select the second beam emitter 106B at the second source location 316 to form the third and fourth segments 308, 310 of the building member 302. Alternatively, the location of the beam source used to form the filling section 312 can be based on considerations other than the incident angle, such as the secondary factors described above. In an embodiment, one or both of the beam emitters 106A and 106B can be used to form the filling section 312, depending on the availability of emitters 106A and 106B and other factors at different stages of the construction process.

[0064] Despite Figure 7 Only one normal line extending from each of the contour segments 304, 306, 308, and 310 is shown, but it has been recognized that the angle of incidence can even vary layer by layer along the linear segments, such as... Figures 4-6 As shown in the illustration. In an embodiment, when determining how to divide the build component 302 into different segments and how to assign these segments to different beam source locations (e.g., locations 314 and 316), the processor 118 can evaluate the geometry of the build component 302 layer by layer.

[0065] After specifying which beam source locations 314, 316 will be used to form each of the segments 304, 306, 308, 310, 312 of the build part 302, the processor 118 can control the AM tool 101 to additively manufacture the build part 302. For example, the processor 118 can generate or at least update the build plan 132 to incorporate associated beam source locations and partial segments. The build plan 132 specifies the operations to be performed by the AM tool 101 to form the build part 302. The build plan 132 can provide a first set of scan paths for a first beam emitter 106A and a second set of scan paths for a second beam emitter 106B. The first set of scan paths outlines the path for the scan head of the first emitter 106A to align a focused energy beam (e.g., beam 320) with segment 306. The second set of scan paths outlines the path for the scan head of the second emitter 106B to align a focused energy beam (e.g., beam 322) with segment 308. The processor 118 can control the components of the AM tool 101 to produce the build part 302 according to the build plan 132. The processor 118 can generate control signals that are transmitted to different components (e.g., beam emitters 106A, 106B, coater device 117, etc.) to control the AM tool 101.

[0066] Despite Figure 7 Two beam emitters 106A and 106B are shown, but the AM tool 101 may optionally include three or more emitters disposed at different designated locations on the AM tool 101. For example, the tool 101 may have three emitters 106 arranged at the same height from the platform 102 to form an equilateral triangle. In another example, the tool 101 may have four emitters 106 arranged at each of the four corners of the housing 104 or along each of the four sides. The above analysis can be performed to determine which of the three or more emitters 106 is best positioned to emit a beam to form the various segments of the building component.

[0067] Figure 8 It shows Figure 1 A schematic diagram of an additive manufacturing (AM) tool 101 according to a first embodiment of the present disclosure is shown. Figure 8 In the AM tool 101, a beam emitter 106 is included, which is translatable relative to other components of the AM tool 101, such as platform 102. (The text abruptly ends here, seemingly mid-sentence.) Figure 1 As shown, the beam emitter 106 is mounted on a track or frame 144 and is moved by an actuator 140. The actuator 140 may be an electric device controlled by a control unit 108 (in... Figure 1The processor 118 (shown in the diagram) controls the beam emitter 106. The actuator 140 can cause the beam emitter 106 to roll or slide along a track defined by the track or frame 144. The actuator 140 can selectively position the beam emitter 106 at a first source position 314 and a second source position 316.

[0068] In the illustrated embodiment, the beam emitter 106 can be used to form Figure 7 The illustrated build component 302 comprises multiple distinct segments. For example, processor 118 may control actuator 140 to position beam emitter 106 at a first source position 314 to emit a focused energy beam 320 toward the surface layer 216 of a second segment 306 to form segment 306. Processor 118 may then control actuator 140 to move beam emitter 106 along a track or rack 144 to a second source position 316 to emit a focused energy beam toward a third segment 308. During build, actuator 140 may be controlled to move beam emitter 106 back and forth between the two source positions 314, 316. Optionally, beam emitter 106 may be the sole beam emitter 106 of AM tool 101. In embodiments, the track along track or rack 144 may be linear, causing beam emitter 106 to move in a straight line. Alternatively, the track may be curved and / or rotatable.

[0069] Alternatively, although only two source locations 314, 316 are described, actuator 140 can be configured to move beam emitter 106 along the length of the track to at least three discrete locations. For example, actuator 140 may include a stepper motor or gear assembly that allows actuator 140 to stop at various predetermined locations along the track or frame 144. In a non-limiting example, actuator 140 may be able to selectively position beam emitter 106 at a sufficiently high spatial frequency to allow emitter 106 to be positioned at approximately any location along the length of the track. According to one or more embodiments, processor 118 can be configured to determine or select the beam source location to which beam emitter 106 will be moved during the build process. Processor 118 may select the beam source location based on one or more geometric features, such as the angle of incidence. In a non-limiting example, processor 118 may determine the angle of incidence of various geometric segments of build component 302 relative to each of three or more different intended (e.g., available) source locations. Processor 118 can select, at least in part, which expected source location to use to form each geometric segment based on a comparison of the incident angles. For example, Figure 8 The two source locations 314 and 316 shown can be locations selected by the processor 118 from three or more expected source locations.

[0070] Figure 9A schematic diagram of an additive manufacturing (AM) tool 101 according to a third embodiment of the present disclosure is shown. Figure 9 In, similar to Figure 7 In the illustrated embodiment, the AM tool 101 includes first and second beam emitters 106A and 106B. (The last sentence appears to be incomplete and possibly refers to a different embodiment.) Figure 7 Unlike other components of the AM tool 101, the first beam emitter 106A is centered above the construction platform 102. The first beam emitter 106A can be fixed in a fixed position relative to other components of the AM tool 101, preventing it from moving. The second beam emitter 106B is translatable relative to the platform 102, the first beam emitter 106A, and other components of the AM tool 101. The second beam emitter 106B is mounted to a curved track 502 and is movable along the length of the curved track 502. The curved track 502 can define a closed shape, such as a circle, ellipse, ellipse, rectangle with curved angles, etc. The track 502 can be annular or toroidal, although... Figure 9 In the perspective view, track 502 appears to be elliptical. The curved track 502 can surround the first beam emitter 106A.

[0071] In an embodiment, the second beam emitter 106B can be moved by an actuator to various positions along the length of track 502, emitting a focused energy beam from the length of track 502 toward the build component on platform 102. For example, processor 118 can control the second beam emitter 106B to move along track 502 between a first source position 504 and a second source position 506 during the build process to change the source of the energy beam striking the build component. Simultaneously or sequentially, processor 118 can control the first beam emitter 106A to emit a focused energy beam toward the build component from a fixed central position 508 (which represents a third source position). The first beam emitter 106A can emit a beam toward a segment of the build component that is different from the segment targeted by the second beam emitter 106B.

[0072] Figure 10 A schematic diagram of an additive manufacturing (AM) tool 101 according to a fourth embodiment of the present disclosure is shown. Figure 10 The illustrated embodiments and Figure 1 and Figure 8The illustrated embodiment is similar, except that the AM tool 101 includes two beam emitters 106A, 106B on two separate tracks or racks 144A, 144B. Tracks 144A, 144B are arranged along opposite sides of the housing 104 above the platform 102. The first beam emitter 106A can be selectively positioned at two or more locations along the length of the first linear track or rack 144A, and the second beam emitter 106B can be selectively positioned at two or more locations along the length of the second linear track or rack 144B. Individual actuators (not shown) can be controlled by the processor 118 to move the beam emitters 106A, 106B to different locations.

[0073] In an alternative embodiment, at least one of tracks 144A and 144B is movable relative to platform 102. For example, track 144A may move along... Figure 10 The position of track 144A shown is towards Figure 10 The position of track 144B is extended by another track. This other track may extend perpendicular to the length of track 144B. In yet another embodiment, AM tool 101 includes only a single track 144A and beam emitter 106A (e.g., lacking track 144B and beam emitter 106B), and track 144A is movable as described above to enable the beam emitter 106A to be positioned... Figure 10 The position of the beam emitter 106B shown.

[0074] Figure 11 and Figure 12 An AM tool 101 according to another embodiment is shown, wherein optical components are used to change the direction of a focused energy beam relative to a building component. Figure 11 and Figure 12 In this configuration, a single beam source 800 is used to generate a focused energy beam. Figure 11 In this configuration, a beam source 800 is operatively coupled to a selector device 802, which may include or represent a transparent prism, a block having one or more reflective surfaces, etc. The selector device 802 may be rotatable to change its orientation relative to the beam source 800. Figure 11 The AM tool 101 also includes two scanning heads 804, 806. The scanning heads 804, 806 are spaced apart from each other and mounted above the platform 102. The scanning heads 804, 806 are configured to redirect a focused energy beam 808 toward the platform 102. Each scanning head 804, 806 may include one or more reflective surfaces, such as mirrors.

[0075] In operation, beam source 800 emits an energy beam 808 toward selector device 802. Selector device 802 redirects beam 808 to either a first scanning head 804 or a second scanning head 806. For example, selector device 802 may direct beam 808 toward the first scanning head 804 so that the first scanning head 804 redirects beam 808 to the upper skin segment 810 of the build member 812. Selector device 802 may then direct a subsequent beam 814 toward the second scanning head 806 so that the second scanning head 806 redirects beam 814 to the lower skin segment 816 of the build member 812. By changing the direction of the beams, the incident angles 819 and 820 associated with beams 808 and 814 are acute angles, indicating that both the upper and lower skin surfaces of the build member 812 are classified as inner skin.

[0076] exist Figure 12 In this configuration, the beam source 800 is directly coupled to the scanning head 822. The AM tool 101 also includes a reflector 826 spaced apart from the beam source 800 and the scanning head 822. For example, the reflector 826 may be positioned along the opposite side, end, or corner of the construction housing or housing opposite to the scanning head 822. The reflector 826 is oriented to reflect the beam toward the platform 102. The scanning head 822 is capable of selectively directing a first energy beam 824 directly toward the lower skin section 816 of the construction member 812. The scanning head 822 may selectively direct a second energy beam 828 toward the reflector 826, which redirects the beam 828 toward the upper skin section 810 of the construction member 812. Similar to... Figure 11 In the embodiment shown, the upper and lower skin surfaces of the building component 812 are both Figure 12 It is classified as an inner skin.

[0077] Figure 13 This is a flowchart of method 700, used to additively manufacture a build part by orienting a focused energy beam from multiple different beam orientations relative to the build part during the build process to improve the properties of the build part (e.g., surface and near-surface quality, porosity, and dimensional accuracy). Method 700 may be wholly or at least partially derived from... Figure 1 The AM system 100 shown is executed by one or more processors 118 of the control unit 108. Optionally, operator input may be provided in one or more steps. Optionally, method 700 may include... Figure 13 More steps are shown than Figure 13 The fewer steps shown Figure 13 Different steps not shown, and / or with Figure 13 The different arrangements or sequences of steps are shown.

[0078] Method 700 begins at 702, where, prior to additive manufacturing of the build part, one or more geometric features of each of a plurality of segments of the build part are determined at a candidate location of the build part relative to the additive manufacturing tool. The one or more geometric features include the angle of incidence between a beamline extending from an electromagnetic energy source of the additive manufacturing tool and a surface normal of the respective skin of the corresponding segment approaching the beamline.

[0079] At 704, the additive manufacturing tool is controlled to guide a focused energy beam from a first direction relative to the build component to form a first segment of the build component. Guiding the focused energy beam from the first direction is based on one or more geometric features of the first segment. For example, guiding the focused energy beam from the first direction may be in response to determining that the angle of incidence defined by a beamline extending from the first direction into the first segment is an acute angle. Furthermore, guiding the focused energy beam from the first direction into the first segment may be in response to determining that the angle of incidence defined by a beamline extending from the first direction into the first segment is smaller than the angle of incidence defined by a beamline extending from a second direction into the first segment.

[0080] At point 706, the additive manufacturing tool is controlled to guide a focused energy beam from a second direction relative to the building part to form a second segment of the building part. Guiding the focused energy beam from the second direction is based on one or more geometric features of the second segment. For example, guiding the focused energy beam from the second direction may be in response to determining that the angle of incidence defined by a beamline extending from the second direction to the second segment is an acute angle. Furthermore, guiding the focused energy beam from the second direction to the second segment may be in response to determining that the angle of incidence defined by the beamline extending from the second direction to the second segment is smaller than the angle of incidence defined by the beamline extending from the first direction to the second segment.

[0081] An AM tool includes one or more beam emitters and one or more actuators controlled to move the beam emitters between different source locations. In one embodiment, one actuator moves a beam emitter to a first source location, where the beam emitter at the first source location emits a focused energy beam to form a first segment of the building component. The actuator is controlled to move the (same) beam emitter to a second source location, whereby the beam emitter emits a focused energy beam to form a second segment of the building component. Alternatively, a first beam emitter of a plurality of beam emitters is positioned at the first source location and controlled to emit a focused energy beam toward the first segment of the building component to form the first segment. A second beam emitter of the plurality of beam emitters is positioned at a second source location and controlled to emit a focused energy beam toward the second segment of the building component to form the second segment. The first and second source locations are determined based on one or more geometric features of the first and second segments, respectively.

[0082] Although various spatial and directional terms, such as top, bottom, lower, middle, side, horizontal, vertical, front, etc., are used to describe embodiments of this disclosure, it should be understood that these terms are used only relative to the orientation shown in the accompanying drawings. The orientation may be reversed, rotated, or otherwise changed such that upper is lower, or vice versa, horizontal becomes vertical, etc.

[0083] The embodiments illustrated herein show one or more control or processing units, such as Figure 1 The control unit 108 shown herein. It should be understood that a control or processing unit represents a circuit, a portion thereof, implemented as hardware having relevant instructions (e.g., software stored on a tangible and non-transitory computer-readable storage medium, such as a computer hard disk drive, ROM, RAM, etc.) to perform the operations described herein. The hardware may include state machine circuitry hardwired to perform the functions described herein. The hardware may include electronic circuitry comprising and / or connected to one or more logic-based devices, such as microprocessors, processors, controllers, etc. Optionally, control unit 108 or one or more processors 118 represent one or more processing circuits such as field-programmable gate arrays (FPGAs), application-specific integrated circuits (ASICs), microprocessors, quantum computing devices, etc. The circuitry in the various embodiments is configured to execute one or more algorithms to perform the functions described herein. One or more algorithms include aspects of the embodiments disclosed herein, whether or not explicitly identified in the flowcharts or methods.

[0084] As used herein, the term "control unit" and the like include any processor-based or microprocessor-based system, including systems using microcontrollers, reduced instruction set computers (RISC), application-specific integrated circuits (ASICs), logic circuits, and any other circuitry or processor (including hardware, software, or a combination thereof) capable of performing the functions described herein. This is merely illustrative and is therefore not intended to limit the definition and / or meaning of these terms in any way. Figure 1 The illustrated control unit 108 is configured to execute a set of instructions stored in one or more storage elements (such as one or more memories) to process data. The instruction set includes various commands that instruct the control unit 108, acting as a processor (e.g., its processor 118), to perform specific operations, such as the methods and processes of various embodiments of the subject matter described herein. In embodiments, the instruction set is in the form of a software program. The processor's processing of input data is in response to user commands, the results of previous processing, or a request made by another processor. As used herein, the term "software" includes any computer program stored in memory for execution by a computer, including but not limited to RAM memory, ROM memory, EPROM memory, EEPROM memory, and non-volatile RAM (NVRAM) memory.

[0085] As used herein, structures "configured" to perform tasks or operations are structurally formed, constructed, or adjusted in a manner specifically corresponding to the task or operation. For clarity and to avoid ambiguity, objects that can only be modified to perform tasks or operations are not "configured" to perform the tasks or operations used herein.

[0086] It should be understood that the above description is intended to be illustrative and not limiting. For example, the above embodiments (and / or aspects thereof) can be used in combination with each other. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of the various embodiments of this disclosure without departing from the scope of the invention. Although the dimensions and types of materials described herein are intended to define parameters of the various embodiments of this disclosure, these embodiments are by no means limiting, but rather exemplary embodiments. Many other embodiments will be apparent to those skilled in the art upon review of the above description. Therefore, the scope of the various embodiments of this disclosure should be determined by referring to the appended solutions and the full scope of their equivalents. In the appended solutions, the terms “comprising” and “wherein” are used as common English equivalents of the corresponding terms “including” and “wherein”. Furthermore, the terms “first,” “second,” and “third,” etc., are used only as labels and are not intended to impose numerical requirements on their objects. Furthermore, unless and until such a limitation of a technical solution explicitly uses the phrase “means for…” followed by a functional statement without further structure, the following limitation of a technical solution is not written in a “function plus function” form and is not intended to be interpreted in accordance with the provisions of Section 112(f) of Title 35 of the United States Code.

[0087] This written description uses examples to disclose various embodiments of this disclosure, including the best mode, and also enables any person skilled in the art to practice the various embodiments of this disclosure, including making and using any device or system and performing any combined methods. The patentable scope of the various embodiments of this disclosure is defined by the technical solution and may include other examples that would occur to a person skilled in the art. Such other examples are intended to be within the scope of the technical solution if they have structural elements that are not different from the literal language of the technical solution, or if they include equivalent structural elements that are not substantially different from the literal language of the technical solution.

Claims

1. An additive manufacturing system, comprising: One or more processors are configured to determine one or more geometric features for each of a plurality of segments of a build component at a candidate location relative to an additive manufacturing tool. The one or more geometric features, for a corresponding segment, include an angle of incidence between a beamline extending from the source of a focused energy beam to a surface layer of the build component in the corresponding segment and a surface normal of the respective skin of the corresponding segment adjacent to the beamline, wherein the skin of the corresponding segment is one or more sides of the build component immediately below the surface layer. The one or more processors are configured to control the additive manufacturing tool based on the one or more geometric features, in response to determining that the incident angle defined by a beamline extending from a first direction toward a first segment of the building member is an acute angle, to guide a focused energy beam from a first direction relative to the building member to form a first segment of the building member, and to guide a focused energy beam from a second direction relative to the building member to form a second segment of the building member.

2. The additive manufacturing system according to claim 1, wherein, The one or more processors are configured to generate a build plan based on the one or more geometric features, wherein the build plan specifies the operations to be performed by the additive manufacturing tool to form the build part.

3. The additive manufacturing system according to claim 1, wherein, In response to determining that the angle of incidence defined by a beam line extending from the first direction toward the first segment of the building component is smaller than the angle of incidence defined by a beam line extending from the second direction toward the first segment of the building component, the one or more processors control the additive manufacturing tool to guide the focused energy beam from the first direction to form the first segment.

4. The additive manufacturing system according to claim 1, wherein, In response to determining that the angle of incidence defined by the beam line extending from the second direction toward the second segment of the building component is an acute angle, the one or more processors control the additive manufacturing tool to guide the focused energy beam from the second direction to form the second segment of the building component.

5. The additive manufacturing system according to claim 1, wherein, The one or more processors are configured to control the additive manufacturing tool to direct the focused energy beam from a first source location to a first segment of the building component and to direct the focused energy beam from a second source location to a second segment of the building component, the first source location and the second source location being spaced apart from each other relative to the additive manufacturing tool.

6. The additive manufacturing system according to claim 5, wherein, The first source position and the second source position are located at opposite angles or opposite sides of the additive manufacturing tool.

7. The additive manufacturing system according to claim 1, wherein, The one or more processors are configured to control the additive manufacturing tool to form the first segment of the building component by controlling a first beam emitter to emit the focused energy beam from the first direction toward the first segment. The one or more processors are configured to control the additive manufacturing tool to form the second segment of the building component by controlling a second beam emitter to emit the focused energy beam from the second direction toward the second segment.

8. The additive manufacturing system according to claim 7, wherein, The coverage area of ​​the first beam emitter along the additive manufacturing tool overlaps with the coverage area of ​​the second beam emitter.

9. The additive manufacturing system according to claim 1, wherein, The additive manufacturing tool includes a beam emitter and an actuator, wherein the actuator is configured to move the beam emitter relative to the build component between a first source position and a second source position, and The one or more processors are configured to control the actuator to position the beam emitter at a first source location to emit the focused energy beam to form a first segment of the building component, and to position the beam emitter at a second source location to emit the focused energy beam to form a second segment of the building component.

10. The additive manufacturing system according to claim 9, wherein, The beam emitter is movable along a track, and the track is movable relative to the platform of the additive manufacturing tool.

11. The additive manufacturing system according to claim 9, wherein, The beam emitter can move along a linear track.

12. The additive manufacturing system according to claim 9, wherein, The beam emitter can move along a curved track.

13. The additive manufacturing system according to claim 9, wherein, The beam emitter is a first beam emitter, and the additive manufacturing tool further includes a second beam emitter, wherein the one or more processors are configured to control the second beam emitter to emit a focused energy beam from a third source location spaced apart from the first source location and the second source location to form a third segment of the building component.

14. An additive manufacturing method, comprising: Before additively manufacturing the component, one or more geometric features are determined for each of a plurality of segments of the component at a candidate location relative to the additive manufacturing tool. The one or more geometric features for the corresponding segment include the angle of incidence between a beamline extending from the source of a focused energy beam to the surface layer of the component in the corresponding segment and the surface normal of the respective skin of the corresponding segment adjacent to the beamline, wherein the skin of the corresponding segment is one or more sides of the component immediately below the surface layer. The additive manufacturing tool is controlled based on the one or more geometric features, and in response to determining that the angle of incidence defined by a beamline extending from a first direction toward a first segment is acute, a focused energy beam is guided from a first direction relative to the building component to form a first segment of the building component; and The additive manufacturing tool is controlled based on one or more geometric features to guide a focused energy beam from a second direction relative to the building part to form a second segment of the building part.

15. The additive manufacturing method according to claim 14, wherein, In response to determining that the angle of incidence defined by the beam line extending from the second direction toward the second segment is an acute angle, the additive manufacturing tool is controlled to guide the focused energy beam from the second direction relative to the building part.

16. The additive manufacturing method according to claim 14, wherein, In response to determining that the angle of incidence defined by a beam line extending from the first direction toward the first segment is less than the angle of incidence defined by a beam line extending from the second direction toward the first segment, the additive manufacturing tool is controlled to guide the focused energy beam from the first direction.

17. The additive manufacturing method according to claim 14, wherein, The additive manufacturing tool includes a beam emitter and an actuator, and the method further includes controlling the actuator to move the beam emitter between a first source position and a second source position, such that the beam emitter at the first source position emits the focused energy beam to form a first segment of the building component, and the beam emitter at the second source position emits the focused energy beam to form a second segment.

18. The additive manufacturing method according to claim 14, wherein, Controlling the additive manufacturing tool to guide a focused energy beam from the first direction includes controlling a first beam emitter positioned at a first source location to emit a focused energy beam toward the first segment, and controlling the additive manufacturing tool to guide a focused energy beam from the second direction includes controlling a second beam emitter positioned at a second source location to emit a focused energy beam toward the second segment.

19. An additive manufacturing system, comprising: An additive manufacturing tool includes a platform and one or more beam emitters configured to emit focused energy beams from multiple different source locations relative to the platform; as well as One or more processors are configured to determine one or more geometric features for each of a plurality of segments of a build component at candidate locations relative to an additive manufacturing tool. The one or more geometric features, for a corresponding segment of the segment, include an angle of incidence between a beamline extending from a corresponding source location to a surface layer of the build component in the corresponding segment and a surface normal of the respective skin of the corresponding segment adjacent to the beamline, wherein the skin of the corresponding segment is one or more side layers of the build component immediately below the surface layer. The one or more processors are configured to control the one or more beam emitters based on the one or more geometric features, in response to determining that the incident angle defined by a beam line extending from a first direction toward a first segment of the building component is an acute angle, to guide the focused energy beam from a first source position relative to the platform to form a first segment of the building component, and from a second source position relative to the platform to form a second segment of the building component.

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