Additive manufacturing method and system

Abstract

A method of additive manufacturing a three-dimensional object includes irradiating a first build plane area with a first energy beam defining a beam diameter, the first energy beam traveling along a first oscillating path in a first direction to consolidate a first wall defining a thickness perpendicular to the first direction, wherein build material adjacent a first side of the first wall and build material adjacent a second side of the first wall remain unconsolidated, the second side of the first wall being opposite the first side of the first wall; and wherein the thickness of the first wall is greater than the beam diameter.

Description

Technical Field

[0001] This disclosure relates to additive manufacturing methods and systems, such as additive manufacturing methods and systems for constructing thin walls. Background Technology

[0002] Three-dimensional objects can be additively manufactured using a variety of methods and systems. For example, additive manufacturing can involve a powder bed fusion process, in which one or more energy beams are directed onto a powder bed to melt, fuse, or sinter continuous layers of building materials such as powder materials. The properties of a three-dimensional object formed by consolidating powder materials depend at least in part on one or more parameters of the energy beam. Additionally, one or more parameters of the energy beam influence operating parameters, such as the processing speed of the additive manufacturing process.

[0003] In some additive manufacturing systems, one or more energy beams can be used to construct one or more walls. For example, a wall is constructed by consolidating its outer edge through one or more passes of one or more energy beams. The interior portions of the wall can be further consolidated by using additional passes parallel to the edge or by filling the interior of the wall in other ways using different strobe patterns. One or more additively manufactured walls can include structures that define, for example, the outer surface or interior features of a three-dimensional object, or even provide a mesh support structure to the interior of a three-dimensional object. Attached Figure Description

[0004] The complete and feasible disclosure of this disclosure, including its best mode, is set forth in the specification with reference to the accompanying drawings for those skilled in the art, wherein:

[0005] Figure 1 An exemplary additive manufacturing system according to one or more exemplary aspects of this disclosure is schematically depicted.

[0006] Figure 2 A construction plane according to one or more exemplary aspects of this disclosure is schematically depicted.

[0007] Figure 3 An oscillation of an energy beam according to one or more exemplary aspects of this disclosure is schematically depicted.

[0008] Figure 4 An energy beam having a first oscillating path forming a first wall is schematically depicted according to one or more exemplary aspects of this disclosure.

[0009] Figure 5 An energy beam with a modified first oscillating path forming another first wall is schematically depicted according to one or more exemplary aspects of this disclosure.

[0010] Figure 6An energy beam having multiple oscillating paths forming yet another first wall is schematically depicted according to one or more exemplary aspects of this disclosure.

[0011] Figure 7 Multiple energy beams having multiple oscillating paths forming another first wall and extensions are schematically depicted according to one or more exemplary aspects of this disclosure.

[0012] Figure 8 Multiple energy beams with varying oscillation paths, forming yet another first wall and extension, are schematically depicted according to one or more exemplary aspects of this disclosure.

[0013] Figure 9 Multiple energy beams having multiple conical oscillating paths forming another first wall and extensions are schematically depicted according to one or more exemplary aspects of this disclosure.

[0014] Figure 10 Multiple energy beams having multiple conical oscillating paths forming another first wall and extensions are schematically depicted according to one or more exemplary aspects of this disclosure.

[0015] Figure 11 A three-dimensional object having multiple intersecting walls is schematically depicted according to one or more exemplary aspects of this disclosure.

[0016] Figure 12 An exemplary method for additive manufacturing of a three-dimensional object according to one or more exemplary aspects of this disclosure is schematically depicted.

[0017] Figure 13 An exemplary control system according to one or more exemplary aspects of this disclosure is schematically depicted, which can be configured to control an additive manufacturing system or machine. Detailed Implementation

[0018] Reference will now be made in detail to the present embodiments of this disclosure, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter names to refer to features in the drawings. The same or similar reference numerals in the drawings and description have been used to refer to the same or similar parts of this disclosure.

[0019] As described herein, the subject matter disclosed herein relates to the use of additive manufacturing machines or systems. As used herein, the term "additive manufacturing" generally refers to a manufacturing technique that produces parts in a layer-by-layer manner. Exemplary additive manufacturing machines can be configured to utilize any suitable additive manufacturing technique. Additive manufacturing machines can utilize additive manufacturing techniques, including powder bed melting (PBF) techniques, such as direct laser metal melting (DMLM), electron beam melting (EBM), selective laser melting (SLM), directional laser metal sintering (DMLS), or selective laser sintering (SLS). In exemplary PBF techniques, thin layers of powder material are sequentially applied to a build plane and then selectively melted or fused together layer by layer to form one or more three-dimensional objects. Additively manufactured objects are typically monolithic in nature and can have various integrated sub-components.

[0020] Additionally or alternatively, suitable additive manufacturing technologies may include, for example, fused deposition modeling (FDM), direct energy deposition (DED), laser engineered net-shape (LENS), laser net-shape manufacturing (LNSM), direct metal deposition (DMD), digital light processing (DLP), and other additive manufacturing technologies that utilize energy beams or other energy sources to solidify additive manufacturing materials (e.g., powder materials). In fact, any suitable additive manufacturing approach can be used in conjunction with the subject matter currently disclosed.

[0021] Additive manufacturing technology can generally be described as manufacturing objects by building them up point by point, line by line, and layer by layer, typically in a vertical direction. Other manufacturing methods are conceivable and are within the scope of this disclosure. For example, while the discussion herein involves adding material to form continuous layers, the subject matter of the present disclosure can be practiced with any additive manufacturing technology or other manufacturing technology, including layer-adding processes, layer-subtracting processes, or hybrid processes.

[0022] The additive manufacturing process described herein can be used to form parts using any suitable material. For example, the material can be a metal, ceramic, polymer, epoxy resin, photopolymer resin, plastic, or any other suitable material, which can be solid, powder, sheet, wire, or any other suitable form or combination thereof. Additionally or alternatively, exemplary materials may include metals, ceramics, or adhesives, and combinations thereof. Exemplary ceramics may include ultra-high temperature ceramics or precursors of ultra-high temperature ceramics, such as polymer precursors. Each continuous layer may, for example, be between approximately 10 μm and 200 μm, but this thickness can be determined based on any number of parameters and can be any suitable size. Furthermore, the additive manufacturing process described herein can be used to form any type of suitable part. For example, a part formed using the additive manufacturing process described herein may include one or more turbine components, such as turbine blades, shrouds, nozzles, heat shields, or impellers.

[0023] As used herein, the term "build plane" refers to a plane defined by a surface on which an energy beam strikes during the additive manufacturing process to selectively irradiate powder material, thereby consolidating the powder material. Generally, the surface of a powder bed defines the build plane. During the irradiation of a corresponding layer of the powder bed, a previously irradiated portion of that layer may define a portion of the build plane. A build plate supporting the powder bed typically defines the build plane before the powder material is distributed onto the build module.

[0024] As used herein, the term “consolidation” or “consolidation in progress” refers to the solidification of a build material (e.g., a powder material) by irradiation of the build material (including by melting, fusion, sintering, etc.), such that multiple individual build material sheets (e.g., multiple individual powder material sheets) are joined together to form a single structure.

[0025] As used herein, the term "unbonded" refers to individual sheets of material that are not bonded or otherwise joined together, such as individual loose powder sheets.

[0026] It should also be understood that terms such as “top,” “bottom,” “outward,” and “inward” are used for convenience and should not be interpreted as restrictive terms.

[0027] As used herein, the terms “first,” “second,” and “third” are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of the individual components.

[0028] The terms “one” and “a” do not indicate a quantity limitation, but rather the presence of at least one of the items mentioned.

[0029] As used herein throughout the specification and claims, approximate language can be used to modify any quantitative expression that allows for variation without altering its underlying function. Therefore, values ​​modified by terms such as “approximately,” “substantially,” and “approximately” are not limited to specified exact values. In at least some cases, approximate language may correspond to the precision of the instrument used to measure the value, or the precision of the method or machine used to construct or manufacture the part or system. For example, approximate language may refer to a margin of 10%.

[0030] Throughout this specification and claims, scope limitations are combined and interchanged, and such scopes are identified and include all subscopes contained herein, unless otherwise indicated by context or language. For example, all scopes disclosed herein include endpoints, and endpoints may be combined with each other independently.

[0031] This disclosure generally relates to additive manufacturing methods and systems for constructing thin walls for three-dimensional objects. One or more energy beams in such systems can be used to construct walls to define, for example, an outer surface, internal feature, or internal support mesh of a three-dimensional object. However, the minimum achievable wall thickness may be limited by the need for multiple passes of the energy beam. Furthermore, when utilizing multiple passes of the energy beam or multiple energy beams, the uniformity of the solid building material within the wall may be suppressed.

[0032] Therefore, alternative additive manufacturing methods and systems will be welcomed in the field, including additive manufacturing methods and systems that use energy beam oscillations to provide thin walls.

[0033] The topic currently being published will now be described in more detail. Figure 1 An additive manufacturing system 100 is schematically depicted. The additive manufacturing system 100 may include one or more additive manufacturing machines 102. It should be understood that... Figure 1 The additive manufacturing system 100 and additive manufacturing machine 102 shown are provided by way of example and not as limiting. In fact, the subject matter of this disclosure can be practiced with any additive manufacturing system 100 and additive manufacturing machine 102 without departing from the scope of this disclosure. As shown, one or more additive manufacturing machines 102 may include a control system 104. The control system 104 may be included as part of the additive manufacturing machine 102, or the control system 104 may be associated with the additive manufacturing machine 102. The control system 104 may include components integrated as part of the additive manufacturing machine 102 or components provided separately from the additive manufacturing machine 102. The various components of the control system 104 may be communicatively coupled to the various components of the additive manufacturing machine 102.

[0034] The control system 104 can be communicatively connected to the management system 106 or the user interface 108. The management system 106 can be configured to interact with the control system 104 in conjunction with enterprise-level operations associated with the additive manufacturing system 100. Such enterprise-level operations may include transferring data from the management system 106 to the control system 104 or vice versa. The user interface 108 may include one or more user input / output devices to allow users to interact with the additive manufacturing system 100.

[0035] As shown in the figure, the additive manufacturing machine 102 may include a build module 110, which includes a build chamber 112 within which an object or three-dimensional object 114 can be additively manufactured. The additive manufacturing machine 102 may include a powder module 116, which contains a supply source of build material 118 (e.g., powder material) contained within a supply chamber 120. The build module 110 or powder module 116 may be provided in the form of a modular container configured to be installed into and removed from the additive manufacturing machine 102, for example, during an assembly line process. Additionally, or alternatively, the build module 110 or powder module 116 may define fixed components of the additive manufacturing machine 102.

[0036] Powder module 116 contains a supply source of build material 118 housed within supply chamber 120. Powder module 116 includes a powder piston 122 that lifts a powder substrate 124 during operation of additive manufacturing machine 102. As the powder substrate 124 rises, a portion of the build material 118 is ejected from powder module 116. A recoater 126, such as a blade or roller, sequentially distributes thin layers of build material 118 onto a build plane 128 above build module 110. Build platform 130 supports the sequential layers of build material 118 distributed on build plane 128. Build platform 130 may include a build plate (not shown) fixed thereon, on which a three-dimensional object 114 can be additively manufactured.

[0037] The additive manufacturing machine 102 includes an energy beam system 132 configured to generate one or more energy beams 134 and direct them onto a build plane 128 to selectively solidify corresponding portions of a powder bed 136 defining the build plane 128. The energy beam 134 may be a laser beam or a beam from any other suitable energy source, such as an LED or other light source. As the energy beam 134 selectively melts or fuses successive layers of build material 118 defining the powder bed 136, a three-dimensional object 114 begins to take shape. The one or more energy beams 134 or laser beams may include electromagnetic radiation having any suitable wavelength or wavelength range, such as wavelengths or wavelength ranges corresponding to infrared, visible, or ultraviolet light, or combinations thereof.

[0038] Typically, using a DMLM, EBM, or SLM system, the build material 118 is completely melted, with the corresponding layers melting or remelting as the energy beam 134 passes through. Using a DMLS or SLS system, the layers of the build material 118 are typically sintered, usually fusing the particles of the build material 118 together without reaching its melting point. The energy beam system 132 may include components integrated into the additive manufacturing machine 102 or components provided separately from the additive manufacturing machine 102.

[0039] The energy beam system 132 may include one or more irradiation devices 138 configured to generate a plurality of energy beams 134 and direct the energy beams onto the build plane 128. The energy beam system 132 may include a plurality of irradiation devices 138, such as a first irradiation device 138a and a second irradiation device 138b. The one or more irradiation devices 138 may each include an energy beam source 140 (e.g., a first energy beam source 140a and a second energy beam source 140b), an optical assembly 142 (e.g., a first optical assembly 142a and a second optical assembly 142b), and a scanner 144 (e.g., a first scanner 144a and a second scanner 144b). The optical assembly 142 may include a plurality of optical elements configured to direct the energy beams onto the build plane 128. The optical assembly 142 may include one or more optical elements, such as lenses, through which the energy beams can be transmitted from the energy beam source to the build plane along an optical path. For example, the optical assembly 142 may include one or more focusing lenses that focus the energy beams 134 onto the build plane 128. Scanner 144 may include a galvanometer scanner, an electro-optic modulator, an acousto-optic modulator, a piezoelectric driven mirror, etc. Additionally, or alternatively, energy beam system 132 may include a window 146, such as protective glass, that separates one or more components of energy beam system 132 from the environment of processing chamber 148, in which building material 118 is irradiated by one or more energy beams 134 to additively manufacture three-dimensional object 114.

[0040] Window 146 prevents contaminants from fumes associated with the additive manufacturing process, such as powder materials, dust, soot, residues, vapors, byproducts, etc., from contacting sensitive components of the energy beam system 132. Accumulation of contaminants on the various optical elements of the optical assembly 142 may adversely affect the operation of the energy beam system 132 or quality metrics associated with the energy beam system. Additionally, or alternatively, such contaminants may damage the various optical elements of the optical assembly 142.

[0041] like Figure 1 As shown, the energy beam system 132 includes a first irradiation device 138a and a second irradiation device 138b. Additionally, or alternatively, the energy beam system 132 may include any number of additional irradiation devices, such as three, four, six, eight, ten, or more, and such irradiation devices may each include an optical assembly 142. The plurality of irradiation devices 138 may be configured to generate one or more energy beams, each capable of scanning within a scanning field incident on at least a portion of the building plane 128, to selectively solidify those portions of the building material 118 that will become part of the three-dimensional object 114.

[0042] For example, a first irradiation device 138a may generate a first energy beam 134a capable of scanning within a first scan field 150a incident on at least a first build-plane region 152a. A second irradiation device 138b may generate a second energy beam 134b capable of scanning within a second scan field 150b incident on at least a second build-plane region 152b. The first scan field 150a and the second scan field 150b may overlap such that the first build-plane region 152a scanned by the first energy beam 134a overlaps with the second build-plane region 152b scanned by the second energy beam 134b. The overlapping portion of the first build-plane region 152a and the second build-plane region 152b may sometimes be referred to as an interlaced region 154. The portion of the powder bed 136 to be irradiated within the interlaced region 154 may be irradiated by the first energy beam 134a, the second energy beam 134b, or a combination thereof. Although the powder bed 136 to be irradiated is exemplarily shown as being irradiated by a first energy beam 134a or a second energy beam 134b, it should be understood that, according to this disclosure, any number of energy beams 134 may be additionally or alternatively used to irradiate the construction plane 128.

[0043] To irradiate the layers of powder bed 136, one or more irradiation devices 138 (e.g., first irradiation device 138a and second irradiation device 138b) respectively guide multiple energy beams 134 (e.g., first energy beam 134a and second energy beam 134b) across corresponding portions of build plane 128 (e.g., first build plane region 152a and second build plane region 152b) to selectively solidify those portions of the build material 118 that will become part of the three-dimensional object 114. For example, one or more energy beams 134 may be incident on the build plane 128 defined by powder bed 136 after passing through one or more optical elements of optical assembly 142 or through window 146 of energy beam system 132. As the sequential layers of powder bed 136 are solidified, build piston 156 gradually lowers build platform 130 to make room for the sequential layers of build material 118. As sequential layers of build material 118 are applied to build plane 128, the next sequential layer of build material 118 defines a surface of powder bed 136 coinciding with build plane 128. Successive layers of powder bed 136 can be selectively consolidated until a complete additively manufactured object 114 has been created. In some aspects of this disclosure, the additive manufacturing machine can utilize an overflow module (not shown) to capture excess build material 118. Additionally, or alternatively, excess build material 118 can be redistributed on build plane 128 as a next sequential layer of build material 118 is applied. It should be understood that other systems can be provided to handle build material 118, including different powder supply systems or excess powder recovery systems. The subject matter of this disclosure can be practiced with any suitable additive manufacturing machine without departing from the scope of this disclosure.

[0044] Still referencing Figure 1 The additive manufacturing machine 102 may include an imaging system 158 (e.g., a first imaging system 158a and a second imaging system 158b) configured to monitor one or more operating parameters of the additive manufacturing machine 102, one or more parameters of the energy beam system 132, or one or more operating parameters of the additive manufacturing process. The imaging system may have a calibration system configured to calibrate one or more operating parameters of the additive manufacturing machine 102 or the additive manufacturing process. The imaging system 158 may be a melt pool monitoring system. One or more operating parameters of the additive manufacturing process may include operating parameters associated with the additively manufactured three-dimensional object 114. The imaging system 158 may be configured to detect the reflected portion of an imaging beam, such as an infrared beam from a laser diode or an energy beam (e.g., a first energy beam 134a or a second energy beam 134b).

[0045] The energy beam system 132 or imaging system 158 may include one or more detection devices. One or more detection devices may be configured to determine one or more parameters of the energy beam system 132, such as one or more parameters associated with the irradiation of a continuous layer of the powder bed 136, based at least in part on the evaluation beam detected by the imaging system 158. The one or more parameters associated with the continuous layer of the consolidated powder bed 136 may include irradiation parameters or object parameters, such as melt pool monitoring parameters. The one or more parameters determined by the imaging system 158 may be utilized, for example, by the control system 104 to control one or more operations of the additive manufacturing machine 102 or the additive manufacturing system 100. One or more detection devices may be configured to obtain evaluation data of the build plane 128 from the corresponding evaluation beam. Exemplary detection devices may include cameras, image sensors, photodiode assemblies, etc. For example, detection devices may include charge-coupled devices (e.g., CCD sensors), active pixel sensors (e.g., complementary metal-oxide-semiconductor (CMOS) sensors), quantum imaging devices (e.g., QIS sensors), etc. Detection devices may also include lens assemblies configured to focus the evaluation beam onto the detection device along the beam path. The imaging system 158 may include one or more imaging optical elements (not shown), such as mirrors, beam splitters, lenses, etc., configured to guide the evaluation beam to the corresponding detection device.

[0046] Additionally, or alternatively, to determine parameters associated with successive layers of the irradiated powder bed 136, the imaging system 158 may be configured to perform one or more calibration operations associated with the additive manufacturing machine 102, such as calibration operations associated with the energy beam system 132, one or more irradiation devices 138 or components thereof, or the imaging system 158 or components thereof. The imaging system 158 may be configured to project an evaluation beam and detect a portion of the evaluation beam reflected from the build plane 128. The evaluation beam may be projected by the irradiation device 138 or a separate beam source associated with the imaging system 158. Additionally, or alternatively, the imaging system 158 may be configured to detect the evaluation beam, which includes radiation emitted from the build plane 128, such as radiation reflected from the powder bed 136 by the energy beam 134, or radiation emitted from the molten pool in the powder bed 136 generated by the energy beam 134, or radiation emitted from a portion of the powder bed 136 adjacent to the molten pool. Imaging system 158 may include components integrated as part of additive manufacturing machine 102 or components provided separately from additive manufacturing machine 102. For example, imaging system 158 may include components integrated as part of energy beam system 132. Additionally, or alternatively, imaging system 158 may include separate components, such as components in the form of modules, that can be mounted as part of energy beam system 132 or as part of additive manufacturing machine 102.

[0047] Still referencing Figure 1In some aspects of this disclosure, the inerting system 160 may supply a flow of inert process gas 162 to one or more regions of the processing chamber 148, such as the region between the energy beam system 132 and the powder bed 136. The flow of inert process gas 162 may remove fumes from the process chamber 148 or reduce the tendency of fumes to interfere with the energy beam 134 used to irradiate the build material 118. Such fumes may be present in the form of a plume emanating from a consolidation zone, and may sometimes be referred to as a smoke plume, in which the energy beam 134 is incident on the powder bed 136. The smoke plume may include build material, dust, soot, residues, vapors, byproducts, etc. The flow of inert process gas 162 may also reduce the tendency of contaminants from the fumes to deposit on the window 146, the optical elements of the optical assembly 142, or other components of the energy beam system 132. The inerting system 160 may provide a directional flow of inert process gas 162 across the build plane 128. For example, as shown, the inert process gas 162 flows from left to right. The inerting system 160 may include a supply manifold 164 and a return manifold 166. Inert process gas 162 may flow from the supply manifold 164 to the return manifold 166. Fumes in the processing chamber 148 may be drawn into the return manifold 166. In some aspects of this disclosure, the supply manifold 164 or the return manifold 166 may be coupled to or define a portion of the peripheral wall of the processing chamber 148. Additionally, or alternatively, the supply manifold 164 or the return manifold 166 may be coupled to a housing assembly 168 that houses one or more components of the energy beam system 132, such as one or more irradiation devices 138 and / or one or more imaging systems 158. Compared to inerting the entire interior of the processing chamber 148, the relatively small volume of space between the energy beam system 132 and the powder bed 136 can be inerted by coupling the supply manifold 164 or the return manifold 166 to the housing assembly 168. Additionally, or alternatively, the plume may have a shorter travel path before being drawn back to the manifold 166 by the flow of inert process gas 162.

[0048] The energy beam system 132 can be positioned at any suitable location within the processing chamber 148. Additionally, or alternatively, the energy beam system 132 can be coupled to the peripheral wall of the processing chamber 148. In some aspects of this disclosure, the additive manufacturing machine may include a positioning system 170 configured to move the energy beam system 132 or one or more components thereof relative to the build plane 128. The positioning system 170 may be configured to move the energy beam system 132 or one or more components thereof to a specified build coordinate or along a specified build vector corresponding to a Cartesian coordinate system, according to control commands provided, for example, by the control system 104. For example, control commands may be provided to perform operations on one or more energy beam systems 132 or the additive manufacturing machine 102 according to this disclosure. The positioning system 170 may include one or more gantry elements 172 configured to move the energy beam system 132 or one or more components thereof across the powder bed. The gantry elements 172 may be configured to move the energy beam system 132 or one or more components thereof along one or more directions, such as the X, Y, or Z directions. In some aspects of this disclosure, the positioning system 170 may be coupled to a housing assembly 168 that houses one or more components of the energy beam system 132. The housing assembly 168 may be coupled to one or more gantry elements 172 via one or more gantry mounts 174. The positioning system 170 may include a drive motor 176 configured to move the housing assembly 168 or one or more components of the energy beam system 132 according to instructions for the control system 104. The positioning system 170 may include components typically associated with a gantry system, such as stepper motors, drive elements, brackets, etc.

[0049] Now referring to 2, a top view of the construction plane 128 for forming the first wall 153a of the three-dimensional object 114 is shown. The first wall 153a may generally refer to one or more energy beams 134 ( Figure 2 (Not shown) Any thin or narrow structure consolidated. The first wall 153a extends in the first direction D1 and may be defined by a first side 157a and a second side 159a of the first wall 153a, wherein the second side 159a is opposite to the first side 157a. The building material 118 adjacent to the first side 157a and the second side 159a of the first wall 153a remains unconsolidated. That is, when the building material 118 is applied to the building plane 128, the building material 118 adjacent to the first wall 153a retains its form (e.g., loose powder material).

[0050] The first wall 153a may include various configurations and orientations. For example, the first wall 153a may include a generally linear orientation, such as... Figure 2As shown. In some aspects of this disclosure, the first wall 153a may include a non-linear orientation, such that it includes one or more bends, turns, curves, etc. Further, the first wall 153a includes a thickness T (i.e., the distance between the first side 157a and the second side 159a of the first wall 153a) in a thickness direction DT perpendicular to the first direction D1. In some aspects of this disclosure, as the first wall 153a extends in the first direction D1, the first wall 153a may include a substantially uniform thickness T. However, in some aspects of this disclosure, the thickness T of the first wall 153a may increase or decrease at one or more locations along the first direction D1.

[0051] Furthermore, although Figure 2 A first wall 153a isolated within the construction plane 128 is shown; however, it should be understood that other structures may also be fixed within the construction plane 128 at one or more locations. For example, the first wall 153a may extend between and connect to one or more larger structures separated by defined distances. Alternatively or additionally, the first wall 153a may intersect with additional structures in the construction plane 128.

[0052] Now refer to another source Figure 3 This shows the method used for consolidation. Figure 2 The diagram shows a top view of the first oscillation path 190 of the first wall 153a. The first oscillation path 190 typically includes a plurality of oscillations 192 repeating along a first direction D1. That is, the first spot 135a of the first energy beam 134a can oscillate as it travels along the first direction D1 across the build plane 128 to generate the plurality of oscillations 192. The oscillation of the first energy beam 134a allows for a larger molten pool in the build plane 128 compared to the case where the first spot 135a travels linearly parallel to the first direction D1. For example, the first spot 135a includes a beam diameter DB defining the diameter of the first spot 135a on the build plane 128. The molten pool MP formed in the build plane 128 by the plurality of oscillations 192 can exceed the size of the beam diameter DB to solidify a larger area via a single pass or fewer passes. For example, the thickness T of the first wall 153a can be greater than the beam diameter DB, partly due to the plurality of oscillations 192. In some aspects of this disclosure, the thickness T of the first wall 153a can be between 1.5 and 7 times the beam diameter DB of the first energy beam 134a. In some aspects of this disclosure, the thickness T of the first wall 153a can be between two and five times the beam diameter DB of the first energy beam 134a. In some aspects of this disclosure, the thickness T of the first wall 153a can be between two and three times the beam diameter DB of the first energy beam 134a.

[0053] The first oscillation path 190 may include various parameters and configurations, including parameters and configurations concerning a plurality of oscillations 192. For example, each oscillation 192 may typically include an amplitude A and a length L. The amplitude A refers to the maximum distance reached by the first spot 135a extending away from the centerline M, which divides the first oscillation path 190 in two along the first direction D1D1. The length L refers to the distance that each oscillation 192 extends along the first direction D1D1. Furthermore, the first oscillation path 190 may include a distance D between the oscillations 192.

[0054] The amplitude A of each oscillation 192 can affect the size of the entire molten pool, which can have the same or similar diameter as the entire oscillation height OH. For example, a larger amplitude can produce a larger molten pool size, which in turn will result in a greater amount of build material 118 being consolidated in the build plane 128 through a single pass of the first energy beam 134a. Figure 1 and 2 The length L of each oscillation 192 can affect the building material 118 applied from the first energy beam 134a to the building plane 128 by adjusting the distance traveled by the first point 135a of the first energy beam 134a over any particular region. Figure 1 and Figure 2 The amount of energy applied to the building material 118. A smaller length L can produce a larger travel distance for the first spot 135a in a smaller area along the direction of travel, thereby increasing the amount of energy applied to the building material 118. Figure 1 and Figure 2 The total amount of energy applied to the building material 118. Furthermore, the frequency of oscillations 192 in the first oscillation path 190 can be customized by adjusting the distance D between the oscillations 192. A smaller distance D results in more frequent oscillations (which is similar to a smaller length L), allowing for a larger travel distance of the first spot 135a to be generated in a smaller area along the travel direction D1, thereby increasing the energy applied to the building material 118. Figure 1 and Figure 2 The total amount of energy on the surface. The length L and distance D parameters can be adjusted to any suitable value to produce a suitable molten pool in the construction plane 128. In some aspects of this disclosure, such as... Figure 3 As shown, the oscillations 192 can be separated from each other. However, in some aspects of this disclosure, the length L can be large enough or the distance D can be small enough such that the oscillations 192 can partially overlap each other along the direction of travel T.

[0055] In some aspects of this disclosure, the amplitude A, length L, and distance D of each oscillation 192 can remain constant along the first oscillation path 190. However, in some aspects of this disclosure, one or more of the amplitude A, length L, and distance D can vary independently within the oscillation 192 along the first oscillation path 190. For example, the amplitude A can be increased for a specific oscillation at a specific distance to temporarily increase the size of the molten pool relative to the first oscillation path 190.

[0056] Oscillator 192 can include various configurations. In some aspects of this disclosure, for example... Figure 3 As shown, oscillation 192 may include a symmetrical loop. In some aspects of this disclosure, one or more of oscillations 192 may additionally or alternatively include other configurations, such as asymmetrical loops, linear or nonlinear modes, or combinations thereof. Furthermore, although the first direction D1 is shown as including a relatively linear path, it should be understood that the first direction D1 may additionally or alternatively include one or more nonlinear components, such as bends, curves, turns, etc.

[0057] Now refer to another source Figure 4 Multiple oscillations 192 of the first oscillation path 190 can irradiate the building material 118 ( Figure 1 and Figure 2 At least a portion of the first wall 153a is solidified. Furthermore, multiple oscillations 192 can define at least a first side 157a of the first wall 153a by irradiating and solidifying the building material 118 at the edges of the first wall 153a, without requiring additional irradiation or passage from the energy beam 134 (not shown). Irradiation applied by the first spot 135a of the first energy beam 134a at the peak amplitude A of each oscillation 192 will thereby cause the first side 157a and the second side 159a of the first wall 153a to be solidified to define them. That is, amplitude A will control the maximum size of the molten pool, which in turn becomes the outer surface of the first side 157a and the second side 159a of the first wall 153a. Thus, a constant amplitude A will produce a linear first side 157a and second side 159a of the first wall 153a. However, a varying amplitude a will produce a wall 153a with either a first side 157a or a second side 159a that is non-linear, for example, expanding and contracting in the thickness direction DT. Compared to additive manufacturing walls using non-oscillating laser paths, these aspects of the present disclosure can allow for the construction of relatively thin-walled structures for three-dimensional objects 114 with greater efficiency, accuracy, and uniformity.

[0058] The main body portion 163 of the first wall 153a, namely the portion between the first side 157a and the second side 159a of the first wall 153a, can be consolidated using the remainder of the oscillation path 190. These aspects of the present disclosure can avoid the need for shadow lines (e.g., multiple linear passes of one or more energy beams 134) to help speed up the manufacturing process and avoid potential curing inconsistencies that may occur due to multiple adjacent passes.

[0059] In some aspects of this disclosure, multiple oscillations 192 can further define a second side 159a of the first wall 153a by irradiating and solidifying the structural building material 118 at another edge of the first wall 153a, without requiring additional irradiation or passage of the energy beam 134. Irradiation by the first spot 135a of the first energy beam 134a at the peak amplitude A of each oscillation 192 will also cause the second side 159a of the first wall 153a to be solidified to define the second side. These aspects of this disclosure can allow the first energy beam 134a to pass through the first oscillation path 190 in a single pass to define the entire first wall 153a.

[0060] Figure 5 Another first oscillation path 290 according to another aspect of this disclosure is shown. First oscillation path 290 is similar to first oscillation path 190; therefore, similar components will be identified by similar numbers plus 100, and it should be understood that, unless otherwise stated, the description of similar portions of first oscillation path 190 applies to first oscillation path 290. Figure 5 As shown, with the first energy beam 134a ( Figure 1 Traveling in the first direction D1, one or more dimensions of the first oscillation path 290 change. For example, as Figure 5 As shown, the amplitude A of the first oscillation path 290 can vary as the first oscillation path travels along the first direction D1. In these aspects of this disclosure, the first oscillation path may include at least a first amplitude A1 at a first position and a second amplitude A2 at a second position further along the first direction D1. The second amplitude A2 may be greater than the first amplitude A1, such that the thickness T of the first wall 253a between the first side 257a and the second side 259a can increase along a first portion of the first wall 253a. Depending on the design of the first wall 253a and the three-dimensional object 114, the amplitude A can vary at a single position or multiple positions (e.g., increase or decrease). Furthermore, as the first oscillation path 190 extends along the first direction D1, the amplitude A can vary steadily (e.g., increase or decrease taperingly), or it can vary rapidly (e.g., increase or decrease immediately), or a combination thereof. Further, when multiple oscillations change, the power of the first energy beam can be adjusted, for example, by increasing or decreasing the power as the amplitude A increases or decreases.

[0061] First energy beam 134a ( Figure 1 The beam parameters can include various beam parameters along the first oscillation path, such as, but not limited to, power, spot size, focusing depth, travel speed, and other beam parameters for fully securing the building material 118. Similar to amplitude A, the beam parameters of the first energy beam 134a can remain constant throughout the oscillation path 190, or can vary wholly or partially throughout the oscillation path 190.

[0062] Figure 6 Another first oscillation path 390 according to another aspect of this disclosure is shown. First oscillation path 390 is similar to first oscillation path 190; therefore, similar components will be identified by similar numbers plus 100, and it should be understood that, unless otherwise stated, the description of similar portions of first oscillation path 190 applies to first oscillation path 290. Figure 6 As shown, the first wall 353a can be solidified using additional irradiation, such as the first energy beam 134a. Figure 1 Additional energy beam 134b (or second energy beam) Figure 1 Additional passage. For example, see reference. Figure 6 In some aspects of this disclosure, the second constructing planar region 152b can be irradiated along the second oscillation path 210 in a second direction D2 opposite to the first direction D1. Figure 1 The first oscillation path 390 and the second oscillation path 210 may include a plurality of oscillations 212 defining a second side 359a of the first wall 353a, which is opposite to a first side 357a of the first wall 352a to jointly define the thickness T of the first wall 352a. Thus, the first oscillation path 390 and the second oscillation path 210 may travel adjacent to each other and substantially parallel to each other to solidify the first wall 353a. While the first energy beam 134a and the second energy beam 134b have been exemplarily described, it should be understood that any number of energy beams 134 may be additionally or alternatively used to irradiate the construction plane 128 in any number of regions.

[0063] In some aspects of this disclosure, the first energy beam 134a may travel along the first oscillation path 390 and the second oscillation path 210. Alternatively, in some aspects of this disclosure, the first energy beam 134a may travel along the first oscillation path 390, and the second energy beam 134b may travel along the second oscillation path 210. Furthermore, the first oscillation path 390 and the second oscillation path 210 may generally include the same dimensions, such as the same amplitude A, length L, or distance D. Figure 3In some aspects of this disclosure, one or more dimensions may vary between the first oscillation path 390 and the second oscillation path 210. Furthermore, the parameters of the energy beam 134 used for the first oscillation path 390 and the second oscillation path 210 may be similar to each other, different from each other, or a combination thereof.

[0064] Now for reference Figure 7-10 In some aspects of this disclosure, different oscillation paths can form adjacent portions of the same wall, wherein the different oscillation paths meet in the overlapping space between two adjacent portions. That is, for example, to form a wall extending from right to left, one oscillation path forms the left half of the wall, another oscillation path forms the right half of the wall, and the two oscillation paths meet in the intersecting region between the left and right halves of the wall. Exemplary aspects of this disclosure will be presented with reference to the various figures, wherein similar components will be identified by similar numerals generally incremented by 100, and it should be understood that, unless otherwise stated, the description of similar components described herein will continue.

[0065] Figure 7 The second construct planar region 452b is shown to be irradiated along the second oscillation path 491 in a second direction D2 opposite to the first direction D1 to solidify the extension 471 of the first wall 453a. The first wall 453a and the extension 471 may overlap 455 in the staggered region 454.

[0066] The interlaced region 454 can be solidified using a combination of a first energy beam 434a and a second energy beam 434b to help improve the three-dimensional object 114 between the first building plane region 452a and the second building plane region 452b. Figure 1 The construction quality of ) despite the use of multiple energy beams 134 ( Figure 1 (in the middle). In the combination, the first building plane region 452a (irradiated by the first energy beam 434a), the second building plane region 452b (irradiated by the second energy beam 434b), and the staggered region 454 (irradiated by both the first energy beam 434a and the second energy beam 434b) may include various relative configurations.

[0067] For example, the first oscillation path 490 of the first energy beam 134a and the second oscillation path 491 of the second energy beam 434b can be combined and overlapped 455 to illuminate the interlaced region 454. Overlapping 455 refers to constructing plane 128 (…). Figure 1 The first spot 435a of the first energy beam 434a and the second spot 435b of the second energy beam 434b irradiate the same building material 118. Figure 1(in the middle) portion. By at least partially overlapping the first oscillation path 490 and the second oscillation path 491, the staggered region 454 can be irradiated and consolidated in a more efficient manner, and the potential misalignment between the first energy beam 434a and the second energy beam 434b is mitigated, for example, by using the building material 118 ( Figure 1 A larger public molten pool is formed in the process.

[0068] The staggered region 454 may include various relative configurations for overlapping, tapering, or otherwise connecting the first wall 453a to the extension 471. For example, in some aspects of this disclosure, such as Figure 7 As shown, the first oscillation path 490 and the second oscillation path 491 may overlap by a distance defined by 455. The overlap distance and amount may depend on, for example, the configuration of the first oscillation path 490 and the second oscillation path 491, or the parameters of the first energy beam 434a and the second energy beam 434b.

[0069] Figure 8 Another embodiment of the first oscillation path 590 and the second oscillation path 591 forming the first wall 553a is shown. In some aspects of this disclosure, for example Figure 8 As shown, the amplitude A of at least one of the plurality of oscillations 592, 593 for the first oscillation path 590 and the second oscillation path 591 can vary in the interleaving region 554. For example, the amplitude A can be increased for oscillation 592 of the first oscillation path 590 or oscillation 593 of the second oscillation path 591 in the interleaving region 554. Therefore, the first wall 553a and the extension 571 will have a greater thickness T where they meet.

[0070] Figure 9 A first wall 653a is shown, wherein a first plurality of oscillations 692 of the first oscillation path 690 may be conical in the interlacing region 654, such that the amplitude A of the first oscillation path 190 decreases as it extends toward the extension 671 until it stops or becomes a peak. Alternatively or additionally, a second plurality of oscillations 693 of the second oscillation path 691 may be conical in the interlacing region 654, such that the amplitude A of the second oscillation path 691 decreases as it extends toward the first wall 653a until it stops or becomes a peak.

[0071] The cone shape of the first oscillation path 690 or the second oscillation path 691 can be implemented with or without overlap. For example, refer to Figure 9 The oscillation 692 of the first oscillation path 690 can be conical towards the first side 657a, or the oscillation 693 of the second oscillation path 691 can be conical towards the second side 659a. In these aspects of this disclosure, the first oscillation path 690 and the second oscillation path 691 can consolidate the building material 118 in the interlaced region 654 without overlapping. Figure 1 ).

[0072] Figure 10 The first wall 753a is shown, wherein the oscillation 792 of the first oscillation path 790 can be conical toward the interior portion of the three-dimensional object 114 (i.e., between the first side 757a and the second side 759a), or the oscillation 793 of the second oscillation path 791 can be conical toward the three-dimensional object 114. Figure 1 The internal portion of the material is conical. In these aspects of this disclosure, the first oscillation path 790 and the second oscillation path 791 can consolidate the building material 118 in the interlaced region 754 upon overlap 755. Figure 1 ).

[0073] It should be understood that while this document presents certain variations and arrangements of the consolidation of the first wall 153a, the extension 171, and the staggered region 154, these examples are not intended to be exclusive, and other embodiments may be employed within the scope of this disclosure.

[0074] For further reference Figure 11 In some aspects of this disclosure, the three-dimensional object 114 may have a plurality of walls 853 intersecting at one or more intersection points 850. Although Figure 11 The three-dimensional object 814 presented in the diagram shows multiple walls 853, but it should be understood that it may include any earlier series numbers and aspects of this disclosure (153, 253, 353, 453, 552, 653, 753). Figure 11 As shown, a three-dimensional object 814 may include a network of walls 853 intersecting at multiple intersection points 850, wherein one or more walls 853 may be consolidated using the methods and systems disclosed herein. These aspects of the disclosure may be advantageous for mesh-like support structures or cross-sections embodying staggered thin-walled structures, such as heat exchangers, flow chambers, or other design configurations suitable for additive manufacturing.

[0075] like Figure 11 As shown, for example, a three-dimensional object 814 may include a first wall 853a, a second wall 853b, a third wall 853c, a fourth wall 853d, a fifth wall 853e, a sixth wall 853f, and a seventh wall 853g. Multiple walls may include parallel groups of walls 853, for example, where the first wall 853a and the second wall 853b form a first parallel group, the third wall 853c and the fourth wall 853d form a second parallel group, and the fifth wall 853c, the sixth wall 853f, and the seventh wall 853g form a third parallel group. Although Figure 11 Seven different walls 153 in three parallel groups are shown, but it should be understood that the three-dimensional object 814 may include any number of walls 853 (with or without parallel orientation) with any suitable configuration.

[0076] One or more walls 853 may include oscillations 892 such as those via a first oscillation path 890 and a second oscillation path 891. For example, the first oscillation path 890 and the second oscillation path 891 may typically include the same dimensions, such as the same amplitude A, length L, or distance D. Figure 3 In some aspects of this disclosure, one or more dimensions between the first oscillation path 890 and the second oscillation path 891 may vary. Furthermore, the parameters of the energy beams used for the first oscillation path 890 and the second oscillation path 891 may be similar to each other, dissimilar to each other, or a combination thereof. For example, in some aspects of this disclosure, for one or more walls 853, or even each wall 853, the amplitude A of the oscillation 192 at the intersection 850 may be increased. These aspects of this disclosure may increase the rigidity of the plurality of walls 853 within the three-dimensional object 814. Alternatively or additionally, in some aspects of this disclosure, for one or more walls 853, or even each wall 853, the amplitude A of the oscillation 892 at the intersection 850 may be decreased.

[0077] Now refer to another source Figure 12 This illustrates a method 300 for additive manufacturing of a three-dimensional object 114. While method 300 is generally referred to below... Figure 2-4 The exemplary aspects of this disclosure are shown, but it should be understood that method 300 is also applicable to... Figure 5-11 The exemplary aspects of this disclosure included herein. Method 300 generally includes, in step 310, irradiating a first build-plane region 152a with a first energy beam 134a traveling along a first oscillation path 190 in a first direction D1 to solidify a first wall 153a, wherein build material 118 adjacent to a first side 157a of the first wall 153a and build material 118 adjacent to a second side 159a of the first wall 153a (opposite to the first side 157a of the first wall 153a) remain unsolidified. The first oscillation path 190 may include a first plurality of oscillations 192, the first plurality of oscillations 192 at least defining the first side 157a of the first wall 153a, and the thickness T of the first wall 153a in a thickness direction DT perpendicular to the first direction D1 may be greater than the beam diameter DB of the first energy beam 134a.

[0078] As described above, the three-dimensional object 114 may include various relevant parameters and configurations regarding one or more walls 153 and their formation.

[0079] For example, method 300 may include, in step 320, irradiating a second construct planar region 152b along a second oscillation path 210 in a second direction D2 opposite to the first direction D1 to solidify the first wall 153a. The second oscillation path 210 may include a second plurality of oscillations 212, the second plurality of oscillations 212 defining a second side 159a of the first wall 153a opposite to a first side 157a of the first wall 153a.

[0080] In some aspects of this disclosure, for example Figure 7 In the aspects shown, method 300 may include, in step 330, irradiating a second construct planar region 452b along a second oscillation path 491 in a second direction D2 opposite to the first direction D1 to solidify the extension 471 of the first wall 453a in the first direction D1. The second oscillation path 491 may include a second plurality of oscillations 493. Furthermore, the first plurality of oscillations 492 and the second plurality of oscillations 493 may overlap 455 in an interleaved region 454.

[0081] In some aspects of this disclosure, such as method 300, a second constructing planar region 152b may be irradiated along a second oscillation path 210 in step 340 in a second direction D2 or a third direction D3 different from the first direction D1 to solidify a second wall 853b, wherein the first wall 853a and the second wall 853b intersect at an intersection point 850.

[0082] Turn now Figure 13 The control system 104 is shown. The control system 104 can be configured to perform one or more control operations associated with the additive manufacturing system 100 or the additive manufacturing machine 102. The control operations may include one or more portions of the method 300 disclosed herein, or one or more operations that otherwise fix the three-dimensional object 114 according to the disclosure presented herein.

[0083] For example, control operations may include irradiating a first build-plane region 152a with a first energy beam 134a traveling along a first oscillation path 190 in a first direction D1 to solidify a first wall 153a, wherein build material 118 adjacent to a first side 157a of the first wall 153a and build material 118 adjacent to a second side 159a of the first wall 153a (opposite to the first side 157a of the first wall 153a) remain unsolidified. The first oscillation path 190 may include a first plurality of oscillations 192, the first plurality of oscillations 192 at least defining the first side 157a of the first wall 153a, and the thickness T of the first wall 153a in a thickness direction DT perpendicular to the first direction D1 may be greater than the beam diameter DB of the first energy beam 134a.

[0084] like Figure 13As shown, the control system 104 may include one or more computing devices 900. The one or more computing devices 900 may be communicatively coupled to the additive manufacturing machine 102 or the additive manufacturing system 100. For example, the computing devices 900 may be communicatively coupled to one or more controllable components 902 of the additive manufacturing machine 102, such as one or more controllable components 902 associated with the energy beam system 132, imaging system 158, inerting system 160, or positioning system 170. Additionally, or alternatively, the computing devices 900 may be communicatively coupled to the management system 106 or the user interface 108. The one or more computing devices 900 may be located locally or remotely relative to the additive manufacturing machine 102.

[0085] One or more computing devices 900 may include one or more control modules 904 configured to cause the computing devices 900 to perform one or more control operations. The one or more control modules 904 may include one or more irradiation control modules 800. The one or more control modules 904 may include control logic executable to provide control commands configured to control one or more controllable components 902 associated with the additive manufacturing machine 102.

[0086] One or more computing devices 900 may include one or more processors 906 and one or more memory devices 908. The one or more processors 906 may include any suitable processing means, such as a microprocessor, microcontroller, integrated circuit, logic device, or other suitable processing means. The one or more memory devices 908 may include one or more computer-readable media, including but not limited to non-transitory computer-readable media, RAM, ROM, hard disk drives, flash drives, or other memory devices 908. One or more control modules 904 may be implemented at least in part by one or more processors 906 or one or more memory devices 908.

[0087] As used herein, the terms “processor” and “computer,” as well as related terms such as “processing device” and “computing device,” are not limited to those integrated circuits referred to in the art as computers, but broadly refer to microcontrollers, microcomputers, programmable logic controllers (PLCs), application-specific integrated circuits (ASICs), and other programmable circuits, and these terms are used interchangeably herein. Memory device 908 may include, but is not limited to, non-transitory computer-readable media such as random access memory (RAM), and computer-readable non-volatile media such as hard disk drives, flash memory, and other memory devices. Alternatively, floppy disks, optical disc read-only memory (CD-ROM), magneto-optical disks (MOD), or digital versatile disks (DVDs) may also be used.

[0088] As used herein, the term "non-transitory computer-readable medium" is intended to represent any tangible computer-based device implemented in any method or technology for storing short-term and long-term information (e.g., computer-readable instructions, data structures, program modules and submodules, or other data in any device). The methods described herein can be encoded as executable instructions embodied in a tangible, non-transitory computer-readable medium (including, but not limited to, storage devices or memory devices). When executed by a processor, such instructions cause the processor to perform at least a portion of the methods described herein. Furthermore, as used herein, the term "non-transitory computer-readable medium" includes all tangible computer-readable media, including but not limited to non-transitory computer storage devices, including but not limited to volatile and non-volatile media, as well as removable and non-removable media such as firmware, physical and virtual storage, CD-ROMs, DVDs, and any other digital source (e.g., networks or the Internet), and undeveloped digital means, with the sole exception of transient, propagating signals.

[0089] One or more memory devices 908 may store information accessible by one or more processors 906, including computer-executable instructions 910 executable by one or more processors 906. The computer-executable instructions 910 may include any set of instructions that, when executed by one or more processors 906, cause one or more processors 906 to perform operations (including calibration operations or additive manufacturing operations). For example, the computer-executable instructions 910 may be configured to cause one or more processors 906 to perform method 300. Figure 12 One or more steps as presented in or otherwise presented in this disclosure. In some aspects of this disclosure, computer-executable instructions 910 may be configured to cause one or more processors 906 to irradiate a first build-plane region 152a with a first energy beam 134a traveling along a first oscillation path 190 in a first direction D1 to solidify a first wall 153a, wherein build material 118 adjacent to a first side 157a of the first wall 153a and build material 118 adjacent to a second side 159a of the first wall 153a (opposite to the first side 157a of the first wall 153a) remain unsolidified. The first oscillation path 190 may include a first plurality of oscillations 192, the first plurality of oscillations 192 at least defining the first side 157a of the first wall 153a, and the thickness T of the first wall 153a in a thickness direction DT perpendicular to the first direction D1 may be greater than the beam diameter DB of the first energy beam 134a.

[0090] Memory device 908 may store multiple data 912 accessible by one or more processors 906. Data 912 may be past, current, real-time, or a combination thereof. Data 912 may be stored in database 914. As an example, data 912 may include data associated with or generated by additive manufacturing system 100 or additive manufacturing machine 102, including data associated with or generated by computing device 900, additive manufacturing machine 102, management system 106, or user interface 108. Data 912 may also include other datasets, parameters, outputs, and information associated with additive manufacturing system 100 or additive manufacturing machine 102.

[0091] One or more computing devices 900 may further include a communication interface 916 configured to communicate with various nodes on a communication network 918 via a wired or wireless communication line 920. The communication interface 916 may include any suitable components for interacting with one or more networks, including, for example, a transmitter, receiver, port, controller, antenna, or other suitable components. The communication interface 916 may allow one or more computing devices 900 to communicate with various nodes associated with the additive manufacturing machine 102, management system 106, or user interface 108. The communication network 918 may include, for example, a local area network (LAN), a wide area network (WAN), a satellite communication (SATCOM) network, a very high frequency (VHF) network, a high frequency (HF) network, a Wi-Fi network, a global microwave access interoperability (WiMAX) network, a gate link network, or any other communication network 918 used for transmitting messages to or from the computing device 900 via the communication line 920. The communication line 920 of the communication network 918 may include a data bus or a combination of wired or wireless communication links.

[0092] The management system 106 may include a server 922 or a data warehouse 924. As an example, at least a portion of the data 912 may be stored in the data warehouse 924, and the server 922 may be configured to transfer the data 912 from the data warehouse 924 to one or more computing devices 900, or to receive the data 912 from one or more computing devices 900 and store the received data 912 in the data warehouse 924 for further purposes. The server 922 or the data warehouse 924 may be implemented as part of one or more computing devices 900 or as part of the management system 106.

[0093] Although computing device 900 and its components have been disclosed herein, it should be understood that these specific aspects of this disclosure are not intended to be limiting, and alternatives may be further implemented within the scope of this disclosure.

[0094] By utilizing one or more oscillation paths 190, thin and uniform walls 153 can be fabricated for a three-dimensional object 114. By utilizing multiple oscillations 192, the thickness of the walls 153 can be reduced while still promoting consistent and uniform consolidation of the building material without excessive irradiation.

[0095] Further details are provided by the following topics:

[0096] A method for additive manufacturing a three-dimensional object, the method comprising: irradiating a first construct planar region with a first energy beam having a defined beam diameter, the first energy beam traveling along a first oscillating path in a first direction to consolidate a first wall defining a thickness perpendicular to the first direction, wherein construct material adjacent to a first side of the first wall and construct material adjacent to a second side of the first wall remain unconsolidated, the second side of the first wall being opposite to the first side of the first wall, and wherein the thickness of the first wall is greater than the beam diameter.

[0097] According to any one of the methods described herein, wherein the first oscillation path comprises a first plurality of oscillations, and wherein the thickness of the first wall is between two and five times the beam diameter of the first energy beam.

[0098] According to any of the methods described herein, the amplitude of the first plurality of oscillations varies along the first oscillation path.

[0099] According to any of the methods described herein, the power of the first energy beam is adjusted when the first plurality of oscillations change.

[0100] According to any of the methods described herein, the first oscillation path includes a first plurality of oscillations, the first plurality of oscillations at least defining the first side of the first wall.

[0101] The method according to any one of the claims herein further includes irradiating a second construction plane region along a second oscillation path in a second direction opposite to the first direction to solidify the first wall, wherein the first oscillation path includes a first plurality of oscillations defining a first side of the first wall, and wherein the second oscillation path includes a second plurality of oscillations defining a second side of the first wall.

[0102] According to any of the methods described herein, wherein the first energy beam irradiates the second construction planar region along the second oscillation path.

[0103] The method according to any one of the claims herein further includes irradiating a second construction planar region along a second oscillation path in a second direction opposite to the first direction to solidify the extension of the first wall in the first direction, wherein the second oscillation path includes a second plurality of oscillations, wherein the first oscillation path includes a first plurality of oscillations, and wherein the first plurality of oscillations and the second plurality of oscillations overlap in an interleaved region.

[0104] According to any of the methods described herein, the first plurality of oscillations and the second plurality of oscillations are conical in the interlaced region.

[0105] According to any of the methods described herein, the amplitude of at least one of the first plurality of oscillations and the second plurality of oscillations varies in the interlaced region.

[0106] According to any of the methods described herein, the second energy beam irradiates the second constructing planar region along the second oscillation path.

[0107] The method according to any one of the claims herein further includes irradiating a second construction planar region along a second oscillation path to solidify a second wall, the second oscillation path including a second plurality of oscillations in a second direction different from the first direction, wherein the first wall and the second wall intersect at an intersection point.

[0108] According to any one of the methods described herein, the first oscillation path includes a first plurality of oscillations, and the amplitude of at least one of the first plurality of oscillations and the second plurality of oscillations increases at the intersection.

[0109] According to any of the methods described herein, the second energy beam irradiates the second constructing planar region along the second oscillation path.

[0110] An additive manufacturing system for additively manufacturing three-dimensional objects, the additive manufacturing system comprising: a first irradiation device configured to generate a first energy beam; a first optical assembly configured to guide the first energy beam; and a control system configured to perform one or more control operations associated with the additive manufacturing system, wherein the one or more control operations include: irradiating a first build planar region with the first energy beam having a defined beam diameter, the first energy beam traveling along a first oscillating path in a first direction to consolidate a first wall defining a thickness perpendicular to the first direction, wherein build material adjacent to a first side and adjacent to a second side of the first wall remains unconsolidated, the second side of the first wall being opposite to the first side of the first wall; and wherein the thickness of the first wall is greater than the beam diameter of the first energy beam.

[0111] According to any of the additive manufacturing systems described herein, the one or more control operations further include: irradiating a second build-plane region along a second oscillation path in a second direction opposite to the first direction to solidify the first wall, wherein the first oscillation path includes a first plurality of oscillations, and wherein the second oscillation path includes a second plurality of oscillations, the second plurality of oscillations defining a second side of the first wall.

[0112] The additive manufacturing system of claim 15, wherein the one or more control operations further include irradiating a second build-plane region along a second oscillation path in a second direction opposite to the first direction to solidify the extension of the first wall in the first direction, wherein the first oscillation path includes a first plurality of oscillations, wherein the second oscillation path includes a second plurality of oscillations, and wherein the first plurality of oscillations and the second plurality of oscillations overlap in an interleaved region.

[0113] According to any of the additive manufacturing systems described herein, the one or more control operations further include: irradiating a second build-plane region along a second oscillating path in a third direction different from the first direction to solidify a second wall, wherein the first wall and the second wall intersect at an intersection point.

[0114] The additive manufacturing system according to any one of the claims herein further includes: a second irradiation device configured to generate a second energy beam; and a second optical component configured to guide the second energy beam, wherein the second energy beam irradiates the second build-plane region along the second oscillation path.

[0115] A three-dimensional object manufactured by a method comprising: irradiating a first construct planar region with a first energy beam having a defined beam diameter, the first energy beam traveling along a first oscillating path in a first direction to solidify a first wall defining a thickness perpendicular to the first direction, wherein construct material adjacent to a first side of the first wall and construct material adjacent to a second side of the first wall remain unsolidified, the second side of the first wall being opposite to the first side of the first wall, and wherein the thickness of the first wall is greater than the beam diameter.

[0116] This written description uses examples to disclose this disclosure, including best practices, and also enables any person skilled in the art to practice this disclosure, including making and using any apparatus or system and performing any incorporated methods. The patentable scope of this disclosure is defined by the claims, but may include other examples that would occur to a person skilled in the art. Such other examples are intended to fall within the scope of the claims if they include structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. A method for additive manufacturing of a three-dimensional object, characterized in that, The method includes: A first construct planar region is irradiated with a first energy beam of a defined diameter. The first energy beam travels in a first direction along a first oscillating path with a varying first amplitude to solidify a first wall defining a thickness perpendicular to the first direction. Construct material adjacent to a first side of the first wall and construct material adjacent to a second side of the first wall remain unsolidified, the second side of the first wall being opposite to the first side of the first wall. The thickness of the first wall is greater than the beam diameter. Further, it includes irradiating a second construction planar region along a second oscillation path with a changed second amplitude in a second direction opposite to the first direction to solidify the first wall, wherein the first oscillation path includes a first plurality of oscillations defining a first side of the first wall, and wherein the second oscillation path includes a second plurality of oscillations defining a second side of the first wall, wherein the first plurality of oscillations and the second plurality of oscillations are conical in an interlacing region; and The first plurality of oscillations and the second plurality of oscillations overlap in the interleaved region, and the first amplitude of the change increases in the interleaved region, and the second amplitude of the change increases in the interleaved region.

2. The method according to claim 1, characterized in that, The first oscillation path includes a first plurality of oscillations, and the thickness of the first wall is between two and five times the beam diameter of the first energy beam.

3. The method according to claim 2, characterized in that, The amplitude of the first plurality of oscillations varies along the first oscillation path.

4. The method according to claim 3, characterized in that, When the first plurality of oscillations change, the power of the first energy beam is adjusted.

5. The method according to claim 1, characterized in that, The first oscillation path includes a first plurality of oscillations, the first plurality of oscillations at least defining the first side of the first wall.

6. The method according to claim 1, characterized in that, The first energy beam irradiates the second construction planar region along the second oscillation path.

7. The method according to claim 1, characterized in that, The method further includes irradiating a second construction plane region along a second oscillation path in a second direction opposite to the first direction to solidify the extension of the first wall in the first direction, wherein the first oscillation path includes a first plurality of oscillations, wherein the second oscillation path includes a second plurality of oscillations, and wherein the first plurality of oscillations and the second plurality of oscillations overlap in the interlaced region.

8. The method according to claim 7, characterized in that, The amplitude of at least one of the first plurality of oscillations and the second plurality of oscillations varies in the interlaced region.

9. The method according to claim 7, characterized in that, The second energy beam irradiates the second construction planar region along the second oscillation path.

10. The method according to claim 1, characterized in that, Further, it includes irradiating a second construction plane region along a second oscillation path to solidify a second wall, the second oscillation path including a second plurality of oscillations in a second direction different from the first direction, wherein the first wall and the second wall intersect at an intersection point.

11. The method according to claim 10, characterized in that, The first oscillation path includes a first plurality of oscillations, and the amplitude of at least one of the first plurality of oscillations and the second plurality of oscillations increases at the intersection point.

12. The method according to claim 10, characterized in that, The second energy beam irradiates the second construction planar region along the second oscillation path.

13. An additive manufacturing system for additively manufacturing three-dimensional objects, characterized in that, The additive manufacturing system includes: A first irradiation device, configured to generate a first energy beam; A first optical component, configured to guide the first energy beam; and A control system configured to perform one or more control operations associated with the additive manufacturing system, wherein the one or more control operations include: The first construct planar region is irradiated with a first energy beam of a defined beam diameter. The first energy beam travels along a first oscillating path with a varying first amplitude in a first direction to consolidate a first wall defining a thickness perpendicular to the first direction. Construct material adjacent to a first side and a second side of the first wall remains unconsolidated, with the second side of the first wall opposite to the first side of the first wall. The thickness of the first wall is greater than the beam diameter of the first energy beam. Further, it includes irradiating a second construction planar region along a second oscillation path with a changed second amplitude in a second direction opposite to the first direction to solidify the first wall, wherein the first oscillation path includes a first plurality of oscillations defining a first side of the first wall, and wherein the second oscillation path includes a second plurality of oscillations defining a second side of the first wall, wherein the first plurality of oscillations and the second plurality of oscillations are conical in an interlacing region; and The first plurality of oscillations and the second plurality of oscillations overlap in the interleaved region, and the first amplitude of the change increases in the interleaved region, and the second amplitude of the change increases in the interleaved region.

14. The additive manufacturing system according to claim 13, characterized in that, The one or more control operations further include: The second building plane region is irradiated along a second oscillation path in a second direction opposite to the first direction to solidify the extension of the first wall in the first direction, wherein the first oscillation path includes a first plurality of oscillations, wherein the second oscillation path includes a second plurality of oscillations, and wherein the first plurality of oscillations and the second plurality of oscillations overlap in the interlaced region.

15. The additive manufacturing system according to claim 13, characterized in that, The one or more control operations further include: The second building plane region is irradiated upward along a second oscillation path from a third direction different from the first direction to solidify the second wall, wherein the first wall and the second wall intersect at an intersection point.

16. The additive manufacturing system according to claim 15, characterized in that, Further includes: A second irradiation device, configured to generate a second energy beam; and A second optical component is configured to guide the second energy beam, wherein the second energy beam illuminates the second construction planar region along the second oscillation path.

17. A three-dimensional object manufactured by a method, characterized in that, The method includes: A first construct planar region is irradiated with a first energy beam of a defined diameter. The first energy beam travels in a first direction along a first oscillating path with a varying first amplitude to solidify a first wall defining a thickness perpendicular to the first direction. Construct material adjacent to a first side of the first wall and construct material adjacent to a second side of the first wall remain unsolidified, the second side of the first wall being opposite to the first side of the first wall. The thickness of the first wall is greater than the beam diameter. Further, it includes irradiating a second construction planar region along a second oscillation path with a changed second amplitude in a second direction opposite to the first direction to solidify the first wall, wherein the first oscillation path includes a first plurality of oscillations defining a first side of the first wall, and wherein the second oscillation path includes a second plurality of oscillations defining a second side of the first wall, wherein the first plurality of oscillations and the second plurality of oscillations are conical in an interlacing region; and The first plurality of oscillations and the second plurality of oscillations overlap in the interleaved region, and the first amplitude of the change increases in the interleaved region, and the second amplitude of the change increases in the interleaved region.

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