Additive manufacturing building unit with process gas inertization system

Abstract

A build unit for additive manufacturing of a three-dimensional object may include an energy beam system having one or more irradiation devices each configured to direct one or more energy beams onto a region of a powder bed; and an inerting system including an irradiation chamber defining an irradiation plenum, one or more supply manifolds, and a return manifold. The one or more supply manifolds may include: a downstream manifold configured to provide a downstream flow of process gas through at least a portion of an irradiation gas chamber defined by the irradiation chamber; and / or a cross flow manifold configured to provide a lateral flow of process gas through at least a portion of an irradiation gas chamber defined by the irradiation chamber. The return manifold may vent or otherwise remove process gas from an irradiation gas chamber defined by the irradiation chamber. When irradiating a region of the powder bed, process gas may flow through one or more supply manifolds, into the irradiation plenum, and from the irradiation plenum into the return manifold.

Description

[0001] This application is a divisional application of the invention patent application with application number 202210397748.4 filed on April 15, 2022, and invention name “Additive manufacturing building unit with process gas inerting system”. Technical Field

[0002] The present disclosure generally relates to build units for additive manufacturing systems, including build units for large-format additive manufacturing operations and / or build units with process gas inerting systems. Background Art

[0003] A large-format additive manufacturing system or machine may include a build unit and a build container, wherein the cross-sectional area of ​​the build container significantly exceeds the cross-sectional area of ​​the build unit. The build unit and / or the build container may be moved relative to each other to additively manufacture relatively large objects and / or a relatively large number of objects within the build container.

[0004] Additive manufacturing operations utilizing powder bed fusion processing can be performed in an inert processing environment, whereby an inert process gas can be supplied to the build chamber while contaminants (such as soot, fumes, particles, powdered material or other byproducts generated during the additive manufacturing operation) can be exhausted from the processing chamber. However, additive manufacturing systems or machines that include a build unit and a build vessel that are movable relative to each other present unique challenges for providing an inert processing environment.

[0005] Therefore, improved additive manufacturing systems and machines including improved build cells that include process gas inerting systems would be welcomed in the art. Summary of the invention

[0006] Aspects and advantages will be set forth in part in the description which follows, or may be obvious from the description, or may be practiced by practicing the presently set subject matter.

[0007] In one aspect, the present disclosure includes an additive manufacturing system and / or an additive manufacturing machine. Exemplary additive manufacturing systems and / or additive manufacturing machines may include a build unit, a build container, a build unit positioning system, and / or a build container positioning system. The build unit, the build container, the build unit positioning system, and the build container positioning system may be constructed according to the present disclosure.

[0008] In another aspect, the present disclosure includes a build unit for additive manufacturing of a three-dimensional object. An exemplary build unit may include an energy beam system, an inerting system, one or more supply manifolds, and a return manifold. The energy beam system may include one or more irradiation devices, each configured to direct one or more energy beams onto an area of ​​a powder bed. The inerting system may include an irradiation chamber defining an irradiation chamber. One or more supply manifolds may include a downflow manifold configured to provide a downward flow of a process gas through at least a portion of the irradiation chamber defined by the irradiation chamber. In addition, or in an alternative, one or more supply manifolds may include a crossflow manifold configured to provide a lateral flow of a process gas through at least a portion of the irradiation chamber defined by the irradiation chamber. In some embodiments, an exemplary build unit may include an inerting system, the inerting system including an irradiation chamber defining an irradiation chamber and one or more supply manifolds, the one or more supply manifolds being configured to supply process gas to the irradiation chamber while irradiating an area of ​​the powder bed using a build unit located above the area of ​​the powder bed. Process gas may flow through one or more supply manifolds and into the irradiation chamber while irradiating a region of the powder bed. A return manifold may exhaust or otherwise remove process gas from the irradiation chamber defined by the irradiation chamber.

[0009] An exemplary downflow manifold may include a downflow manifold body that defines one or more downflow manifold paths within the downflow manifold body. The downflow manifold body may include one or more inward downflow manifold walls that define an optical gas chamber that coincides with a distal portion of an irradiation gas chamber relative to a powder bed. One or more inward downflow manifold walls may diverge from the longitudinal axis of the downflow manifold body in a proximal direction relative to the powder bed at a divergence angle that allows one or more energy beams of the energy beam system to approach a portion of the powder bed corresponding to a scanning field of one or more energy beams. One or more inward downflow manifold walls may include a plurality of downflow manifold orifices that are fluidly connected between the optical gas chamber and one or more downflow manifold paths defined by the downflow manifold body. A plurality of downflow manifold orifices may be oriented parallel to the longitudinal axis of the downflow manifold body. In some embodiments, a plurality of downflow manifold orifices may be oriented within 10 degrees parallel to the longitudinal axis of the downflow manifold body.

[0010] An exemplary cross-flow manifold may include a plurality of cross-flow manifold bodies arranged along the width of the cross-flow manifold. The plurality of cross-flow manifold bodies may be respectively connected to each other or may define corresponding integrally formed portions of the cross-flow manifold. A corresponding cross-flow manifold body among the plurality of cross-flow manifold bodies may include a cross-flow manifold inlet fluidly connected to a process gas supply line and a plurality of cross-flow manifold paths defined by the corresponding cross-flow manifold bodies. The cross-flow manifold may include a cross-flow manifold outlet at least partially defined by a corresponding cross-flow manifold body among the plurality of cross-flow manifold bodies. The cross-flow manifold outlet may be fluidly connected to an irradiation gas chamber defined by an irradiation chamber and a plurality of cross-flow manifold path fluids of a corresponding cross-flow manifold body among the plurality of cross-flow manifold bodies.

[0011] The cross-flow manifold outlet can have an elongated cross-sectional profile. A corresponding cross-flow manifold body among a plurality of cross-flow manifold bodies can include a lateral expansion region and a lateral translation region. The lateral expansion region can be located downstream of the corresponding cross-flow manifold inlet. The lateral translation region can be located downstream of the lateral expansion region and upstream of the cross-flow manifold outlet. The lateral expansion region can present a lateral expansion of the corresponding cross-flow manifold body relative to the longitudinal axis of the corresponding cross-flow manifold inlet and / or relative to the lateral axis of the cross-flow manifold outlet. The lateral translation region can present a lateral translation relative to the longitudinal axis of the corresponding cross-flow manifold inlet and / or relative to the lateral axis of the cross-flow manifold outlet in the axial orientation of the corresponding cross-flow manifold body.

[0012] An exemplary return manifold may include a plurality of return manifold bodies arranged along the width of the return manifold. The plurality of return manifold bodies may be coupled to each other or may define respective integrally formed portions of the return manifold. The return manifold may include a return manifold inlet defined at least in part by a respective return manifold body in the plurality of return manifold bodies. A respective return manifold body in the plurality of return manifold bodies may include one or more return manifold paths and a return manifold outlet, the return manifold outlet being in fluid communication with one or more return manifold paths of the return manifold body and a process gas exhaust line. The return manifold inlet may be in fluid communication with an irradiation chamber defined by the irradiation chamber and one or more return manifold paths defined by a respective return manifold body in the plurality of return manifold bodies. The return manifold may be configured to receive a lateral flow of process gas from at least a portion of the irradiation chamber defined by the irradiation chamber. The return manifold inlet may have an elongated cross-sectional profile. The return manifold may include one or more narrowing regions and / or one or more rib elements disposed around the return manifold inlet and / or within one or more return manifold paths.

[0013] In yet another aspect, the present disclosure includes a method for additively manufacturing a three-dimensional object. An exemplary method may include irradiating the powder bed with a build unit located above the powder bed, causing a process gas to flow through one or more supply manifolds and into an irradiation chamber while the powder bed is irradiated, and exhausting or otherwise removing the process gas from the irradiation chamber through a return manifold while the powder bed is irradiated. The build unit may include an energy beam system and an inerting system. The inerting system may include an irradiation chamber defining an irradiation chamber, one or more supply manifolds configured to supply process gas to the irradiation chamber, and a return manifold configured to receive and / or exhaust process gas from the irradiation chamber. The one or more supply manifolds may include: a downflow manifold configured to provide a downward flow of process gas through at least a portion of the irradiation chamber defined by the irradiation chamber; and a crossflow manifold configured to provide a lateral flow of process gas through at least a portion of the irradiation chamber defined by the irradiation chamber.

[0014] In some embodiments, an exemplary method may include irradiating an area of ​​a powder bed using a build unit located above an area of ​​a powder bed, and flowing a process gas through one or more supply manifolds and into an irradiation chamber while irradiating the powder bed. The build unit may include an energy beam system and an inerting system. The energy beam system may include one or more irradiation devices that are respectively configured to direct one or more energy beams onto an area of ​​the powder bed. The inerting system may include an irradiation chamber that defines an irradiation chamber and one or more supply manifolds that are configured to supply process gas to the irradiation chamber. The one or more supply manifolds may include a downflow manifold that is configured to provide a downward flow of process gas through at least a portion of the irradiation chamber defined by the irradiation chamber. The downflow manifold may include: a downflow manifold body that defines one or more downflow manifold paths within the downflow manifold body; and one or more inward downflow manifold walls that define an optical chamber that includes a distal portion of the irradiation chamber relative to the powder bed. One or more inward downflow manifold walls may diverge from the longitudinal axis of the downflow manifold body in a proximal direction relative to the powder bed at a divergence angle that allows one or more energy beams of the energy beam system to approach a portion of the powder bed corresponding to a scanning field of the one or more energy beams.

[0015] In some embodiments, flowing the process gas through one or more supply manifolds and into the irradiation plenum can include flowing the process gas through a plurality of downflow manifold orifices disposed within one or more inward downflow manifold walls. The plurality of downflow manifold orifices can be in fluid communication between the optical plenum and one or more downflow manifold paths defined by the downflow manifold body. The plurality of downflow manifold orifices can be oriented parallel to, or within 10 degrees of, the longitudinal axis of the downflow manifold body.

[0016] In addition, or in the alternative, flowing the process gas through one or more supply manifolds and into the irradiation chamber may include flowing the process gas through a cross-flow manifold, which is configured to provide a lateral flow of the process gas through at least a portion of the irradiation chamber defined by the irradiation chamber. The cross-flow manifold may include a plurality of cross-flow manifold bodies, which are arranged along the width of the cross-flow manifold and are respectively connected to each other or define corresponding integrally formed parts of the cross-flow manifold. A corresponding cross-flow manifold body in the plurality of cross-flow manifold bodies may include a cross-flow manifold inlet fluidly connected to the process gas supply line and a plurality of cross-flow manifold paths defined by the corresponding cross-flow manifold body, and the cross-flow manifold may include a cross-flow manifold outlet at least partially defined by a corresponding cross-flow manifold body in the plurality of cross-flow manifold bodies. The cross-flow manifold outlet may have an elongated cross-sectional profile, and the cross-flow manifold outlet may be fluidly connected to the irradiation chamber defined by the irradiation chamber and a plurality of cross-flow manifold paths of a corresponding cross-flow manifold body in the plurality of cross-flow manifold bodies.

[0017] In some embodiments, causing the process gas to flow through one or more supply manifolds and into the irradiation gas chamber may include laterally expanding the process gas at a lateral expansion region of a corresponding cross-flow manifold body in a plurality of cross-flow manifold bodies, and / or laterally translating the process gas at a lateral translation region of a corresponding cross-flow manifold body in a plurality of cross-flow manifold bodies. The process gas may be laterally translated after laterally expanding the process gas. The lateral expansion region may be located downstream of the corresponding cross-flow manifold inlet, and the lateral translation region may be located downstream of the lateral expansion region and upstream of the cross-flow manifold outlet. The lateral expansion region may exhibit lateral expansion relative to the longitudinal axis of the corresponding cross-flow manifold inlet and / or relative to the lateral axis of the cross-flow manifold outlet. The lateral translation region may exhibit lateral translation relative to the longitudinal axis of the corresponding cross-flow manifold inlet and / or relative to the lateral axis of the cross-flow manifold outlet in the axial orientation of the corresponding cross-flow manifold body.

[0018] In some embodiments, process gas may be exhausted or otherwise removed from the irradiation chamber through a return manifold while the powder bed is being irradiated. Exhausting or otherwise removing process gas from the irradiation chamber may include accelerating the flow of process gas into the return manifold inlet and / or through one or more return manifold paths by reducing pressure within the return manifold inlet and / or within one or more return manifold paths. The pressure reduction may be provided by one or more narrowed regions and / or one or more rib elements disposed around the return manifold inlet and / or within one or more return manifold paths. The return manifold may include a plurality of return manifold bodies arranged along the width of the return manifold. The plurality of return manifold bodies may be coupled to each other, respectively, or may define corresponding integrally formed portions of the return manifold. The return manifold may include a return manifold inlet at least partially defined by a corresponding return manifold body in a plurality of return manifold bodies, wherein a corresponding return manifold body in a plurality of return manifold bodies includes one or more return manifold paths and a return manifold outlet, and the return manifold outlet is fluidly connected to one or more return manifold paths of the corresponding return manifold body and a process gas exhaust line. The return manifold inlet may have an elongated cross-sectional profile, and the return manifold inlet may be in fluid communication with an irradiation plenum defined by the irradiation chamber and one or more return manifold paths defined by respective ones of the plurality of return manifold bodies.

[0019] In yet another aspect, the present disclosure includes a computer-readable medium. An exemplary computer-readable medium may include computer-executable instructions that, when executed by a processor associated with an additive manufacturing machine, may cause the additive manufacturing machine to perform a method of additively manufacturing a three-dimensional object. An exemplary method that may be performed according to the computer-executable instructions may be constructed as described in the present disclosure.

[0020] These and other features, aspects and advantages will become better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate exemplary embodiments and, together with the description, serve to explain certain principles of the presently provided subject matter. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] A complete and enabling disclosure, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings, in which:

[0022] Figure 1A and 1B An exemplary additive manufacturing system is schematically depicted;

[0023] Figures 2A-2C schematically depicts a cross-sectional cutaway view of a build unit and a build vessel of an additive manufacturing machine or system;

[0024] Figure 2Dschematically depicts a top view of a build unit and a build vessel of an additive manufacturing machine or system;

[0025] Figures 3A-3D schematically depicting a perspective view of an exemplary irradiation chamber of a building unit, respectively;

[0026] Figure 4A schematically depicts a top perspective view of an exemplary downflow manifold for supplying a downflow gas flow to a build unit;

[0027] Figure 4B schematically depicts a cutaway top perspective view of an exemplary downflow manifold;

[0028] Figure 4C schematically depicts a bottom perspective view of an exemplary downflow manifold;

[0029] Figure 4D schematically depicts a cut-away side view of an exemplary downflow manifold;

[0030] Figure 4E schematically depicts a cutaway perspective view of an exemplary downflow manifold;

[0031] Figure 5A schematically depicts a perspective view of an exemplary cross-flow manifold for supplying a cross-flow gas stream to a build cell;

[0032] Figure 5B schematically depicts a rear view of an exemplary cross-flow manifold;

[0033] Fig. 6A schematically depicts a top view of an exemplary flow conditioning vane of a cross-flow manifold;

[0034] Figure 6B schematically depicts a perspective view of an exemplary inlet flow conditioner for a cross-flow manifold;

[0035] Figure 6C and 6D schematically depicting a top view and a cross-sectional view, respectively, of an exemplary inlet flow conditioner inserted into a cross-flow manifold;

[0036] Fig. 6E and 6F schematically depict a top view and a cross-sectional view, respectively, of another exemplary inlet flow conditioner inserted into a cross-flow manifold;

[0037] Fig. 7A schematically depicts a front view of an exemplary exhaust flow conditioner for a cross-flow manifold;

[0038] Figure 7B and 7Cschematically depicting a front view and a top cross-sectional view, respectively, of another exemplary exhaust flow conditioner for a cross-flow manifold;

[0039] Fig. 8A and 8B schematically depict a front view and a cutaway perspective view, respectively, of an exemplary return manifold;

[0040] Figures 9A-9C schematically depicting a perspective view, a front view, and a side view, respectively, of an exemplary cross-flow wall for constructing a cross-flow chamber of a cell;

[0041] Fig.9D and 9E schematically depicting a front view and a side view, respectively, of another exemplary cross-flow wall for constructing a cross-flow chamber of a cell;

[0042] Fig. 10A and 10B schematically depicting exemplary flow vectors superimposed on front and side cross-sectional views, respectively, of an exemplary building block;

[0043] Fig. 10C Schematically depicts the superposition of Fig. 10A and 10B Exemplary flow vectors on a top cross-sectional view taken at cross section "A" shown in;

[0044] Figures 10D-10F Schematically depicts the superposition of Fig. 10A and 10B Additional exemplary flow vectors on a top cross-sectional view taken at cross section "A" shown in;

[0045] Fig.11 schematically depicts an exemplary control system for an additive manufacturing machine or system; and

[0046] Fig.12 A flow chart depicting an exemplary method of additively manufacturing a three-dimensional object is shown.

[0047] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present disclosure. DETAILED DESCRIPTION

[0048] The subject matter of the present disclosure will now be described in more detail with reference to one or more of the accompanying drawings in some cases. Examples are provided in an explanatory manner and should not be construed as limiting the present disclosure. In fact, it is apparent to those skilled in the art that various modifications and variations may be made to the present disclosure without departing from the scope of the present disclosure. For example, a feature shown or described in one part of the present disclosure may be used together with a feature (including modifications and variations thereof) shown or described in another part of the present disclosure. The present disclosure is intended to encompass these modifications and variations that fall within the scope of the appended claims and their equivalents.

[0049] It should be understood that the terms "upstream" and "downstream" refer to the relative directions of the flow of fluid in a fluid path. For example, "upstream" refers to the direction from which the fluid flows, and "downstream" refers to the direction to which the fluid flows. It should also be understood that terms such as "top", "bottom", "outward", "inward", etc. are convenient words and should not be interpreted as restrictive terms. As used herein, the terms "first", "second", and "third" can be used interchangeably to distinguish one component from another, and are not intended to indicate the position or importance of each component. The terms "one" and "a" do not indicate a limitation of quantity, but rather indicate that there is at least one referenced item.

[0050] As used throughout the specification and claims, approximating language may be used to modify any quantitative representation that may be permissibly varied without resulting in a change in the basic function to which it is related. Thus, values ​​modified by terms such as "about," "substantially," and "approximately" are not limited to the precise values ​​specified. In at least some cases, approximating language may correspond to the precision of an instrument used to measure a value, or the precision of a method or machine used to construct or manufacture a component and / or system. For example, approximating language may mean within a margin of 10%.

[0051] Here and throughout the specification and claims, range limitations are combined and interchanged, and unless context or language indicates otherwise, such ranges are identified and include all sub-ranges contained therein. For example, all ranges set forth herein include the endpoints, and the endpoints are independently combinable with each other.

[0052] As described herein, the subject matter currently disclosed relates to the use of additive manufacturing machines or systems. As used herein, the term "additive manufacturing" generally refers to a manufacturing technique that manufactures parts in a layer-by-layer manner. An exemplary additive manufacturing machine can be configured to utilize any desired additive manufacturing technology. The additive manufacturing machine can utilize additive manufacturing technology, which includes powder bed fusion (PBF) technology, such as direct metal laser melting (DMLM) technology, electron beam melting (EBM) technology, electron beam sintering (EBS) technology, selective laser melting (SLM) technology, directional metal laser sintering (DMLS) technology, or selective laser sintering (SLS) technology. In the exemplary PBF technology, thin layers of powdered material are continuously applied to a build plane and then selectively melted or fused to each other in a layer-by-layer manner to form one or more three-dimensional objects. Additively manufactured objects are generally integral in nature and can have various integral sub-components.

[0053] As used herein, the term "build plane" refers to a plane defined by a surface upon which an energy beam impinges during an additive manufacturing process. Typically, the surface of a powder bed defines the build plane; however, during irradiation of a respective layer of the powder bed, a previously irradiated portion of the respective layer may define a portion of the build plane, and / or a build plate supporting the powder bed prior to distributing the powder material across the build modules typically defines the build plane.

[0054] Additionally or alternatively, suitable additive manufacturing techniques include, for example, binder jetting technology, fused deposition modeling (FDM) technology, direct energy deposition (DED) technology, laser engineered net shaping (LENS) technology, laser net shaping manufacturing (LNSM) technology, direct metal deposition (DMD) technology, digital light processing (DLP) technology, vat polymerization (VP) technology, stereolithography (SLA) technology, and other additive manufacturing technologies utilizing energy beams.

[0055] Additive manufacturing techniques can generally be described as making objects by building up the object point by point, layer by layer, usually in a vertical direction; however, other methods of making are also contemplated and within the scope of the present disclosure. For example, although the discussion herein relates to adding material to form successive layers, the subject matter of the present arrangement can be practiced with any additive manufacturing technique or other manufacturing technique, including layer-additive, layer-subtractive, or hybrid processes.

[0056] The additive manufacturing processes described herein can be used to form parts using any suitable material. For example, the material can be metal, ceramic, polymer, epoxy resin, photopolymer resin, plastic, concrete, or any other suitable material that can be solid, liquid, powder, sheet, wire, or any other suitable form. Each successive layer can be, for example, between about 10 μm and 200 μm, but the thickness can be selected based on any number of parameters and can be any suitable size.

[0057] The present disclosure generally relates to a build unit for an additive manufacturing system or machine, including a process gas inerting system. The presently disclosed build unit can be used with a large-format additive manufacturing system or machine including a build unit and a build container, for example, where the cross-sectional area of ​​the build container can significantly exceed the cross-sectional area of ​​the build unit. The build unit and / or the build container can be moved relative to each other to additively manufacture relatively large objects and / or a relatively large number of objects within the build container.

[0058] The build unit may include an inerting system, the inerting system including: an irradiation chamber, which defines an irradiation gas chamber; one or more supply manifolds, which are configured to supply process gas to one or more regions of the irradiation chamber; and one or more return manifolds, which are configured to receive and / or exhaust process gas from one or more regions of the irradiation chamber. The energy beam system can be connected to the irradiation chamber, and one or more optical windows can separate one or more optical elements of the energy beam system from the irradiation gas chamber defined by the irradiation chamber. The one or more supply manifolds can supply process gas (e.g., inert gas) to the irradiation gas chamber, thereby providing an environment suitable for irradiating powder materials using one or more energy beams generated by the energy beam system, such as an inert environment. The one or more return manifolds can receive and / or exhaust process gas and contaminants from the irradiation gas chamber, such as soot, smoke, particles, powder materials or other byproducts generated during the additive manufacturing operation.

[0059] The inerting system can be configured to provide one or more flow fields that improve the quality of the inerting environment within the irradiation chamber and / or improve the efficiency of utilizing the process gas and / or removing and / or exhausting contaminants from the processing chamber. As used herein, the term "flow field" refers to a process gas flow having one or more identifiable overall flow characteristics (e.g., direction vector, velocity, flow rate, pressure, boundary layer, etc.).

[0060] An exemplary inerting system may include one or more downflow manifolds that provide a flow field for process gas, such as a downward flow field, that prevents contaminants within the irradiation chamber from contacting and / or depositing on components of the energy beam system, and / or reduces the amount of contaminants that contact and / or deposit on components of the energy beam system over time. In addition, or in the alternative, the inerting system may include one or more crossflow manifolds that provide a flow field for process gas, such as a lateral flow field, that quickly removes or discharges contaminants generated when the energy beam irradiates the powder material, for example, without the flow field disturbing the powder bed. In addition, the inerting system may include one or more return manifolds that effectively remove and / or discharge process gas and / or contaminants from the irradiation chamber, for example, without allowing large amounts of process gas to escape from the inerting system.

[0061] The presently disclosed subject matter will now be described in further detail. Figure 1A and 1B An exemplary embodiment of an additive manufacturing system 100 is schematically depicted. The additive manufacturing system 100 may include one or more additive manufacturing machines 102. The one or more additive manufacturing machines 102 may include a control system 104. The control system 104 may include components that are integrated as part of the additive manufacturing machine 102 and / or components that are provided separately from the additive manufacturing machine 102. Various components of the control system 104 may be communicatively coupled to various components of the additive manufacturing machine 102.

[0062] The control system 104 may be communicatively coupled to a management system 106 and / or a user interface 108. The management system 106 may be configured to interact with the control system 104 in connection with enterprise-level operations related to the additive manufacturing system 100. Such enterprise-level operations may include transferring data from the management system 106 to the control system 104, and / or transferring data from the control system 104 to the management system 106. The user interface 108 may include one or more user input / output devices to allow a user to interact with the additive manufacturing system 100.

[0063] The additive manufacturing machine 102 may include one or more building units 110. Additionally or alternatively, the additive manufacturing machine 102 may include a building container 112. The one or more building units 110 may be configured to supply powder material 114 to the building container 112. Additionally or alternatively, the one or more building units 110 may be configured to selectively solidify the powder material 114 to additively manufacture a three-dimensional object 116. Figure 1A and 1BAs shown, the exemplary build unit 110 may include an energy beam system 118, an irradiation chamber 120, and a powder module 122. The energy beam system 118 and the irradiation chamber 120 may be operably coupled to each other. The irradiation chamber 120 and the powder module 122 may be operably coupled to each other. In addition, or in an alternative, the irradiation chamber 120 and the powder module 122 may be provided as separate build units 110.

[0064] The additive manufacturing system 100 or the additive manufacturing machine 102 may be configured for large-format additive manufacturing. For example, the build container 112 and / or the one or more objects 116 additively manufactured therein may have a cross-sectional area that exceeds the cross-sectional area of ​​the one or more build units 110 used to additively manufacture the one or more objects 116. The one or more build units 110 and / or the build container 112 may be movable relative to performing large-format additive manufacturing operations.

[0065] like Figure 1A As shown, one or more build units 110 may be operably coupled to a build unit positioning system 124. The build unit positioning system 124 may be configured to move the one or more build units 110 to a specified build coordinate, and / or to move the one or more build units 110 along a specified build vector corresponding to a three-dimensional 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 of the one or more build units 110 according to the present disclosure. The build unit positioning system 124 may include one or more build unit-stage elements 126 configured to movably support the one or more build units 110. The respective build unit-stage elements 126 may be configured to move the one or more build units 110 in one or more directions, such as an X direction, a Y direction, and / or a Z direction.

[0066] like Figure 1B As shown, one or more build containers 112 can be operably coupled to a build container positioning system 128. The build container positioning system 128 can be configured to move the build container 112 to a specified build coordinate, and / or move the build container 112 along a specified build vector corresponding to a three-dimensional Cartesian coordinate system, according to control commands provided, for example, by the control system 104. For example, control commands can be provided to perform operations of one or more build units 110 according to the present disclosure. The build container positioning system 128 can include one or more build container-stage elements 130 configured to movably support the build container 112. The respective build container-stage elements 130 can be configured to move the build container 112 in one or more directions (e.g., the X direction, the Y direction, and / or the Z direction).

[0067] In addition to or in lieu of one or more build units 110 being operably coupled to a build unit positioning system 124, one or more build containers 112 may be operably coupled to a build container positioning system 128. For example, the additive manufacturing machine 102 may include a build container positioning system 128 and one or more stationary build units 110. Additionally, or in the alternative, the additive manufacturing machine 102 may include a build container positioning system 128 and a build unit positioning system 124. The build container positioning system 128 may be configured to move the build container 112 in one or more directions, and the build container positioning system 128 may be configured to move the build container 112 in one or more directions. For example, the build container positioning system 128 may be configured to move the build container 112 in the X direction and / or the Y direction. Additionally, or in the alternative, the build unit positioning system 124 may be configured to move the build unit 110 in the Z direction.

[0068] Build container positioning system 128 can be configured to horizontally move build container 112 while one or more build units 110 selectively irradiate portions of powder material 114 in build container 112. For example, build container positioning system 128 can be configured to move build container 112 according to an XY coordinate system. In addition, or in the alternative, build unit positioning system 124 can be configured to horizontally move build unit 110 while build unit 110 selectively irradiates portions of powder material 114 in build container 112. For example, build container positioning system 128 can be configured to move build container 112 according to an XY coordinate system. The vertical position of one or more build units 110 and / or build container 112 can increase in conjunction with adding successive layers of powder material 114 to build container 112 and selectively irradiating corresponding layers of powder material 114 in build container 112. Build container positioning system 128 can be configured to continuously move build container 112 vertically to provide space for the next successive layer of powder material 114 to be added to build container 112. In addition, or in the alternative, build unit positioning system 124 can be configured to continuously move build unit 110 vertically to provide space for the next successive layer of powder material 114 to be added to build container 112. Movement of build unit 110 and / or build container 112 can occur before, during, or after irradiating successive layers of powder material 114.

[0069] Reference now Figures 2A-2D , aspects of an exemplary additive manufacturing system 100 and / or additive manufacturing machine 102 will be further described. Figures 2A-2DAs shown, the additive manufacturing system 100 and / or additive manufacturing machine 102 may include one or more building units 110 located above a building container 112. An exemplary building unit 110 may include an energy beam system 118, an irradiation chamber 120, and an inerting system 200. For example, Figure 2B and 2D As shown, build unit 110 may additionally or alternatively include one or more powder modules 122 .

[0070] like Figures 2A-2D As shown, the inerting system 200 may include one or more supply manifolds 202 configured to supply process gas to one or more regions of the irradiation chamber 120. In addition, or in the alternative, the inerting system 200 may include one or more return manifolds 204 configured to receive and / or exhaust process gas from one or more regions of the irradiation chamber 120. The irradiation chamber 120 may define a gas chamber or space containing a process gas (e.g., an inert gas) to provide an environment suitable for irradiating the powder material 114 with one or more energy beams, such as an inert environment. The gas chamber or space within the irradiation chamber 120 may sometimes be referred to as an irradiation gas chamber 121. Process gas may enter the irradiation gas chamber 121 defined by the irradiation chamber 120 through one or more supply manifolds 202. Process gas may leave the irradiation chamber 120 through one or more return manifolds 204. The process gas may flow through the irradiation chamber 120 along a flow path from a corresponding supply manifold in the one or more supply manifolds 202 to a corresponding return manifold in the one or more return manifolds 204, passing through the irradiation plenum 121. The one or more supply manifolds 202 and / or the one or more return manifolds 204 may be operably coupled to the irradiation chamber 120. Additionally, or in the alternative, the one or more supply manifolds 202 and / or the one or more return manifolds 204 may be integrally formed as a single component with at least a portion of the irradiation chamber 120. Additionally, or as another alternative, the one or more supply manifolds 202 and / or the one or more return manifolds 204 may define at least a portion of the irradiation chamber 120.

[0071] Process gas may be supplied to the one or more supply manifolds 202 via one or more process gas supply lines 206. Process gas may be removed or exhausted from the one or more return manifolds 204 via one or more process gas exhaust lines 208. The inerting system 200 may include one or more fans, pumps, etc. (not shown) configured to supply a process gas flow to the process gas supply lines 206. The inerting system 200 may include a process gas recirculation system (not shown) configured to recirculate the process gas, such as from the one or more process gas exhaust lines 208 back to the one or more process gas supply lines 206. The recirculation system may include one or more screens, filters, etc. (not shown) configured to remove contaminants, such as soot, smoke, particles, powder material, or other byproducts, from the powder material and / or the process gas that may be generated when irradiating the powder material. The recirculated process gas may be filtered, screened, etc. before being supplied to the one or more supply manifolds 202 and / or before being supplied to the one or more process gas supply lines 206.

[0072] The inerting system 200 may include one or more supply manifolds 202 that are constructed and arranged as downflow manifolds 210. The one or more downflow manifolds 210 may be configured to provide a downward flow of at least a portion of the process gas through the irradiation chamber 120. The downflow manifolds 210 may be in fluid communication with one or more process gas supply lines 206. For example, Figure 2A and 2C As shown, downflow manifold 210 can be disposed around an upward portion of irradiation chamber 120 (e.g., a distal portion of irradiation chamber 120 relative to build vessel 112). Downflow manifold 210 can be coupled to irradiation chamber 120. Additionally, or in the alternative, downflow manifold 210 can be integrally formed as a single component with at least a portion of irradiation chamber 120. Additionally, or as another alternative, downflow manifold 210 can define at least a portion of irradiation chamber 120.

[0073] For example, Figure 2A and 2C As shown, the supply manifold 202 (e.g., the downflow manifold 210) can surround at least a portion of the scanning field 212 of one or more energy beams 214 of the energy beam system 118. In addition, or in the alternative, the supply manifold 202 (e.g., the downflow manifold 210) can surround at least a portion of one or more irradiation devices 216 of the energy beam system 118. In addition, or in the alternative, the supply manifold 202 (e.g., the downflow manifold 210) can surround at least a portion of one or more monitoring devices 218 of the energy beam system 118. The one or more monitoring devices 218 can be integrated with the irradiation device 216 as part of a combined device (e.g., Figure 2A), and / or one or more monitoring devices 218 and one or more irradiation devices 216 may be provided as separate devices (e.g., Figure 2D ).

[0074] One or more components of the energy beam system 118 may be coupled to the supply manifold 202, such as the downflow manifold 210. For example, an energy beam system housing 220 may be coupled to the supply manifold 202. The energy beam system housing 220 may include housing elements corresponding to one or more irradiation devices 216, and / or housing elements corresponding to one or more monitoring devices 218. In addition, or in the alternative, one or more components of the energy beam system 118 (e.g., the energy beam system housing 220) may be integrally formed as a single component with at least a portion of the supply manifold 202 (e.g., the downflow manifold 210). In addition, or as another alternative, one or more components of the energy beam system 118 (e.g., the energy beam system housing 220) may define at least a portion of the supply manifold 202 (e.g., the downflow manifold 210).

[0075] The supply manifold 202 (e.g., the downflow manifold 210) can provide a process gas flow that is configured to protect the components of the energy beam system 118 from contaminants within the irradiation chamber 120. For example, the downward flow of process gas from the downflow manifold 210 can protect the components of the energy beam system 118 from contaminants within the irradiation chamber 120. The downward flow of process gas from the downflow manifold 210 can provide a flow field that prevents contaminants within the irradiation chamber 120 from contacting and / or depositing on the components of the energy beam system 118, and / or reduces the amount of contaminants that contact and / or deposit on the components of the energy beam system 118 over time. In addition, or as an alternative to the downward flow, the supply manifold 202 (e.g., the downflow manifold 210) can provide a crossflow of process gas. The process gas crossflow can also protect components of the energy beam system 118 from contaminants within the irradiation chamber 120, including preventing contaminants from contacting and / or depositing on components of the energy beam system 118 and / or reducing the amount of contaminants that contact and / or deposit on components of the energy beam system 118 over time.

[0076] The inerting system 200 may include one or more supply manifolds 202 that are constructed and arranged as cross-flow manifolds 222. The one or more cross-flow manifolds 222 may be configured to provide a lateral flow of process gas through at least a portion of an irradiation plenum 121 defined by the irradiation chamber 120. One or more process gas supply lines 206 may be in fluid communication with the cross-flow manifolds 222. The process gas supply lines 206 may supply a first portion of the process gas flow to the downflow manifold 210 and a second portion of the process gas flow to the cross-flow manifold 222.

[0077] For example, Figure 2B and 2C As shown, the cross-flow manifold 222 can be disposed about a downward portion of the irradiation chamber 120 (e.g., a proximal portion of the irradiation chamber 120 relative to the build vessel 112). The cross-flow manifold 222 can be disposed laterally adjacent to the proximal portion of the irradiation chamber 120. The cross-flow manifold 222 can be coupled to the irradiation chamber 120. Additionally, or in the alternative, the cross-flow manifold 222 can be integrally formed as a single component with at least a portion of the irradiation chamber 120. Additionally, or as another alternative, the cross-flow manifold 222 can define at least a portion of the irradiation chamber 120.

[0078] In addition to the one or more supply manifolds 202 , the inerting system 200 may include one or more return manifolds 204 configured to receive and / or exhaust process gas from an irradiation plenum 121 defined by the irradiation chamber 120 .

[0079] For example, Figure 2C As shown, the return manifold 204 can be disposed around the downward portion of the irradiation chamber 120 (e.g., the proximal portion of the irradiation chamber 120 relative to the construction container 112). The return manifold 204 can be disposed laterally adjacent to the proximal portion of the irradiation chamber 120. The return manifold 204 can be coupled to the irradiation chamber 120. In addition, or in the alternative, the return manifold 204 can be integrally formed as a single component with at least a portion of the irradiation chamber 120. In addition, or as another alternative, the return manifold 204 can define at least a portion of the irradiation chamber 120. The return manifold 204 can be disposed opposite to the cross-flow manifold 222. For example, the cross-flow manifold 222 and the return manifold 204 can be disposed around opposite sides of the irradiation chamber 120, respectively. The lateral flow of the process gas from the cross-flow manifold 222 can be directed to the return manifold 204. In addition, or in the alternative, the downward flow from the downflow manifold 210 can be directed to the return manifold 204.

[0080] The one or more return manifolds 204 may be configured to work in combination with the one or more supply manifolds 202. For example, the one or more return manifolds 204 may be configured and arranged to receive a process gas flow flowing through at least a portion of the irradiation chamber 121 defined by the irradiation chamber 120, such as a process gas flow supplied from at least one of the one or more supply manifolds 202. The return manifold 204 may be configured to receive a process gas flow supplied by one or more cross-flow manifolds 222, such as a lateral flow of process gas from one or more cross-flow manifolds 222. In addition, or in the alternative, the return manifold 204 may be configured to receive a process gas flow supplied by one or more downflow manifolds 210, such as a downward flow of process gas from one or more downflow manifolds 210. For example, the cross-flow of process gas from the cross-flow manifold 222 to the return manifold 204 may be configured to provide a flow field that quickly removes and / or discharges contaminants generated by energy beam irradiation of the powder material, for example, without disturbing the powder bed 227. The flow field provided by the cross-flow manifold 222 can remove and / or exhaust contaminants from the irradiation plenum 121 defined by the irradiation chamber 120 before the contaminants have a chance to propagate to the upward region of the irradiation plenum 121 where components of the energy beam system are located. Contaminants that are not entrained in the lateral flow field can be redirected and / or accelerated into the lateral flow field by the downward flow field from the downflow manifold 210.

[0081] The inerting system 200 may include one or more supply manifolds 202 operably grouped with one or more return manifolds 204 with respect to crossflow and / or downflow. Figures 2A-2D As shown, the inerting system 200 may include one or more supply manifolds 202, such as one or more downflow manifolds 210 and / or one or more crossflow manifolds 222, grouped with one or more corresponding return manifolds 204. Figure 2C As shown, the first cross-flow manifold 222 can be paired with the first return manifold 204 relative to a first cross-flow (e.g., a first lateral cross-flow). In addition, or in an alternative, the second cross-flow manifold 222 can be paired with the second return manifold 204 relative to a second cross-flow (e.g., a second lateral cross-flow). The first cross-flow can have a flow field oriented in a first lateral direction, and the second cross-flow can have a second flow field oriented in a second lateral direction different from the first lateral direction. For example, the first lateral direction can differ from the second lateral direction by about 90 degrees, such as from about 30 degrees to about 150 degrees.

[0082] For example, Figure 2BAs shown, a plurality of cross-flow manifolds 222 can be arranged adjacent to each other. In addition, or in the alternative, the cross-flow manifold 222 can be connected to a plurality of process gas supply lines 206. A plurality of process gas supply lines 206 can be fluidly connected to one or more cross-flow manifolds 222 at intervals along the width of one or more process gas supply lines 206. The supply manifold header 224 can distribute process gas between one or more supply manifolds 202. For example, as shown, the supply manifold header 224 can distribute process gas between the downflow manifold 210 and the cross-flow manifold 222. The supply manifold header 224 can include one or more supply header connection elements 226.

[0083] The supply manifold header 224 may include a plurality of process gas supply lines 206 configured to supply manifold distribution elements 205, such as a plurality of cross-flow manifold distribution elements 207 and / or a plurality of downflow manifold distribution elements 209. As an example, as shown, the supply manifold header 224 may include a first cross-flow manifold distribution element 207 and a second cross-flow manifold distribution element 207. In addition, or in the alternative, as shown, the supply manifold header 224 may include a first downflow manifold distribution element 209 and a second downflow manifold distribution element 209. One or more of the plurality of supply manifold distribution elements 205 may be fluidly connected to each other, for example, via one or more supply header connection elements 226. For example, a first end of the supply header connection element 226 may be fluidly connected to the first cross-flow manifold distribution element 207, and a second end of the supply header connection element 226 may be fluidly connected to the second cross-flow manifold distribution element 207. In addition, or in the alternative, a first end of the supply header connection element 226 can be in fluid communication with the downflow manifold distribution element 209, and a second end of the supply header connection element 226 can be in fluid communication with a second downflow manifold distribution element 209. One or more supply header connection elements 226 can allow process gas flow to be proportionally distributed between corresponding cross-flow manifold distribution elements 207 and / or between corresponding paths of the cross-flow manifold 222.

[0084] The supply manifold header 224 may include one or more multi-way fittings 228. The one or more multi-way fittings 228 may distribute the process gas to a plurality of supply manifold distribution elements 205, such as to a plurality of cross-flow manifold distribution elements 207 and / or a plurality of downflow manifold distribution elements 209. The supply manifold header 224 may be constructed and arranged to provide a desired flow rate of the process gas between a plurality of supply manifold distribution elements 205 (e.g., between a plurality of cross-flow manifold distribution elements 207 and / or a plurality of downflow manifold distribution elements 209), and / or to balance the flow rate of the process gas. For example, the respective supply manifold distribution elements 205 may have respective inner diameters selected to provide a desired flow rate of the process gas between the respective supply manifold distribution elements 205 and / or to balance the flow rate of the process gas. In addition, or in the alternative, the supply manifold header 224 may include one or more supply header valves 230. One or more supply manifold valves 230 can be configured to regulate the process gas flow between one or more supply manifolds 202 (e.g., between the downstream manifold 210 and one or more cross-flow manifolds 222). One or more supply manifold valves 230 can be integrated into a corresponding one of the one or more multi-way fittings 228. In addition, or in an alternative, one or more supply manifold valves 230 can be provided separately from one or more multi-way fittings 228. The supply manifold valve 230 can be manually or automatically actuated. For example, one or more supply manifold valves can be controlled by the control system 104 to provide a desired flow rate of process gas between multiple supply manifold distribution elements 205 (e.g., between multiple cross-flow manifold distribution elements 207 and / or multiple downstream manifold distribution elements 209), and / or to balance the flow rate of process gas.

[0085] like Figure 2CAs shown, the process gas flow from the one or more process gas supply lines 206 to the cross-flow manifold 222 can have a downward direction vector 260. In addition, or in the alternative, the process gas flowing from the one or more downflow manifolds 210 into the irradiation chamber 121 defined by the irradiation chamber 120 can have a downward direction vector 260. The process gas flow flowing through the irradiation chamber 121 defined by the irradiation chamber 120 (e.g., from the cross-flow manifold 222 to the return manifold 204) can have a lateral direction vector 262. The cross-flow manifold 222 can be configured to conform the process gas flow from the one or more process gas supply lines 206 having a downward direction vector 260 to the process gas flow having a lateral direction vector 262, for example, to supply the process gas cross-flow to the irradiation chamber 120. For example, when the directional flow of the process gas changes from a downward direction to a lateral direction, the process gas flowing through the cross-flow manifold 222 can have a lateral acceleration direction vector 264. Process gas flowing laterally through the irradiation plenum 121 defined by the irradiation chamber 120 may flow into the one or more return manifolds 204. Process gas having a lateral direction vector 262 (e.g., from one or more cross-flow manifolds 222) may flow laterally into the one or more return manifolds 204. Process gas flowing through the irradiation plenum 121 (e.g., from one or more downflow manifolds 210) having a downward direction vector 260 may also flow into the one or more return manifolds 204. Such a downward direction vector 260 of process gas may at least partially conform to the lateral direction vector 262, for example, by entrainment of a cross-flow of process gas from one or more cross-flow manifolds 222, and / or by suction from one or more return manifolds 204. For example, when the directional flow of the process gas changes from a downward direction to a lateral direction, the process gas flowing from the irradiation plenum 121 into the return manifold 204 may have a lateral acceleration direction vector 264. The return manifold 204 may be configured to coincide process gas flow having a lateral direction vector 262 entering the return manifold 204 with process gas flow having an upward direction vector 266 flowing from the return manifold into one or more process gas exhaust lines 208, e.g., to remove and / or exhaust process gas from the irradiation plenum 121 defined by the irradiation chamber 120. For example, process gas flowing through the return manifold 204 may have an upward acceleration direction vector 268 when the directional flow of the process gas changes from a lateral direction to an upward direction.

[0086] The inerting system 200 may include a plurality of supply manifolds 202 and corresponding return manifolds 204 oriented at a series of longitudinal positions of the irradiation chamber 120. For example, a first supply manifold 202 (e.g., cross-flow manifold 222) and a first return manifold 204 may be oriented respectively around a first longitudinal region of the irradiation chamber 120. A second supply manifold 202 (e.g., cross-flow manifold 222) and a second return manifold 204 may be oriented respectively at a second longitudinal region of the irradiation chamber 120. The first longitudinal region may include a relatively proximal portion of the irradiation chamber 120 relative to the build vessel 112, and the second longitudinal region may include a relatively intermediate portion of the irradiation chamber 120 relative to the first longitudinal region and / or relative to the build vessel 112 and / or a relatively distal portion of the irradiation chamber 120. The first supply manifold 202 can provide a first cross-flow having a flow field oriented in a first lateral direction, and the second supply manifold 202 can provide a second cross-flow having a second flow field oriented in a second lateral direction, which differs from the first lateral direction by, for example, about 90 degrees, such as about 30 degrees to about 150 degrees.

[0087] Reference again Figure 2A and 2C , the energy beam system 118 may include one or more irradiation devices 216. The one or more irradiation devices 216 are each configured to generate one or more energy beams 214 and direct the energy beams 214 onto a powder bed 227 defining a build plane 225. The build plane 225 defined by the powder bed 227 may include, for example, a next continuous layer of powder material 114 distributed across the object 116 being additively manufactured and / or uncured powder material 114 within the powder bed 227. The build unit 110 including the energy beam system 118 and the inerting system 200 may be located above an area of ​​the powder bed 227 to be irradiated by the one or more irradiation devices 216. The one or more energy beams 214 may be used to selectively irradiate a portion of the powder bed 227 above which the build unit 110 is located. The irradiation chamber 120 may provide an irradiation gas chamber 121 including a process gas (e.g., an inert process gas) above an area of ​​the powder bed 227 located below the build unit 110 and / or the irradiation chamber 120.

[0088] The irradiation device 216 can be configured to generate a laser beam, an electron beam, or any other energy beam suitable for additive manufacturing. The irradiation device can be configured to cause the energy beam 214 to selectively solidify the corresponding portion of the powder bed 227 defining the build plane 225. When the corresponding energy beam 214 selectively melts or melts the continuous layer of the powder material 114 defining the powder bed 227, the object 116 begins to take shape. Typically, for DMLM, EBM, or SLM systems, the powder material 114 is completely melted, and the corresponding layer is melted or re-melted as the energy beam passes accordingly. On the contrary, for DMLS or SLS systems, the powder material 114 layer is usually sintered, and the particles of the powder material 114 are usually melted to each other without reaching the melting point of the powder material 114. The energy beam system 118 may include a component integrated as a part of the additive manufacturing machine 102, such as a component integrated as a part of the building unit 110. In addition, or in an alternative, the energy beam system 118 may include a component provided separately from the additive manufacturing machine 102 and / or separately from the building unit 110.

[0089] For example, Figure 2A As shown, the energy beam system 118 may include one or more irradiation devices 216, and the corresponding irradiation devices in the one or more irradiation devices 216 may respectively include an energy beam source 231, a scanner 232, and one or more optical elements 233, and the one or more optical elements 233 are configured to adjust and / or focus the energy beam 214 onto the construction plane 225. The corresponding irradiation device in the one or more irradiation devices 216 may be separated from the irradiation chamber 120 by one or more optical windows 234. The one or more optical windows 234 may separate the one or more optical elements 233 of the energy beam system 118 from the irradiation gas chamber 121 defined by the irradiation chamber 120. For example, the one or more optical windows 234 may separate the one or more optical elements 233 of the irradiation device 216 from the irradiation gas chamber 121. In addition, or in the alternative, the one or more optical windows 234 may separate the one or more optical elements 233 of the monitoring device 218 from the irradiation gas chamber 121. One or more optical windows 234 can separate the one or more optical elements 233 from an optical plenum 235 that defines a portion of the irradiation plenum 121 adjacent to the supply manifold 202 (e.g., downflow manifold 210). The one or more optical windows 234 can be supported by at least a portion of the energy beam system housing 220. The one or more optical windows 234 can define a top portion of the optical plenum 235.

[0090] One or more optical windows 234 and / or at least a portion of the energy beam system housing 220 supporting the one or more optical windows 234 may be configured to fit at least partially within an optical plenum 235 defined by the supply manifold 202 (e.g., the downflow manifold 210). In addition, or in the alternative, the one or more optical windows 234 and / or at least a portion of the energy beam system housing 220 supporting the one or more optical windows 234 may be supported by the supply manifold 202 (e.g., the downflow manifold 210) above the optical plenum 235. The supply manifold (e.g., the downflow manifold 210) may circumferentially surround the optical plenum 235. The optical plenum 235 may be adjacent to the optical window 234. The supply manifold 202 (e.g., the downflow manifold 210) may surround at least a portion of the one or more optical windows 234. One or more optical windows 234 and / or at least a portion of the energy beam system housing 220 supporting the one or more optical windows 234 may define a portion of the supply manifold 202 (e.g., the downflow manifold 210). The inerting system 200 can be configured to provide one or more flow fields that prevent contaminants in the irradiation chamber 121 from contacting and / or depositing on one or more optical windows 234 and / or other components of the energy beam system 118, and / or reduce the amount of contaminants that contact and / or deposit on one or more optical windows 234 and / or other components of the energy beam system 118 over time.

[0091] The supply manifold 202 (e.g., the downflow manifold 210) can define an optical gas chamber 235 that is constructed and arranged to interchangeably accommodate a selected one of a plurality of different energy beam systems 118, such as a selected one of a plurality of different irradiation devices 216, and / or a selected one of a plurality of different monitoring devices 218, and / or a selected one of a plurality of different optical elements 233 thereof. As shown, the optical gas chamber 235 can have an elongated cross-sectional area, such as an elongated rectangular cross-sectional area, configured to accommodate a plurality of adjacently disposed optical elements 233. As an example, as Figure 2D As shown, the downflow manifold 210 can be constructed and arranged to accommodate two irradiation devices 216 and two monitoring devices 218. However, it should be understood that Figure 2D The embodiments shown in are not limiting, and in various embodiments, the supply manifold 202 (eg, the downflow manifold 210 ) may accommodate any number of irradiation devices 216 and / or any number of monitoring devices 218 .

[0092] like Figure 2AAs shown, the energy beam system 118 includes a first irradiation device 216a and a second irradiation device 216b. In other embodiments, the energy beam system 118 may include three, four, six, eight, ten or more irradiation devices 216. The plurality of irradiation devices 216 may be configured to generate one or more energy beams 214, respectively, and the one or more energy beams 214 may be scanned in a scanning field 212 incident on at least a portion of the construction plane 225, respectively. For example, the first irradiation device 216a may generate a first energy beam 214a, and the first energy beam 214a may be scanned in a first scanning field 212a incident on at least the first construction plane area 236a. The second irradiation device 216b may generate a second energy beam 214b, and the second energy beam 214b may be scanned in a second scanning field 212b incident on at least the second construction plane area 236b. First scan field 212a and second scan field 212b may overlap, so that first build plane region 236a scannable by first energy beam 214a overlaps second build plane region 236b scannable by second energy beam 214b. The overlapping portion of first build plane region 236a and second build plane region 236b may sometimes be referred to as staggered region 238. In accordance with the present disclosure, the portion of powder bed 227 to be irradiated within staggered region 238 may be irradiated by first energy beam 214a and / or second energy beam 214b.

[0093] For example, Figure 2B and 2D As shown, the build unit 110 may include one or more powder modules 122. One or more powder modules 122 may be coupled to the irradiation chamber 120 and / or one or more supply manifolds 202. In addition, or in the alternative, one or more powder modules 122 may be provided as separate build units 110. One or more powder modules 122 may be configured to move in coordination with the irradiation chamber 120, for example, as respective parts of a combined build unit 110 and / or as separate cooperating build units 110.

[0094] The powder module 122 may include a supply of powder material 114 contained within a supply chamber 240. The powder module 122 may be coupled to the irradiation chamber 120 via one or more powder module supports 242. The powder module 122 includes a metering mechanism 244 configured to dispense powder material 114 from the supply chamber 240. The metering mechanism 244 may include a piston 246 configured to open and / or close a powder door 248. When the metering mechanism 244 is actuated, a portion of the powder material 114 may be discharged from the powder module 122. A recoater 250 (such as a blade or roller) may continuously distribute a thin layer of powder material 114 across the build plane 225.

[0095] To irradiate the layers of powder bed 227, one or more irradiation devices 216 may respectively direct one or more energy beams 214 through corresponding portions of build plane 225 to melt or fuse portions of powder material 114 that will become part of object 116 being additively manufactured. Build unit positioning system 124 may laterally move build unit 110 to position corresponding scanning fields 212 over designated portions of build plane 225. In addition, or in the alternative, build container positioning system 128 may laterally move build container 112 to position corresponding scanning fields 212 over designated portions of build plane 225. As successive layers of powder material 114 fuse or fuse to one another, build container positioning system 128 may continuously and gradually lower build container 112 to make room for recoater 250 to distribute successive layers of powder material 114. Recoater 250 may include one or more recoater blades 252, etc., configured to provide a smooth layer of powder material 114. Additionally, or in the alternative, build unit positioning system 124 may continuously and incrementally lift build unit 110 to make room for recoater 250 to distribute sequential layers of powder material 114. As successive layers of powder material 114 are applied across build plane 225, the next successive layer of powder material 114 defines a surface of powder bed 227 that coincides with build plane 225. Successive layers of powder bed 227 may be selectively melted or fused until a completed object 116 has been additively manufactured.

[0096] Still reference Figures 2A-2D , additive manufacturing machine 102 may include monitoring system 254. Monitoring system 254 may include one or more monitoring devices 218 configured to detect a monitoring beam (not shown) (e.g., an infrared beam from a laser diode and / or a reflected portion of energy beam 214), and determine one or more parameters associated with irradiating successive layers of powder bed 227 based at least in part on the detected monitoring beam. Build unit positioning system 124 may laterally move build unit 110 to position a corresponding monitoring device 218 over a designated portion of build plane 225. In addition, or in the alternative, build container positioning system 128 may laterally move build container 112 to position a corresponding monitoring device 218 over a designated portion of build plane 225.

[0097] One or more parameters determined by monitoring system 254 may be used, for example, by control system 104 to control one or more operations of additive manufacturing machine 102 and / or additive manufacturing system 100. Monitoring system 254 may be configured to project a monitoring beam (not shown) and detect a portion of the monitoring beam reflected from build plane 225. In addition, and / or in the alternative, monitoring system 254 may be configured to detect a monitoring beam that includes radiation emitted from build plane 225, such as radiation from the energy beam reflected from powder bed 227, and / or radiation generated by the energy beam emitted from a melt pool in powder bed 227, and / or radiation emitted from a portion of powder bed 227 adjacent to the melt pool.

[0098] Monitoring system 254 may include components that are integrated as part of additive manufacturing machine 102 and / or components that are provided separately from additive manufacturing machine 102. For example, monitoring system 254 may include components that are integrated as part of energy beam system 118 and / or components that are integrated as part of build unit 110. In addition, or in the alternative, monitoring system 254 may include separate components, such as in the form of assemblies, that may be installed as part of energy beam system 118 and / or installed as part of additive manufacturing machine 102, and / or installed as part of a separate build unit 110.

[0099] Now turn to Figures 3A-3D , an exemplary irradiation chamber 120 will be further described. Irradiation chamber 120 can define an irradiation plenum 121, which can contain a process gas, such as an inert gas, suitable for irradiating at least a portion of build plane 225. Irradiation plenum 121 can be defined by one or more irradiation chamber walls 300. One or more irradiation chamber walls 300 can define a portion of an integrally formed component. In addition, or in the alternative, one or more irradiation chamber walls 300 can include separate wall elements 302 coupled to each other. One or more supply manifolds 202 and / or one or more return manifolds 204 can define at least a portion of irradiation chamber 120 and / or at least a portion of irradiation plenum 121 defined by one or more irradiation chamber walls 300. A bottom portion 304 of irradiation plenum 121 defined by irradiation chamber 120 and / or its irradiation chamber walls 300 can be at least partially open to build plane 225. The top portion 306 of the irradiation chamber 121 defined by the irradiation chamber 120 and / or its irradiation chamber walls 300 may be at least partially defined by the energy beam system 118 and / or one or more optical windows 234. In addition, or in the alternative, the top portion 306 of the irradiation chamber 121 defined by the irradiation chamber 120 and / or its irradiation chamber walls 300 may be at least partially open to receive the energy beam system 118 and / or one or more optical windows 234.

[0100] The irradiation chamber 120 may include a downflow chamber 308 and / or a crossflow chamber 310. For example, the irradiation chamber 120 may include a downflow chamber 308 coupled to the crossflow chamber 310. The downflow chamber 308 may be disposed around a distal portion of the irradiation chamber 120 relative to the build plane 225. The downflow chamber 308 may define a downflow plenum 309. The downflow plenum 309 may include or refer to at least a portion of the irradiation plenum 121 in which the process gas presents a downflow. The downflow chamber 308 may be at least partially defined by the downflow manifold 210. In addition, or in the alternative, the downflow chamber 308 may be at least partially defined by one or more irradiation chamber walls 300 and / or wall elements 302. Such one or more irradiation chamber walls 300 and / or wall elements 302 may be coupled to the downflow manifold 210, and / or may be integrally formed as a single component with the downflow manifold 210. The cross-flow chamber 310 can be disposed around a proximal portion of the irradiation chamber 120 relative to the build plane 225. The cross-flow chamber 310 can define a cross-flow plenum 311. The cross-flow plenum 311 can include or refer to at least a portion of the irradiation plenum 121 in which the process gas exhibits a cross-flow. The downflow chamber 308 can include one or more downflow walls 312, which are connected to the downflow manifold 210 and / or are formed integrally with the downflow manifold 210 as a single component. The cross-flow chamber 310 can be at least partially defined by the cross-flow manifold 222 and / or at least partially by the return manifold 204. In addition, or in the alternative, the cross-flow chamber 310 can be at least partially defined by one or more irradiation chamber walls 300 and / or wall elements 302. Such one or more irradiation chamber walls 300 and / or wall elements 302 may be coupled to the cross-flow manifold 222 and / or the return manifold 204 and / or may be integrally formed as a single component with the cross-flow manifold 222 and / or the return manifold 204. The cross-flow chamber 310 may include one or more cross-flow walls 314 coupled to the cross-flow manifold 222 and / or the return manifold 204 and / or may be integrally formed as a single component with the cross-flow manifold 222 and / or the return manifold 204.

[0101] The irradiation chamber 120 and / or the irradiation chamber 121 defined by the irradiation chamber 120 and / or one or more irradiation chamber walls 300 thereof may exhibit any desired three-dimensional shape, including a prism, a cylinder, a truncated cone, etc., and combinations thereof. As an example, Figure 3A and 3B An exemplary irradiation chamber 120 is shown, which has a prismatic shape. Figure 3A and 3B As shown, the irradiation chamber 120 may have a rectangular prism shape. As a further example, Figure 3C and 3D An exemplary irradiation chamber 120 and / or an exemplary irradiation gas chamber 121 are shown, which have a cylindrical shape. Figure 3CAs shown, the irradiation chamber 120 and / or the irradiation gas chamber 121 may have a truncated cone shape. Figures 3A-3D The examples shown in are provided as examples only and are not intended to be limiting. Many other configurations and arrangements are contemplated, including combinations of the provided examples, all of which are within the scope of the present disclosure.

[0102] As used herein, the term "prism" refers to a polyhedron having an n-sided polygonal base and an n-sided polygonal top. A prism may include an n-sided polygonal base and a top representing a translation of the n-sided polygonal base. The polygonal base and the polygonal top may have different numbers of sizes. As used herein, the term "cylinder" refers to a three-dimensional shape defined by an elliptical base and an elliptical top. The elliptical top and / or the elliptical bottom of the cylinder may include any elliptical shape, including circular, oval, etc. As used herein, the term "truncated cone" refers to a prism or cylinder having a base and a top, the base and the top having different sizes, respectively. For example, a truncated cone may include an n-sided polygonal base and an n-sided polygonal top having different sizes, respectively. As another example, a truncated cone may include an elliptical base and an elliptical top having different sizes, respectively.

[0103] One or more downflow walls 312 and / or one or more cross-flow walls 314 may be oriented parallel to and / or inclined to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross-flow chamber 310. One or more downflow walls 312 and / or one or more cross-flow walls 314 may be oriented parallel to and / or inclined to the lateral axis 318 of the irradiation chamber 120 and / or the cross-flow chamber 310. In addition, or in the alternative, one or more downflow walls 312 and / or one or more cross-flow walls 314 may have a curvilinear orientation having one or more tangents that are parallel and / or inclined relative to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross-flow chamber 310. One or more downflow walls 312 and / or one or more cross-flow walls 314 may have a curvilinear orientation having one or more tangents that are parallel and / or inclined relative to the lateral axis 318 of the irradiation chamber 120 and / or the cross-flow chamber 310.

[0104] Figures 3A-3C An exemplary irradiation chamber 120 is shown having a downflow wall 312 oriented parallel to a longitudinal axis 316 of the irradiation chamber 120 . Figures 3A-3C Also shown is an exemplary cross-flow chamber 310 having a cross-flow wall 314 oriented parallel to a longitudinal axis 316 of the irradiation chamber 120 . Figure 3D An exemplary irradiation chamber 120 is shown having one or more downflow walls oriented obliquely to the longitudinal axis 316 of the cross flow chamber 310 . Figure 3DAlso shown is an exemplary cross flow chamber 310 having one or more downflow walls oriented obliquely to a longitudinal axis 316 of the cross flow chamber 310 .

[0105] One or more downflow walls 312 and / or one or more cross-flow walls 314 can be oriented parallel to and / or inclined to the lateral axis 318 of the irradiation chamber and / or the cross-flow chamber 310. The lateral axis 318 can be aligned with the lateral flow field discharged from the cross-flow chamber 310. In addition, or in the alternative, one or more downflow walls 312 and / or one or more cross-flow walls 314 can have a curvilinear orientation having one or more tangents parallel to and / or inclined to the lateral axis 318 of the irradiation chamber 120 and / or the cross-flow chamber 310.

[0106] Figure 3A and 3C An exemplary irradiation chamber 120 is shown having a downflow wall 312 oriented parallel to a lateral axis 318 of the irradiation chamber 120 . Figure 3A and 3C Also shown is an exemplary cross-flow chamber 310 having a cross-flow wall 314 oriented parallel to a lateral axis 318 of the irradiation chamber 120 . Figure 3B An exemplary irradiation chamber 120 is shown having one or more downflow walls 312 oriented obliquely to a lateral axis 318 of the irradiation chamber 120 . Figure 3B Also shown is an exemplary cross flow chamber 310 having one or more cross flow walls 314 oriented obliquely to a lateral axis 318 of the cross flow chamber 310. An exemplary irradiation chamber 120 may include one or more downflow walls 312 oriented laterally and obliquely to the lateral axis 318 of the irradiation chamber 120, and one or more downflow walls 312 oriented transversely and perpendicularly to the lateral axis of the irradiation chamber 120. An exemplary cross flow chamber 310 may include one or more cross flow walls 314 oriented laterally and obliquely to the lateral axis 318 of the cross flow chamber 310, and one or more cross flow walls 314 oriented transversely and perpendicularly to the lateral axis of the cross flow chamber 310. Figure 3D An exemplary irradiation chamber 120 is shown having one or more curvilinear downflow walls 312 having one or more tangent lines oriented parallel and / or oblique to a lateral axis 318 of the irradiation chamber 120 . Figure 3D Also shown is an exemplary cross flow chamber 310 having one or more curvilinear cross flow walls 314 having one or more tangents oriented parallel and / or oblique to a lateral axis 318 of the cross flow chamber 310 .

[0107] The irradiation chamber 120 and / or the irradiation chamber 121 may exhibit a change in one or more dimensions corresponding at least in part to the direction vector of the flow field. One or more dimensions of the irradiation chamber 120 and / or the irradiation chamber 121 may increase or decrease corresponding at least in part to the direction vector of the flow field. For example, Figure 3D As shown, the downflow manifold 210 can provide a downward flow field having a downward direction vector 260. The cross-sectional width and / or cross-sectional area of ​​the irradiation chamber 120 and / or the irradiation plenum 121 can increase and / or decrease in the direction of the downward direction vector 260. For example, Figure 3B As shown, the cross-flow manifold 222 can provide a lateral flow field having a lateral direction vector 262. The cross-sectional width and / or cross-sectional area of ​​the irradiation chamber 120 and / or the irradiation plenum 121 can increase and / or decrease in the direction of the lateral direction vector 262.

[0108] For example, Figure 3B As shown, the cross-sectional width and / or cross-sectional area of ​​the irradiation chamber 120 and / or the irradiation gas chamber 121 can be reduced in the direction of the lateral direction vector 262 (e.g., from the cross-flow manifold 222 to the return manifold 204, and / or through at least a portion of the cross-flow chamber 310). This reduced cross-sectional width and / or area can improve the fluid characteristics of the lateral flow field. For example, the reduced cross-sectional width and / or area can provide an improved velocity distribution, such as improved uniformity across the width of the lateral flow field. In addition, or in the alternative, the tendency for backflow and / or eddy currents along the edge of the lateral flow field can be reduced by providing a reduced cross-sectional width and / or area across at least a portion of the cross-flow chamber 310 (e.g., across at least a portion of the lateral flow path from the cross-flow manifold 222 to the return manifold 204).

[0109] An irradiation chamber 120 and / or irradiation plenum 121 and / or cross flow chamber 310 having a reduced cross-sectional width and / or area can increase the velocity of the lateral flow field as the lateral flow of process gas approaches the return manifold 204. A velocity gradient can exist in the lateral flow field of the process gas, for example, increasing from the cross flow manifold 222 to the return manifold 204 and / or across at least a portion of the cross flow chamber 310. For example, such an increased velocity gradient can provide a sufficiently high velocity in the flow field to move contaminants in the process gas out of the processing chamber and into one or more return manifolds 204, rather than such contaminants being redeposited on the powder bed 227. In addition, or in the alternative, a lateral flow field having a sufficiently large lateral direction vector can provide at least partial stratification in the lateral flow field (e.g., in the cross flow chamber 310). For example, the lateral flow field may exhibit stratification between at least a portion of the lateral flow field corresponding to process gas from the cross-flow manifold 222 and at least a portion of the lateral flow field corresponding to process gas from the downflow manifold 210 .

[0110] For example, Figure 3D As shown, the cross-sectional width and / or cross-sectional area of ​​the irradiation chamber 120 and / or the irradiation gas chamber 121 can increase in the direction of the downward direction vector 260 (e.g., from the downflow manifold 210 and / or the downflow chamber 308 to the cross-flow chamber 310). As the downward flow of the process gas approaches the build plane 225, this increased cross-sectional width and / or area can reduce the velocity of the downward flow field. A velocity gradient can exist in the downward flow field of the process gas, for example, decreasing from the downflow manifold 210 and / or the downflow chamber 308 to the cross-flow chamber 310. This reduced velocity gradient can provide a sufficiently high velocity in the flow field near one or more optical windows 234 and / or other components of the energy beam system 118 to protect the one or more optical windows 234 and / or other components of the energy beam system 118, while also providing a sufficiently low velocity in the flow field near the cross-flow chamber 310 and / or the powder bed 227 to avoid the downward flow of the process gas from interfering with the powder bed 227. In addition, or in the alternative, the reduced velocity gradient can enhance entrainment of process gas in the lateral flow field with process gas in the downward flow field. Such entrainment of downwardly flowing process gas by the lateral flow field can help draw the downwardly flowing process gas into the one or more return manifolds 204, for example, by transforming the downward flow field into a lateral flow field.

[0111] Now turn to Figures 4A-4E , an exemplary downflow manifold 210 will be further described. As shown, the downflow manifold 210 may include a downflow manifold body 400. The downflow manifold body 400 may circumferentially surround the optical gas chamber 235. The downflow manifold body 400 may be in fluid communication with one or more process gas supply lines 206. The one or more process gas supply lines 206 may be directly in fluid communication with the downflow manifold body 400. In addition, or in the alternative, the downflow manifold 210 may include a supply manifold header 224, which is configured to supply process gas from one or more process gas supply lines 206 to the downflow manifold body 400. The supply manifold header 224 may be connected to one or more process gas supply lines 206 (e.g., Figure 2B-2D ) fluid communication. One or more process gas supply lines 206 may be coupled to the supply manifold header 224, for example, at one or more multi-way header fittings 404. Figure 4A As shown, and reference Figure 2B-2D , a first portion of the process gas flow may be supplied from one or more process gas supply lines 206 via a supply manifold header 224 (e.g., by coupling the supply manifold header 224 to a multi-way header fitting 404 of the process gas supply lines 206). Additionally, or in the alternative, a second portion of the process gas flow may be supplied to the cross flow manifold 222, for example, via a portion of a process gas supply line 206 extending downstream from the supply manifold header 224.

[0112] The exemplary downflow manifold body 400 may include one or more top downflow manifold walls 406, one or more bottom downflow manifold walls 408, one or more outward downflow manifold walls 410, and / or one or more inward downflow manifold walls 412. The downflow manifold body 400 may include a top downflow manifold wall 406 that is configured to be oriented toward the energy beam system 118 (e.g., toward one or more irradiation devices 216 and / or one or more monitoring devices 218). The downflow manifold body 400 may include one or more attachment points 411, for example, at the top downflow manifold wall 406 that are configured to connect the downflow manifold 210 to one or more components of the energy beam system 118. In addition, or in the alternative, the top downflow manifold wall 406 may be integrally formed with one or more walls of the energy beam system. The downflow manifold body 400 may include one or more outward downflow manifold walls 410 that define the periphery of the downflow manifold body 400. The one or more outward downflow manifold walls 410 may include attachment points 411 for attaching the one or more irradiation chamber walls 300 to the downflow manifold body 400. In addition, or in the alternative, the one or more outward downflow manifold walls 410 may be integrally formed with the one or more irradiation chamber walls 300. The downflow manifold body 400 may include one or more bottom downflow manifold walls 408 configured to be oriented toward the irradiation plenum 121. The bottom downflow manifold wall 408 may define at least a portion of the irradiation chamber 120. For example, the bottom downflow manifold wall 408 may provide an upward boundary for the irradiation plenum 121. In addition, or in the alternative, the one or more bottom downflow manifold walls 408 may be integrally formed with at least a portion of the irradiation chamber 120 (e.g., with the one or more irradiation chamber walls 300).

[0113] The supply manifold header 224 may be in fluid communication with the downflow manifold body 400 at a plurality of locations, such as at the top downflow manifold wall 406 and / or at one or more outward downflow manifold walls 410. The supply manifold header 224 may be in fluid communication with the downflow manifold body 400 at a plurality of locations distributed around the one or more outward downflow manifold walls 410. The outward downflow manifold walls 410 may include end walls and side walls. An end wall may refer to an outward downflow manifold wall 410 having a length less than an average length of the outward downflow manifold walls 410. A side wall may refer to an outward downflow manifold wall 410 having a length greater than an average length of the outward downflow manifold walls 410. The supply manifold header 224 may be in fluid communication with one or more outward downflow manifold walls 410 configured as end walls of the downflow manifold body 400 and / or with one or more outward downflow manifold walls 410 configured as side walls of the downflow manifold body 400.

[0114] The supply manifold header 224 may include one or more downflow manifold distribution elements 209 that are in fluid communication with the downflow manifold body 400, for example, at one or more locations around one or more outward downflow manifold walls 410. The first downflow manifold distribution element 209 may be in fluid communication with the downflow manifold body 400 at a first outward downflow manifold wall 410 (e.g., a first end wall of the downflow manifold body 400). The first downflow manifold distribution element 209 may be in fluid communication with the first process gas supply line 206 via a first multi-way header fitting 404. The second downflow manifold distribution element 209 may be in fluid communication with the downflow manifold body 400 at a second outward downflow manifold wall 410 (e.g., a second end wall of the downflow manifold body 400). The second downflow manifold distribution element 209 may be in fluid communication with the second process gas supply line 206 via a second multi-way header fitting 404.

[0115] The supply manifold header 224 may include a plurality of downflow manifold distribution elements 209, such as a first downflow manifold distribution element 209 and a second downflow manifold distribution element 209, in fluid communication with each other, such as through supply manifold connection elements 226. For example, a first end of the supply manifold connection element 226 may be in fluid communication with the first multi-way manifold fitting 404, and a second end of the supply manifold connection element 226 may be in fluid communication with the second multi-way manifold fitting 404. In addition, or in the alternative, respective ends of the supply manifold connection element 226 may be in direct fluid communication with the first and second downflow manifold distribution elements 209. One or more supply manifold connection elements 226 may allow the process gas flow to be proportionally distributed between respective paths of the downflow manifold 210 (e.g., between respective paths through the supply manifold header 224 and / or between respective paths through the downflow manifold body 400).

[0116] like Figure 4B , 4D As shown in 4E, the downflow manifold body 400 may include one or more downflow manifold paths 418 disposed therein. The one or more downflow manifold paths 418 may be defined by one or more inner walls of the downflow manifold body 400. The downflow manifold body 400 may include one or more downflow manifold baffles 420 disposed within the one or more downflow manifold paths 418. The downflow manifold paths 418 and / or the downflow manifold baffles 420 may be configured to provide desired flow characteristics within the one or more downflow manifold paths 418. For example, the downflow manifold baffles 420 may cause the process gas to uniformly pressurize the one or more downflow manifold paths 418.

[0117] The downflow manifold body 400 may include one or more inward downflow manifold walls 412. The one or more inward downflow manifold walls 412 may be oriented parallel to or obliquely to the longitudinal axis 424 of the downflow manifold body 400. For example, Figure 4B-4EAs shown, one or more inward downflow manifold walls 412 can diverge from the longitudinal axis 424 of the downflow manifold body 400. The inward downflow manifold wall 412 can diverge in the proximal direction relative to the powder bed 227, such that the distance from the longitudinal axis 424 to the inward downflow manifold wall 412 increases as it gets closer to the powder bed 227. The divergence of the one or more inward downflow manifold walls 412 can be determined with reference to the divergence angle relative to the longitudinal axis 424 of the downflow manifold body 400. For example, Figure 2A As shown, the divergence angle of the one or more inward downflow manifold walls 412 may be determined at least in part based on the position of the scan field 212 of the one or more energy beams 214 of the energy beam system 118. The divergence angle of the one or more inward downflow manifold walls 412 may provide clearance for the one or more energy beams 214 of the energy beam system 118 to approach a portion of the build plane 225 corresponding to the corresponding scan field 212, for example, without the corresponding scan field 212 being interrupted by the one or more inward downflow manifold walls 412.

[0118] The downflow manifold body 400 may include a plurality of downflow manifold orifices 422 disposed about one or more walls of the downflow manifold body 400 (e.g., one or more inward downflow manifold walls 412 and / or one or more bottom downflow manifold walls 408). The orifices 422 may be in the form of apertures, holes, slits, perforations, pinholes, etc. The process gas flowing through the one or more downflow manifold paths 418 may be discharged into the irradiation gas chamber 121 and / or the optical gas chamber 235 through the plurality of downflow manifold orifices 422. The plurality of downflow manifold orifices 422 may be constructed and arranged to provide a process gas flow having desired flow characteristics from the downflow manifold body 400 into the irradiation gas chamber 121 and / or the optical gas chamber 235. One or more downflow manifold baffles 420 may facilitate uniform flow of process gas across the plurality of downflow manifold apertures 422 and / or relative to various areas of the downflow manifold body 400 (eg, relative to one or more inward downflow manifold walls 412 and / or one or more bottom downflow manifold walls 408 ).

[0119] The plurality of downflow manifold orifices 422 may have any desired orientation. The plurality of downflow manifold orifices 422 may be configured to provide a flow field having a downward direction vector 260, such as a flow field oriented perpendicular to the construction plane 225. The flow field may additionally or alternatively be oriented perpendicular to the downflow manifold body 400 (e.g., perpendicular to one or more bottom downflow manifold walls 408). In addition, or in the alternative, the plurality of downflow manifold orifices 422 may be configured to provide a flow field having a downward direction vector 260 oriented parallel to the longitudinal axis 424 of the downflow manifold body 400.

[0120] Additionally or alternatively, the plurality of downflow manifold apertures 422 may be configured to provide a flow field having a lateral direction vector 262, such as a flow field oriented parallel to the construction plane 225. The flow field may additionally or alternatively be oriented parallel to the downflow manifold body 400 (e.g., parallel to one or more bottom downflow manifold walls 408). For example, Figure 4D and 4E As shown, the direction vector of the flow field from at least some of the plurality of downflow manifold orifices 422 can have any desired orientation, including the downward direction vector 260, the lateral direction vector 262, and / or a combination thereof. At least some of the plurality of downflow manifold orifices 422 can be oriented parallel to or substantially parallel to the longitudinal axis 424 of the downflow manifold body 400, such as within about 10 degrees of being parallel to the longitudinal axis 424 of the downflow manifold body 400, such as within about 5 degrees of being parallel to the longitudinal axis 424 of the downflow manifold body 400, or such as within about 1 degree of being parallel to the longitudinal axis 424 of the downflow manifold body 400.

[0121] The plurality of downflow manifold apertures 422 disposed about the one or more inward downflow manifold walls 412 may be oriented parallel or substantially parallel to the longitudinal axis 424 of the downflow manifold body 400. Additionally, or in the alternative, the plurality of downflow manifold apertures 422 disposed about the one or more bottom downflow manifold walls 408 may be oriented parallel or substantially parallel to the longitudinal axis 424 of the downflow manifold body 400. A majority of the downflow manifold apertures 422 may be oriented parallel or substantially parallel to the longitudinal axis of the downflow manifold body 400, and / or substantially all of the downflow manifold apertures 422 may be oriented parallel or substantially parallel to the longitudinal axis of the downflow manifold body 400. For example, at least 60%, at least 80%, and / or at least 90% of the downflow manifold apertures 422 may be oriented parallel or substantially parallel to the longitudinal axis of the downflow manifold body 400. Additionally, or in the alternative, at least some of the plurality of downflow manifold apertures 422 may be oriented obliquely and / or perpendicularly to the longitudinal axis 424 of the downflow manifold body 400. For example, the plurality of downflow manifold apertures 422 disposed about one or more inward downflow manifold walls 412 may be oriented obliquely and / or perpendicularly to the longitudinal axis 424 of the downflow manifold body 400. Additionally, or in the alternative, the plurality of downflow manifold apertures 422 oriented perpendicularly to the longitudinal axis 424 of the downflow manifold body 400 may at least partially surround the plurality of downflow manifold apertures 422 oriented obliquely and / or perpendicularly to the longitudinal axis 424 of the downflow manifold body 400. The plurality of downflow manifold apertures 422 oriented perpendicularly to the longitudinal axis 424 may be disposed about one or more bottom downflow manifold walls 408 and / or one or more inward downflow manifold walls 412.

[0122] The size, shape and / or number of the plurality of downflow manifold orifices 422 can be selected based on the desired flow characteristics of the process gas provided from the downflow manifold 210 to the irradiation gas chamber 121. At least some of the plurality of downflow manifold orifices 422 can be configured to provide a laminar flow of the process gas. In addition, or in an alternative, at least some of the plurality of downflow manifold orifices 422 can be configured to provide a turbulent flow of the process gas. For example, the downflow manifold body 400 can include a first plurality of downflow manifold orifices 422 configured to provide a laminar flow and a second plurality of downflow manifold orifices 422 configured to provide a turbulent flow.

[0123] The downflow manifold 210 may include a downflow manifold body 400 having an annular or semi-annular configuration. For example, Figures 4A-4E The downflow manifold 210 shown in has a downflow manifold body 400, and the downflow manifold body 400 has a rectangular annular structure. As another example, the downflow manifold 210 may include a downflow manifold body 400 having a curved annular or semi-annular structure. For example, a plurality of downflow manifolds 210 may respectively include a downflow manifold body 400, which has a semi-annular structure that provides an annular structure together. In addition, or in an alternative, the downflow manifold 210 may include a plurality of downflow manifold bodies 400, which have, for example, a semi-annular structure that provides an annular structure together. The downflow manifold body 400 may include one or more inward downflow manifold walls 412 that define at least a portion of the irradiation air chamber 121. The downflow manifold body 400 may include one or more inward downflow manifold walls 412 and one or more bottom downflow manifold walls 408 that respectively define a portion of the irradiation air chamber 121. Additionally, or in the alternative, at least a portion of one or more bottom downflow manifold walls 408 may be constructed and arranged outside of the irradiation plenum 121, e.g., only one or more inward downflow manifold walls 412 of the downflow manifold body 400 define a portion of the irradiation plenum 121. However, in other embodiments, a first portion of the bottom downflow manifold wall 408 may define a portion of the irradiation plenum 121, while a second portion of the bottom downflow manifold wall 408 may be outside of the irradiation plenum 121.

[0124] The downflow manifold 210 may include one or more inward downflow manifold walls 412 defining an optical gas chamber 235. The optical gas chamber 235 may include or refer to a portion of the irradiation gas chamber 121 adjacent to one or more optical windows 234, which separate the one or more optical elements 233 of the irradiation device 216 from the irradiation gas chamber 121. The optical gas chamber 235 may include or refer to the portion of the irradiation gas chamber 121 defined by the one or more inward downflow manifold walls 412 of the downflow manifold body 400. The optical gas chamber 235 may be at least partially defined by one or more inward downflow manifold walls 412 including a plurality of downflow manifold orifices 422. The plurality of downflow manifold orifices 422 disposed about the inward downflow manifold wall 412 may supply process gas to the optical gas chamber 235. The process gas supplied to the optical gas chamber 235 can prevent contaminants from contacting and / or being deposited on one or more optical windows 234 or other components of the energy beam system 118, and / or can reduce the amount of contaminants that contact and / or are deposited on one or more optical windows 234 or other components of the energy beam system 118 over time.

[0125] A plurality of downflow manifold orifices 422 disposed around the inner downflow manifold wall 412 can supply a turbulent flow of the process gas to the optical gas chamber 235, while a plurality of downflow manifold orifices 422 disposed around one or more bottom downflow manifold walls 408 can supply a laminar flow of the process gas to the irradiation gas chamber 121. The turbulent flow of the process gas supplied by the plurality of downflow manifold orifices 422 disposed around the inner downflow manifold wall 412 can provide a turbulent region adjacent to one or more optical windows 234. The turbulent region can occupy at least a portion of the optical gas chamber 235. The laminar flow of the process gas supplied by the plurality of downflow manifold orifices 422 disposed around one or more bottom downflow manifold walls 408 can provide a laminar flow region within at least a portion of the irradiation gas chamber 121. The turbulent region can be located within the optical gas chamber 235 defined by the one or more inner downflow manifold walls 412, and the laminar flow region can be disposed below the turbulent region. The laminar flow region can provide a flow field that propagates laminarly toward the cross flow chamber 310. The turbulent flow region can provide a turbulent cross flow that resists contaminants from entering the optical gas chamber 235 and / or quickly removes contaminants from the optical gas chamber 235. Both the laminar flow region and the turbulent flow region can exhibit turbulence while still providing similar effects. For example, the process gas supplied to the optical gas chamber 235 can exhibit a higher degree of turbulence than the process gas supplied to the irradiation gas chamber 121.

[0126] In addition, or in the alternative, a plurality of downflow manifold orifices 422 disposed about the inner downflow manifold wall 412 can supply a laminar flow of process gas to the optical gas chamber 235, while a plurality of downflow manifold orifices 422 disposed about one or more bottom downflow manifold walls 408 can supply a turbulent flow of process gas to the irradiation gas chamber 121. The laminar flow of process gas supplied by the plurality of downflow manifold orifices 422 disposed about the inner downflow manifold wall 412 can provide a laminar flow region within the optical gas chamber 235 and / or a stagnant region adjacent to the one or more optical windows 234. The laminar flow region and / or the stagnant region can occupy at least a portion of the optical gas chamber 235. The turbulent flow of process gas supplied by the plurality of downflow manifold orifices 422 disposed about the one or more bottom downflow manifold walls 408 can provide a turbulent flow region within at least a portion of the irradiation gas chamber 121. The laminar flow region and / or the stagnant region can be located in the optical gas chamber 235 defined by one or more inwardly downwardly flowing manifold walls 412, and the turbulent flow region can be arranged below the laminar flow region and / or the stagnant region. The laminar flow region and / or the turbulent flow region can provide a flow field propagating toward the cross flow chamber 310. The stagnant region can resist the entry of pollutants into the optical gas chamber 235 and / or can cause pollutants to fall out of the optical gas chamber 235 by the vultures (vulture) of the flow stagnation in the optical gas chamber 235. Both the laminar flow region and the turbulent flow region can present turbulence and / or laminar flow, while still providing similar effects. For example, the process gas supplied to the optical gas chamber 235 can present a lower degree of flow than the process gas supplied to the irradiation gas chamber 121.

[0127] Now turn to Figure 5A and 5B , an exemplary cross-flow manifold 222 will be further described. The cross-flow manifold 222 may be in fluid communication with one or more process gas supply lines 206. The cross-flow manifold 222 may be configured to provide a cross-flow of process gas to the irradiation chamber 121 defined by the irradiation chamber 120 and / or to the cross-flow chamber 311 defined by the cross-flow chamber 310. The cross-flow manifold 222 may include one or more cross-flow manifold bodies 500. For example, as Figure 5A and 5B As shown, the cross-flow manifold 222 can include a plurality of cross-flow manifold bodies 500 constructed and arranged along the width of the cross-flow manifold 222. The plurality of cross-flow manifold bodies 500 can be coupled to each other. In addition, or in an alternative, the plurality of cross-flow manifold bodies 500 can define corresponding portions of the cross-flow manifold 222 formed integrally.

[0128] The cross-flow manifold body 500 can be configured to change the cross-sectional area of ​​the process gas flow field flowing into the cross-flow manifold 222 and through the cross-flow manifold body 500. The flow field flowing into the cross-flow manifold body 500 can have, for example, a circular cross-sectional profile corresponding to the process gas supply line 206. The flow field discharged from the cross-flow manifold body 500 can have, for example, an elongated cross-sectional profile corresponding to the cross-flow plenum 311 defined by the cross-flow chamber 310. In addition, or in the alternative, the flow field flowing into the cross-flow manifold body 500 can include, for example, a downward direction vector 260 corresponding to the orientation of the process gas supply line 206. The flow field discharged from the cross-flow manifold body 500 can include a lateral flow field having, for example, a lateral direction vector 262 corresponding to the orientation of the cross-flow plenum 311 defined by the cross-flow chamber 310. The process gas flow flowing through the cross-flow manifold body 500 can conform to the elongated flow field. Lateral flow fields (eg, elongated flow fields) may flow laterally through cross-flow plenum 311 defined by cross-flow chamber 310. Cross-flow manifold body 500 may conform one or more circular cross-sectional flow fields having downward direction vector 260 to one or more elongated flow fields having lateral direction vector 262.

[0129] The cross-flow manifold 222 and / or the cross-flow manifold body 500 may include one or more cross-flow manifold inlets 502 and one or more cross-flow manifold outlets 504. The cross-flow manifold 222 may include one or more cross-flow manifold paths 506 at least partially defined by one or more cross-flow manifold bodies 500. One or more cross-flow manifold path walls 508 may define at least a portion of the plurality of cross-flow manifold paths 506. One or more cross-flow manifold path walls 508 may be disposed within the cross-flow manifold body 500, and / or one or more cross-flow manifold path walls 508 may be integrally formed with the cross-flow manifold body 500 as a single component.

[0130] Process gas entering one or more cross-flow manifold inlets 502 may flow through one or more cross-flow manifold paths 506 and exit the cross-flow manifold 222 at one or more cross-flow manifold outlets 504. For example, Figure 5A and 5BAs shown, the cross-flow manifold may include a plurality of cross-flow manifold inlets 502 and a common cross-flow manifold outlet 504. The corresponding cross-flow manifold inlet in the plurality of cross-flow manifold inlets 502 may correspond to the corresponding cross-flow manifold body in the plurality of cross-flow manifold bodies 500. The plurality of cross-flow manifold bodies 500 may have a common cross-flow manifold outlet 504. One or more cross-flow manifold outlets 504 may be configured to discharge a lateral flow field of a process gas having an elongated cross-sectional area. The cross-flow manifold body 500 may have a shape that conforms the cross-sectional area of ​​the flow field from the inlet cross-sectional area corresponding to the one or more cross-flow manifold inlets 502 to the outlet cross-sectional area corresponding to the one or more cross-flow manifold outlets 504. As shown, one or more cross-flow manifold inlets 502 may have an elliptical cross-sectional profile, such as a circular cross-sectional profile. However, cross-flow manifold inlets 502 with other cross-sectional profiles are also envisioned, including cross-flow manifold inlets 502 with rectangular or polygonal cross-sectional profiles. One or more cross-flow manifold outlets 504 may have an elongated cross-sectional profile. As shown, the elongated cross-sectional area of ​​the cross-flow manifold outlet 504 may have a rectangular cross-sectional profile; however, other cross-sectional profiles are also contemplated, including curved cross-sectional profiles, such as an elliptical cross-sectional profile.

[0131] The crossflow manifold outlet 504 can discharge process gas flows supplied from multiple crossflow manifold inlets 502. In addition, or in the alternative, the crossflow manifold outlet 504 can discharge process gas flows from multiple crossflow manifold paths 506. The number of crossflow manifold inlets 502 can exceed the number of crossflow manifold outlets 504 by at least one. The crossflow manifold 222 can include multiple crossflow manifold inlets 502 and one or more crossflow manifold outlets 504, such as two to six crossflow manifold inlets 502 and one to three crossflow manifold outlets 504, such as two, three, four, five or six crossflow manifold inlets 502, and one, two or three crossflow manifold outlets 504. Figure 5A and 5B As shown, the cross-flow manifold 222 may include two cross-flow manifold inlets 502 and one cross-flow manifold outlet 504 .

[0132] The configuration and arrangement of the cross-flow manifold body 500 can be determined at least in part to provide a lateral flow field with a desired flow characteristic. The cross-flow manifold body 500, one or more cross-flow manifold paths 506, and / or one or more cross-flow manifold path walls 508 can be configured to change the cross-sectional profile of the flow field. The cross-sectional profile of the flow field can be modified relative to the geometry and / or surface area. The cross-sectional profile of the flow field can be modified from the elliptical cross-sectional profile (e.g., circular cross-sectional profile) at one or more cross-flow manifold inlets 502 to the elongated cross-sectional profile (e.g., rectangular cross-sectional profile) at the cross-flow manifold outlet 504. In addition, or in an alternative, the cross-flow manifold body 500, one or more cross-flow manifold paths 506, and / or one or more cross-flow manifold path walls 508 can be configured to modify the direction vector of the flow field. For example, the direction vector of the flow field can be modified from the downward direction vector 260 at one or more cross-flow manifold inlets 502 to the lateral direction vector 262 at one or more cross-flow manifold outlets 504.

[0133] The cross-flow manifold body 500 may include one or more cross-flow manifold paths 506 having a curved profile. The curved profile of the one or more cross-flow manifold paths 506 may facilitate a change in one or more geometric dimensions of the one or more cross-flow manifold paths 506 from the one or more cross-flow manifold inlets 502 to the one or more cross-flow manifold outlets 504. In addition, or in the alternative, the curved profile of the one or more cross-flow manifold paths 506 may facilitate a change in the direction vector of the flow field of the process gas from the one or more cross-flow manifold inlets 502 to the one or more cross-flow manifold outlets 504. The cross-flow manifold body 500 may expand laterally relative to the longitudinal axis 510 of the one or more cross-flow manifold inlets 502 and / or relative to the lateral axis 512 of the one or more cross-flow manifold outlets 504. The curved profile of one or more cross flow manifold paths 506 can facilitate changes in one or more geometric dimensions and / or changes in the direction vector of the flow field of the process gas from one or more cross flow manifold inlets 502 to one or more cross flow manifold outlets 504 without significantly disturbing the boundary layer air within the cross flow manifold body 500 (e.g., within the corresponding cross flow manifold paths 506). For example, the curved profile of one or more cross flow manifold paths 506 can avoid the formation of drag and flow separation, for example, by generating counter-rotating vortices that draw the process gas further into the corresponding cross flow manifold paths 506. At least a portion of the curved profile cross flow manifold body 500 can mimic at least a portion of a NACA air duct.

[0134] The cross-flow manifold body 500 may include a lateral expansion region 514 and / or a lateral translation region 516. The lateral expansion region 514 may be located downstream of the cross-flow manifold inlet 502. The lateral expansion region 514 includes an area of ​​the cross-flow manifold body 500 that exhibits lateral expansion relative to the longitudinal axis 510 of one or more cross-flow manifold inlets 502 and / or relative to the lateral axis 512 of one or more cross-flow manifold outlets 504. At least some of the multiple cross-flow manifold paths 506 may exhibit lateral expansion in the lateral expansion region 514 described with reference to the cross-flow manifold body 500. The lateral expansion rate may be different between the corresponding cross-flow manifold paths in the multiple cross-flow manifold paths 506. One or more of the multiple cross-flow manifold paths 506 do not have to exhibit lateral expansion, and at least some of the multiple cross-flow manifold paths 506 exhibit lateral expansion in the lateral expansion region 514.

[0135] The lateral translation region 516 can be located downstream of the lateral expansion region 514. In addition, or in the alternative, the lateral translation region 516 can be located upstream of the cross-flow manifold outlet 504. The lateral translation region 516 includes an area of ​​the cross-flow manifold body 500 that exhibits a lateral translation in the axial orientation of the cross-flow manifold body 500, for example, relative to the longitudinal axis 510 of one or more cross-flow manifold inlets 502, and / or relative to the lateral axis 512 of one or more cross-flow manifold outlets 504. The axial orientation of the cross-flow manifold body 500 can be aligned with the longitudinal axis 510, for example, at one or more cross-flow manifold inlets 502. The axial orientation of the cross-flow manifold body 500 can be aligned with the lateral axis 512, for example, at one or more cross-flow manifold outlets 504. The alignment of the axial orientation of the cross-flow manifold body 500 can be laterally translated within the lateral translation region 516, for example, to provide an increased alignment with the lateral axis 512 and / or a reduced alignment with the longitudinal axis 510. The lateral translation region can include a translation of the axial orientation of the cross-flow manifold body 500 from alignment with the longitudinal axis 510 to alignment with the lateral axis 512. However, the cross-flow manifold body 500 does not need to be precisely aligned with the longitudinal axis 510 and / or the cross-flow manifold body 500 does not need to be precisely aligned with the lateral axis 512. At least some of the multiple cross-flow manifold paths 506 can present a lateral translation in a corresponding axial orientation within the lateral translation region 516 described with reference to the cross-flow manifold body 500. The lateral translation rate can be different between corresponding cross-flow manifold paths in the multiple cross-flow manifold paths 506.

[0136] At least a portion of the lateral expansion region 514 may overlap with at least a portion of the lateral translation region 516. In addition, or in the alternative, at least a portion of the lateral expansion region 514 may be separated from at least a portion of the lateral translation region 516. For example, the cross-flow manifold body 500 may include a longitudinal extension region 518, which is disposed between at least a portion of the lateral expansion region 514 and at least a portion of the lateral translation region 516. The longitudinal extension region 518 represents an area of ​​the cross-flow manifold body 500 that exhibits a longitudinal extension relative to the longitudinal axis 510 of one or more cross-flow manifold inlets 502. At least some of the multiple cross-flow manifold paths 506 may exhibit a longitudinal extension in the longitudinal extension region 518 described with reference to the cross-flow manifold body 500. The extent of the longitudinal extension region 518 may be different between corresponding cross-flow manifold paths in the multiple cross-flow manifold paths 506. One or more of the plurality of cross-flow manifold paths 506 need not exhibit a longitudinal extension, whereas at least some of the plurality of cross-flow manifold paths 506 exhibit a longitudinal extension within the longitudinal extension region 518 .

[0137] The cross-flow manifold body 500 may include a lateral profile area 520. The lateral profile area 520 represents an area of ​​the cross-flow manifold body 500 that presents a lateral change in the cross-sectional profile, for example, relative to the cross-sectional profile of one or more cross-flow manifold inlets 502. For example, the cross-sectional profile of the cross-sectional profile of the cross-flow manifold body 500 can be laterally changed from the cross-sectional profile at one or more cross-flow manifold inlets 502 to the cross-sectional profile at one or more cross-flow manifold outlets 504. At least some of the multiple cross-flow manifold paths 506 can present a lateral change in the cross-sectional profile in the lateral profile area 520 described with reference to the cross-flow manifold body 500. The rate of change of the lateral cross-sectional profile can be different between the corresponding cross-flow manifold paths in the multiple cross-flow manifold paths 506. One or more of the multiple cross-flow manifold paths 506 do not have to present a lateral change in the cross-sectional profile, and at least some of the multiple cross-flow manifold paths 506 present a lateral change in the cross-sectional profile within the lateral profile area 520.

[0138] The lateral profile region 520 may overlap at least a portion of the lateral expansion region 514 and / or at least a portion of the lateral translation region 516. Additionally, or in the alternative, at least a portion of the lateral profile region 520 may be separate from at least a portion of the lateral expansion region 514 and / or at least a portion of the lateral translation region 516. The lateral profile region 520 may overlap at least a portion of the longitudinal extension region 518. Additionally, or in the alternative, at least a portion of the lateral profile region 520 may be separate from at least a portion of the longitudinal extension region 518. The longitudinal extension region 518 may be disposed between at least a portion of the lateral profile region 520 and at least a portion of the lateral translation region 516. The longitudinal extension region 518 may present a longitudinal extension relative to the longitudinal axis 510 of the one or more cross-flow manifold inlets 502 without a lateral change in cross-sectional profile such as may be present in the lateral profile region 520. At least some of the plurality of cross-flow manifold paths 506 may present a longitudinal extension in the longitudinal extension region 518 without a lateral variation in cross-sectional profile, such as may be present in the lateral profile region 520. One or more of the plurality of cross-flow manifold paths 506 need not present a lateral variation in cross-sectional profile, while at least some of the plurality of cross-flow manifold paths 506 present a lateral variation in cross-sectional profile within the lateral profile region 520.

[0139] One or more geometric characteristics of the cross-sectional profile of one or more cross-flow manifold paths 506 and / or flow fields can be modified at one or more regions from one or more cross-flow manifold inlets 502 to one or more cross-flow manifold outlets 504. For example, an elliptical cross-sectional profile (e.g., a circular cross-sectional profile) at one or more cross-flow manifold inlets 502 can be confirmed as an elongated cross-sectional profile (e.g., a rectangular cross-sectional profile) at one or more cross-flow manifold outlets 504. In addition, or in an alternative, the cross-sectional area of ​​the cross-sectional profile of the flow field can be modified between one or more cross-flow manifold inlets 502 and one or more cross-flow manifold outlets 504. In various embodiments, the cross-sectional area can be increased, reduced, and / or maintained. The cross-sectional area of ​​the flow field can remain substantially equal between one or more cross-flow manifold inlets 502 and one or more cross-flow manifold outlets 504. In addition, or in the alternative, the cross-sectional area can be increased from one or more cross-flow manifold inlets 502 to one or more cross-flow manifold outlets 504, for example, by an amount of about 5% to about 95% (e.g., about 10% to about 80%, or, for example, about 25% to about 75%). Increasing the cross-sectional area can provide a pressure reduction and / or a velocity reduction of the flow field, which can result in a lateral flow field with desired flow characteristics. In addition, or in the alternative, the cross-sectional area can be reduced from one or more cross-flow manifold inlets 502 to one or more cross-flow manifold outlets 504, for example, by an amount of about 5% to about 90% (e.g., about 10% to about 80%, or, for example, about 25% to about 75%). Reducing the cross-sectional area can provide a pressure increase and / or a velocity increase of the flow field, which can result in a lateral flow field with desired flow characteristics. The cross-sectional area of ​​one or more cross-flow manifold inlets 502 and the cross-sectional area of ​​one or more cross-flow manifold outlets 504 can differ from each other by about 25%, for example, within about 10%, for example, within about 5%, or for example, within about 1%. In addition, or in the alternative, the cross-sectional area of ​​one or more cross-flow manifold inlets 502 and the cross-sectional area of ​​one or more cross-flow manifold outlets 504 can differ from each other by up to 125%, for example, up to 100%, for example, up to 50%, for example, up to 25%. Such pressure increase and / or decrease can be determined from pressure measurements obtained using one or more pressure sensors, one or more pressure sensors being configured to determine upstream and downstream pressures, and / or pressure differentials. As an example, such pressure or pressure differential can be determined by a differential pressure sensor.

[0140] One or more cross flow manifold outlets 504 may have a proportional width and height such that the width exceeds the height by a factor of, for example, about 10:1 to 100:1, such as about 10:1 to about 50:1, or such as about 10:1 to about 20:1. The width of the lateral flow field for process gas discharged from the one or more cross flow manifold outlets 504 may exceed the height of the lateral flow field. For example, the ratio of the width of the lateral flow field to the height of the lateral flow field may be about 10:1 to 100:1, such as about 10:1 to about 50:1, or such as about 10:1 to about 20:1.

[0141] In addition to or in lieu of changing the cross-sectional profile of the flow field, the cross-flow manifold body 500 can be configured to change the direction vector of the flow field. The cross-flow manifold body 500 can include one or more cross-flow manifold inlets 502 that are fluidly connected to the process gas supply line 206, respectively. The cross-flow manifold body 500 can be configured to change the direction vector of the flow field at one or more cross-flow manifold inlets 502 to the direction vector at one or more cross-flow manifold outlets 504. The cross-flow manifold body 500 can modify the downward direction vector 260 at one or more cross-flow manifold inlets 502 to the lateral direction vector 262 at one or more cross-flow manifold outlets 504. The cross-flow manifold body 500 can provide a lateral acceleration direction vector 264. The modification of the direction vector from one or more cross-flow manifold inlets 502 to one or more cross-flow manifold outlets 504 can be about 90 degrees, such as about 80 degrees to about 100 degrees, such as about 70 degrees to about 90 degrees, or such as about 85 degrees to about 95 degrees. In addition, or in the alternative, the direction vector of the flow field can be modified by an amount from about 10 degrees to about 100 degrees (e.g., about 30 degrees to about 90 degrees, e.g., about 60 degrees to about 90 degrees, or about 10 degrees to about 45 degrees) from one or more cross flow manifold inlets 502 to one or more cross flow manifold outlets 504.

[0142] The longitudinal axis 510 of the one or more cross-flow manifold inlets 502 can be oriented perpendicular to the build plane 225, or substantially perpendicular to the build plane 225, such as about 90 degrees relative to the build plane 225, such as about 80 to 100 degrees relative to the build plane 225, or such as about 85 to 95 degrees relative to the build plane. In addition, or in the alternative, the longitudinal axis 510 of the one or more cross-flow manifold inlets 502 can be oriented parallel to or substantially parallel to the build plane 225, such as within about 10 degrees of parallel to the build plane 225, such as within about 5 degrees of parallel to the build plane 225, or within about 1 degree of parallel to the build plane 225. In addition, or in the alternative, the longitudinal axis 510 of one or more cross-flow manifold inlets 502 can be oriented to be inclined relative to the build plane 225, for example, at about 5 degrees to about 85 degrees, for example, about 30 degrees to about 85 degrees, for example, about 60 degrees to about 80 degrees, or for example, about 10 degrees to about 45 degrees relative to the build plane 225.

[0143] In addition to or in lieu of the orientation of the longitudinal axis 510 of one or more cross-flow manifold inlets 502 relative to the build plane 225, the longitudinal axis 510 of one or more cross-flow manifold inlets 502 can be oriented parallel to or substantially parallel to the longitudinal axis 424 of the downflow manifold body 400, for example within approximately 10 degrees of the longitudinal axis 424 of the downflow manifold body 400, for example within approximately 5 degrees of the longitudinal axis 424 of the downflow manifold body 400, or for example within approximately 1 degree of the longitudinal axis 424 of the downflow manifold body 400. In addition, or in the alternative, the longitudinal axis 510 of one or more cross-flow manifold inlets 502 can be oriented to be inclined relative to the longitudinal axis 424 of the downflow manifold body 400, for example, from about 5 degrees to about 85 degrees relative to the longitudinal axis 424 of the downflow manifold body 400, for example, from about 30 degrees to about 85 degrees relative to the longitudinal axis 424 of the downflow manifold body 400, for example, from about 60 degrees to about 80 degrees relative to the longitudinal axis 424 of the downflow manifold body 400, for example, from about 10 degrees to about 45 degrees relative to the longitudinal axis 424 of the downflow manifold body 400.

[0144] In addition, or in the alternative, the longitudinal axis 510 of one or more cross-flow manifold inlets 502 can be oriented parallel to or substantially parallel to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross-flow chamber 310, for example within about 10 degrees parallel to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross-flow chamber 310, for example within about 5 degrees parallel to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross-flow chamber 310, or within about 1 degree parallel to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross-flow chamber 310. In addition, or in the alternative, the longitudinal axis 510 of one or more cross-flow manifold inlets 502 can be oriented to be inclined relative to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross-flow chamber 310, for example, about 5 degrees to about 85 degrees relative to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross-flow chamber 310, for example, about 30 degrees to about 85 degrees relative to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross-flow chamber 310, for example, about 60 degrees to about 80 degrees relative to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross-flow chamber 310, for example, about 10 degrees to about 45 degrees relative to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross-flow chamber 310. In addition, or in the alternative, the longitudinal axis 510 of one or more cross-flow manifold inlets 502 can be oriented perpendicular or substantially perpendicular to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross-flow chamber 310, for example within about 10 degrees perpendicular to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross-flow chamber 310, for example within about 5 degrees perpendicular to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross-flow chamber 310, or within about 1 degree perpendicular to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross-flow chamber 310.

[0145] Lateral axis 512 of one or more cross-flow manifold outlets 504 can be oriented parallel to build plane 225, or substantially parallel to build plane 225, such as at about 0 degrees relative to build plane 225, such as within about 10 degrees parallel to build plane 225, such as within about 5 degrees parallel to build plane 225, or within about 1 degree parallel to build plane 225. One or more cross-flow manifold outlets 504 can discharge a lateral flow field having a lateral direction vector 262 oriented parallel to build plane 225, or substantially parallel to build plane 225, such as at about 0 degrees relative to build plane 225, such as within about 10 degrees parallel to build plane 225, such as within about 5 degrees parallel to build plane 225, or within about 1 degree parallel to build plane 225. Lateral direction vector 262 can be oriented obliquely and / or upwardly relative to build plane 225, e.g., about 1 degree to about 20 degrees obliquely and / or upwardly relative to build plane 225, e.g., about 1 degree to about 10 degrees obliquely and / or upwardly relative to build plane 225, or e.g., about 1 degree to about 5 degrees obliquely and / or upwardly relative to build plane 225.

[0146] Reference now Figures 6A-6F , an exemplary cross-flow manifold inlet 502 will be further described. Fig. 6A As shown, one or more cross-flow manifold path walls 508 can be disposed within the cross-flow manifold inlet 502. In addition, or in the alternative, one or more cross-flow manifold path walls 508 can be located within the cross-flow manifold body 500 downstream of the cross-flow manifold inlet 502. At least some of the cross-flow manifold path walls 508 and / or at least a portion of the respective cross-flow manifold path walls 508 can be oriented parallel to the lateral axis 512 of the cross-flow manifold body 500, or substantially parallel to the lateral axis 512 of the cross-flow manifold body 500, such as within about 10 degrees of parallel to the lateral axis 512 of the cross-flow manifold body 500, such as within about 5 degrees of parallel to the lateral axis 512 of the cross-flow manifold body 500, or within about 1 degree of parallel to the lateral axis 512 of the cross-flow manifold body 500. However, additionally or alternatively, at least some of the cross-flow manifold path walls 508 and / or at least a portion of the respective cross-flow manifold path walls 508 may be oriented obliquely and / or perpendicularly to the lateral axis 512 of the cross-flow manifold body 500. The plurality of cross-flow manifold path walls 508 may have a spacing determined at least in part based on the desired cross-sectional area of ​​the respective cross-flow manifold paths 506. The plurality of cross-flow manifold path walls 508 may be spaced relative to one another so as to provide a uniformly sized cross-sectional area between the respective cross-flow manifold paths 506. The uniformly sized cross-sectional area may differ in a cross-sectional profile, for example, corresponding at least in part to a cross-sectional profile of the cross-flow manifold inlet 502.

[0147] like Figure 6B-6F As shown, the cross-flow manifold inlet 502 may include and / or may be configured to receive one or more inlet flow conditioners 600. The inlet flow conditioner 600 may include a grid 602 defining a plurality of inlet flow conditioning channels 604. A plurality of inlet flow conditioning channels 604 may be constructed and arranged in an array, such as an array of inlet flow conditioning channels 604. The inlet flow conditioning channels 604 may have any desired geometry. The appropriate geometry of the array of the plurality of inlet flow conditioning channels 604 and / or the inlet flow conditioning channels 604 may be selected based at least in part on the effect of the inlet flow conditioner 600 on the process gas flow through the cross-flow manifold 222. For example, as shown, the inlet flow conditioner 600 may include a grid 602 defining a plurality of inlet flow conditioning channels 604 and / or an array of inlet flow conditioning channels 604 having a hexagonal cross section. Additionally, or in the alternative, the plurality of inlet flow conditioning channels 604 and / or array of inlet flow conditioning channels 604 may have any other desired geometric configuration, including polygonal, elliptical, and / or curvilinear configurations.

[0148] like Figure 6C and 6D As shown, at least some of the plurality of inlet flow conditioning channels 604 may be oriented parallel to the longitudinal axis 510 of the cross-flow manifold inlet 502. Additionally, or in the alternative, as shown Fig. 6E and 6F As shown, at least some of the plurality of inlet flow conditioning channels 604 may be oriented obliquely to the longitudinal axis 510 of the cross-flow manifold inlet 502. For example, at least some of the plurality of inlet flow conditioning channels 604 may have an orientation that diverges from the longitudinal axis 510 of the cross-flow manifold inlet 502. The obliquely oriented and / or converging inlet flow conditioning channels 604 may have an angle relative to the longitudinal axis 510 of the cross-flow manifold inlet 502 that is about 0.1 degrees to about 20 degrees, such as about 1 degree to about 10 degrees, or about 0.1 degrees to about 5 degrees.

[0149] At least some of the multiple inlet flow conditioning channels 604 can be oriented relative to a normal to a tangent perpendicular to the curvilinear plane. For example, the curvilinear plane can correspond to a portion of a sphere, an oval, etc. The orientation of at least some of the inlet flow conditioning channels 604 can correspond at least in part to the orientation of the corresponding cross-flow manifold path 506 downstream of the inlet flow conditioning channel 604. For example, the longitudinal axis of at least some of the inlet flow conditioning channels 604 can be parallel or substantially parallel to the longitudinal axis of the respectively corresponding cross-flow manifold path 506, and the respectively corresponding cross-flow manifold path 506 is determined, for example, around the cross-flow manifold inlet 502 and / or the cross-flow manifold body 500 adjacent to the inlet flow conditioner 600 and / or the respectively oriented inlet flow conditioning channel 604 downstream. As an example, the longitudinal axis of at least some of the inlet flow conditioning channels 604 can be within approximately 10 degrees of the longitudinal axis of the respectively corresponding cross-flow manifold path 506, for example within approximately 5 degrees of the longitudinal axis of the respectively corresponding cross-flow manifold path 506, or for example within approximately 1 degree of the longitudinal axis of the respectively corresponding cross-flow manifold path 506, the respectively corresponding cross-flow manifold path 506 being determined, for example, around an area of ​​the cross-flow manifold inlet 502 and / or the cross-flow manifold body 500 downstream of an adjacent inlet flow conditioner 600 and / or a respectively oriented inlet flow conditioning channel 604.

[0150] The inlet flow conditioner 600 may include one or more features configured to adapt the inlet flow conditioner 600 to the cross-flow manifold inlet 502. For example, Figure 6C-6FAs shown, the inlet flow regulator 600 may have an outer circumference corresponding to the inner circumference of the cross-flow manifold inlet 502. The inlet flow regulator 600 may be movably and / or fixedly inserted into the cross-flow manifold inlet 502. For example, the inlet flow regulator 600 may exhibit a snap-fit ​​or press-fit characteristic when inserted into the inner circumference of the cross-flow manifold inlet 502. The inlet flow regulator 600 may include one or more alignment tabs 606. The one or more alignment tabs 606 may be adapted to the corresponding one or more alignment grooves 608 in the cross-flow manifold inlet 502. In addition, or in the alternative, the one or more alignment tabs 606 may be provided as a part of the cross-flow manifold inlet 502, and the inlet flow regulator 600 may include the corresponding one or more alignment grooves 608. In addition, or in the alternative, the inlet flow regulator 600 may be integrally formed as a part of the cross-flow manifold body 500 that defines the cross-flow manifold inlet 502.

[0151] Reference now Figures 7A-7C , and further reference Figure 5A , the cross flow manifold 222 may include an outlet flow conditioner 700 disposed in the cross flow manifold outlet 504. The cross flow manifold outlet may be configured to receive the outlet flow conditioner 700. The exemplary outlet flow conditioner 700 may be disposed in the cross flow manifold outlet 504. Figures 7A-7C As shown in Figure 5A As shown, the cross-flow manifold body 500 and / or the cross-flow manifold outlet 504 may include one or more cross-flow manifold sidewalls 522 having one or more outlet flow regulator access ports 524, respectively. One or more cross-flow manifold bodies 500 may include one or more outlet flow regulator grooves 526 extending laterally through at least a portion of the one or more cross-flow manifold bodies 500. The corresponding outlet flow regulator access port 524 may provide access to one or more outlet flow regulator grooves 526. One or more outlet flow regulator grooves 526 may extend laterally through one or more cross-flow manifold bodies adjacent to the cross-flow manifold outlet 504 and / or upstream of the cross-flow manifold outlet 504. One or more outlet flow regulators 700 may be movably inserted through the corresponding outlet flow regulator access port 524 and laterally enter the corresponding outlet flow regulator groove 526. In addition, or in an alternative, the outlet flow regulator 700 may be integrally formed as a part of the cross-flow manifold outlet 504 and / or a part of the cross-flow manifold body 500.

[0152] like Figures 7A-7CAs shown, the outlet flow regulator 700 may include a grid 702 defining a plurality of outlet flow regulating channels 704. A plurality of outlet flow regulating channels 704 may be constructed and arranged in an array, such as an array of outlet flow regulating channels 704. The outlet flow regulating channels 704 may have any desired geometry. The appropriate geometry of the array of a plurality of outlet flow regulating channels 704 and / or outlet flow regulating channels 704 may be selected based at least in part on the effect of the outlet flow regulator 700 on the process gas flow discharged from the cross-flow manifold outlet 504. For example, as shown, the outlet flow regulator 700 may include a grid 702 defining a plurality of outlet flow regulating channels 704 and / or an array of outlet flow regulating channels 704 having a hexagonal cross section. In addition, or in an alternative, a plurality of outlet flow regulating channels 704 and / or an array of outlet flow regulating channels 704 may have any other desired geometric configuration, including polygonal, elliptical and / or curved configurations.

[0153] like Fig. 7A As shown, at least some of the plurality of outlet flow conditioning channels 704 may be oriented parallel to the lateral axis 512 of the cross-flow manifold outlet 504. Additionally, or in the alternative, as Figure 7B and 7C As shown, at least some of the plurality of outlet flow conditioning channels 704 may be oriented to be oblique to the lateral axis 512 of the cross-flow manifold outlet 504. For example, at least some of the plurality of outlet flow conditioning channels 704 may have an orientation that converges toward the lateral axis 512 of the cross-flow manifold outlet 504 in the direction of the process gas flow through the outlet flow conditioning channels 704. The obliquely oriented and / or converging outlet flow conditioning channels 704 may have an angle of about 0.1 degrees to about 20 degrees, such as about 1 degree to about 10 degrees, or about 0.1 degrees to about 5 degrees, relative to the lateral axis 512 of the cross-flow manifold outlet 504. The oblique and / or converging orientation of the outlet flow conditioning channels 704 may provide a pressure increase and / or velocity increase in the lateral flow field discharged from the cross-flow manifold outlet 504, thereby providing desired flow characteristics.

[0154] At least some of the multiple outlet flow regulating channels 704 can be oriented relative to a normal to a tangent perpendicular to the curved plane. For example, the curved plane can correspond to a portion of a sphere, an oval, etc. The orientation of at least some of the outlet flow regulating channels 704 can correspond at least in part to the desired configuration of the lateral flow field discharged from the cross-flow manifold outlet 504. For example, the orientation of the outlet flow regulating channels 704 can be configured to provide a converging lateral flow field discharged from the cross-flow manifold outlet 504. The converging lateral flow field can, for example, provide a uniform crossflow of process gas from the cross-flow manifold 222 to the return manifold 204. In addition, or in an alternative, the converging lateral flow field can prevent or reduce the tendency of process gas to escape from below the cross-flow wall 314 of the cross-flow chamber 310. As an example, at least some of the outlet flow regulating channels 704 can be oriented along a normal line perpendicular to a tangent line of the curvilinear plane, wherein the length of the outlet flow regulator 700 transverse to the lateral axis 512 of the cross-flow manifold outlet 504 corresponds to the chord length of an arc extending laterally through the curvilinear plane, such as an arc. In addition, or in an alternative, the width of the outlet flow regulator 700 can correspond to the sagitta of an arc extending laterally through the curvilinear plane, such as an arc. In addition, or in an alternative, at least some of the outlet flow regulating channels 704 can be oriented along a normal line that intersects at a point corresponding to a radius of an arc extending laterally through the curvilinear plane. The arc length can be from about 1 degree to about 90 degrees, such as from about 5 degrees to about 60 degrees, such as from about 10 degrees to about 30 degrees.

[0155] Reference again Figure 5A , the cross-flow manifold body 500 and / or the cross-flow manifold outlet 504 may include one or more features configured to hold one or more outlet flow regulators 700 in the corresponding outlet flow regulator groove 526. For example, the cross-flow manifold body 500 and / or the cross-flow manifold outlet 504 may have one or more outlet ridges 528 that hold the corresponding outlet flow regulators in the one or more outlet flow regulators 700. The outlet flow regulator 700 may have a cross-sectional profile configured to match the cross-sectional profile of the outlet flow regulator approaching the port 524 and / or the outlet flow regulator groove 526. For example, as shown in the figure, the outlet flow regulator approaching the port 524 and / or the outlet flow regulator groove 526 may have a "D" shaped cross-sectional profile, and the outlet flow regulator 700 may have a corresponding "D" shape. In addition, or in an alternative, the outlet flow regulator 700 may include one or more alignment tabs similar to those described with reference to the inlet flow regulator 600. One or more alignment tabs 606 may mate with corresponding one or more alignment slots 608 in the cross-flow manifold outlet 504 .

[0156] Now turn to Figures 8A-8B, an exemplary return manifold 204 will be described. The return manifold 204 may be in fluid communication with one or more process gas exhaust lines 208. The return manifold 204 may be configured to receive and / or exhaust a process gas flow from an irradiation chamber 121 defined by the irradiation chamber 120. In addition, or in the alternative, the return manifold 204 may be configured to receive and / or exhaust a process gas flow from a cross-flow chamber 311 defined by the cross-flow chamber 310 and / or from a downflow chamber 309 defined by the downflow chamber 308. For example, the return manifold 204 may receive and / or exhaust a process gas flow from a cross-flow manifold 222 and / or a process gas flow from a downflow manifold 210. The return manifold 204 may include one or more return manifold bodies 800. For example, as Fig. 8A and 8B As shown, the return manifold body 800 may include a plurality of return manifold bodies 800 constructed and arranged along the width of the return manifold 204. The plurality of return manifold bodies 800 may be coupled to each other. Additionally, or in the alternative, the plurality of return manifold bodies 800 may define respective portions of the return manifold 204 that are integrally formed.

[0157] The return manifold body 800 can be configured to change the cross-sectional area of ​​the process gas flow field flowing into the return manifold 204 and through the return manifold body 800. The flow field flowing into the return manifold body 800 can have, for example, an elongated cross-sectional profile corresponding to the cross-flow plenum 311 defined by the cross-flow chamber 310 and / or the downflow plenum 309 defined by the downflow chamber 308. The flow field leaving the return manifold body 800, for example, entering one or more process gas exhaust lines 208 can have, for example, a circular cross-sectional profile corresponding to one or more process gas exhaust lines 208. The flow field flowing into the return manifold body 800 can include a lateral flow field having a lateral direction vector 262. The lateral flow field and / or the lateral direction vector 262 can correspond to the orientation of the cross-flow plenum 311 defined by the cross-flow chamber 310. In addition, or in the alternative, the lateral flow field and / or the lateral direction vector 262 can correspond to an orientation that redirects and / or laterally accelerates the downward flow of process gas entering the return manifold body 800. The flow field present in return manifold body 800 may include, for example, an upward direction vector 266 that corresponds to the orientation of process gas exhaust line 208 .

[0158] The return manifold 204 may include one or more return manifold inlets 802 and one or more return manifold outlets 804. The return manifold 204 may include one or more return manifold paths 806 defined at least in part by a return manifold body 800. One or more return manifold path walls 808 may define at least a portion of the one or more return manifold paths 806. The one or more return manifold path walls 808 may be disposed within the return manifold body 800, and / or the one or more return manifold path walls 808 may be integrally formed as a single component with the return manifold body 800. Process gas entering the return manifold inlet 802 may flow through the one or more return manifold paths 806 and exit the return manifold 204 at the one or more return manifold outlets 804.

[0159] One or more return manifold inlets 802 may be configured to receive a lateral flow of process gas, for example, from a crossflow plenum 311 defined by the crossflow chamber 310 and / or from an irradiation plenum 121 defined by the irradiation chamber 120. In addition, or in the alternative, one or more return manifold inlets 802 may be configured to receive a process gas flow, such as a lateral flow and / or a lateral acceleration flow, from a downflow plenum 309 defined by the downflow chamber 308 and / or from an irradiation plenum 121 defined by the irradiation chamber 120. The lateral flow of process gas received by the return manifold inlet 802 may have an elongated cross-sectional area. The return manifold body 800 may have a shape that conforms the cross-sectional area of ​​the flow field from an inlet cross-sectional area corresponding to one or more return manifold inlets 802 to an outlet cross-sectional area corresponding to one or more return manifold outlets 804.

[0160] As shown, the return manifold inlet 802 can have an elongated cross-sectional profile, such as a circular cross-sectional profile. As shown, the elongated cross-sectional area of ​​the return manifold inlet 802 can have a rectangular cross-sectional profile; however, other cross-sectional profiles are also contemplated, including curved cross-sectional profiles, such as an elliptical cross-sectional profile. One or more return manifold outlets 804 can have an elliptical cross-sectional profile, such as a circular cross-sectional profile. However, return manifold outlets 804 having other cross-sectional profiles are also contemplated, including return manifold inlets 802 having rectangular or polygonal cross-sectional profiles.

[0161] The return manifold outlet 804 can discharge the process gas flow supplied from one or more return manifold inlets 802. In addition, or in the alternative, the return manifold outlet 804 can discharge the process gas flow from one or more return manifold paths 806. The number of return manifold outlets 804 can exceed the number of return manifold inlets 802 by at least one. The return manifold 204 can include one or more return manifold inlets 802 and a plurality of return manifold outlets 804, such as one to three return manifold outlets 804 and two to six return manifold inlets 802, such as one, two, or three return manifold inlets 802, and two, three, four, five, or six return manifold outlets 804. Fig. 8A As shown, the return manifold 204 may include one return manifold inlet 802 and two return manifold outlets 804 .

[0162] The configuration and arrangement of the return manifold body 800 can be at least partially determined to receive a lateral flow field with a desired flow characteristic. The return manifold body 800, one or more return manifold paths 806, and / or one or more return manifold path walls 808 can be configured to modify the cross-sectional profile of the flow field received by the return manifold 204. The cross-sectional profile of the flow field can be modified relative to the geometry and / or surface area. The cross-sectional profile of the flow field can be modified from the elongated cross-sectional profile (e.g., rectangular cross-sectional profile) at the return manifold inlet 802 to the elliptical cross-sectional profile (e.g., circular cross-sectional profile) at one or more return manifold outlets 804. In addition, or in an alternative, the return manifold body 800, one or more return manifold paths 806, and / or one or more return manifold path walls 808 can be configured to modify the direction vector of the flow field. For example, the direction vector of the flow field can be modified from the lateral direction vector 262 at the return manifold inlet 802 to the upward direction vector 266 at one or more return manifold outlets 804.

[0163] The return manifold body 800 may include one or more return manifold paths 806 having a curved profile. The curved profile of the one or more return manifold paths 806 may facilitate a change in one or more geometric dimensions of the one or more return manifold paths 806 from the one or more return manifold inlets 802 to the one or more return manifold outlets 804. In addition, or in the alternative, the curved profile of the one or more return manifold paths 806 may facilitate a change in a directional vector of a flow field of process gas from the one or more return manifold inlets 802 to the one or more return manifold outlets 804. The return manifold body 800 may contract laterally relative to a longitudinal axis 810 of the one or more return manifold outlets 804 and / or relative to a lateral axis 812 of the return manifold inlet 802. The curved profile of the one or more return manifold paths 806 may facilitate a change in one or more geometric dimensions and / or a change in a directional vector of a flow field of process gas from the return manifold inlet 802 to the one or more return manifold outlets 804 without significantly disturbing boundary layer air within the return manifold body 800 (e.g., within one or more corresponding return manifold paths 806). For example, the curved profile of one or more return manifold paths 806 can avoid drag and flow separation, for example by creating counter-rotating vortices that draw process gas further into one or more respective return manifold paths 806. At least a portion of the curved profile return manifold body 800 can mimic at least a portion of a NACA air duct.

[0164] The return manifold body 800 may include an upward translation region 814 and / or a lateral contraction region 816. The upward translation region 814 may be located downstream of the return manifold inlet 802. The upward translation region 814 includes a region of the return manifold body 800 that exhibits an upward translation in the axial orientation of the return manifold body 800, for example, relative to a lateral axis 812 of the return manifold inlet 802 and / or relative to a longitudinal axis 810 of one or more return manifold outlets 804. The axial orientation of the return manifold body 800 may be aligned with the lateral axis 812, for example, at the return manifold inlet 802. The axial orientation of the return manifold body 800 may be aligned with the longitudinal axis 810, for example, at the one or more return manifold outlets 804. The alignment of the axial orientation of the return manifold body 800 may translate upward within the upward translation region 814, for example, providing an increased alignment with the longitudinal axis 810 and / or a decreased alignment with the lateral axis 812. The upward translation region 814 may include a translation of the axial orientation of the return manifold body 800 from alignment with the lateral axis 812 to alignment with the longitudinal axis 810. However, the return manifold body 800 need not be precisely aligned with the lateral axis 812, and / or the return manifold body 800 need not be precisely aligned with the longitudinal axis 810. At least some of the plurality of return manifold paths 806 may exhibit an upward translation in a respective axial orientation within the upward translation region 814 as described with reference to the return manifold body 800. The upward translation rate may differ between respective ones of the plurality of return manifold paths 806.

[0165] The lateral contraction region 816 can be located downstream of the upward translation region 814. In addition, or in the alternative, the lateral contraction region 816 can be located upstream of the return manifold outlet 804. The lateral contraction region 816 includes an area of ​​the return manifold body 800 that exhibits a lateral contraction relative to the lateral axis 812 of the return manifold inlet 802 and / or relative to the longitudinal axis 810 of one or more return manifold outlets 804. At least one of the one or more return manifold paths 806 can exhibit a lateral contraction in the lateral contraction region 816 described with reference to the return manifold body 800. The lateral contraction rate can be different between the respective return manifold paths in the plurality of return manifold paths 806. One or more of the plurality of return manifold paths 806 need not exhibit a lateral contraction, while at least some of the plurality of return manifold paths 806 exhibit a lateral contraction within the lateral contraction region 816.

[0166] At least a portion of the upward translation region 814 may overlap at least a portion of the lateral contraction region 816. Additionally, or in the alternative, at least a portion of the upward translation region 814 may be separate from at least a portion of the lateral contraction region 816. For example, the return manifold body 800 may include a longitudinal extension region 818 disposed between at least a portion of the upward translation region 814 and at least a portion of the lateral contraction region 816. The longitudinal extension region 818 represents an area of ​​the return manifold body 800 that exhibits a longitudinal extension relative to the longitudinal axis 810 of the return manifold outlet 804. At least one of the one or more return manifold paths 806 may exhibit a longitudinal extension in the longitudinal extension region 818 described with reference to the return manifold body 800. The extent of the longitudinal extension region 818 may differ between respective ones of the one or more return manifold paths 806. At least one of the one or more return manifold paths 806 need not exhibit a longitudinal extension, and at least one of the one or more return manifold paths 806 may exhibit a longitudinal extension within the longitudinal extension region 818.

[0167] The return manifold body 800 may include a lateral profile region 820. The lateral profile region 820 represents an area of ​​the return manifold body 800 that presents a lateral change in cross-sectional profile, for example, relative to the cross-sectional profile of the return manifold inlet 802. For example, the cross-sectional profile of the return manifold body 800 may change laterally from the cross-sectional profile at the return manifold inlet 802 to the cross-sectional profile at one or more return manifold outlets 804. At least some of the plurality of return manifold paths 806 may present a lateral change in cross-sectional profile in the lateral profile region 820 described with reference to the return manifold body 800. The rate of change of the lateral cross-sectional profile may be different between respective return manifold paths in the plurality of return manifold paths 806. One or more of the plurality of return manifold paths 806 need not present a lateral change in cross-sectional profile, while at least some of the plurality of return manifold paths 806 present a lateral change in cross-sectional profile within the lateral profile region 820.

[0168] The lateral profile region 820 may overlap at least a portion of the upward translation region 814 and / or at least a portion of the lateral contraction region 816. Additionally, or in the alternative, at least a portion of the lateral profile region 820 may be separate from at least a portion of the upward translation region 814 and / or at least a portion of the lateral contraction region 816. The lateral profile region 820 may overlap at least a portion of the longitudinal extension region 818. Additionally, or in the alternative, at least a portion of the lateral profile region 820 may be separate from at least a portion of the longitudinal extension region 818. The longitudinal extension region 818 may be disposed between at least a portion of the lateral profile region 820 and at least a portion of the upward translation region 814. The longitudinal extension region 818 may present a longitudinal extension relative to the longitudinal axis 810 of the return manifold outlet 804 without a lateral change in cross-sectional profile such as may be present in the lateral profile region 820. At least one of the one or more return manifold paths 806 may present a longitudinal extension in the longitudinal extension region 818 without a lateral variation in cross-sectional profile, such as may be present in the lateral profile region 820. At least one of the one or more return manifold paths 806 need not present a lateral variation in cross-sectional profile, whereas at least one of the one or more return manifold paths 806 may present a lateral variation in cross-sectional profile within the lateral profile region 820.

[0169] One or more geometric characteristics of the cross-sectional profile of one or more return manifold paths 806 and / or flow fields can be modified at one or more regions from the return manifold inlet 802 to one or more return manifold outlets 804. For example, an elongated cross-sectional profile (e.g., a rectangular cross-sectional profile) at the return manifold inlet 802 can be confirmed as an elliptical cross-sectional profile, such as a circular cross-sectional profile, at one or more return manifold outlets 804. In addition, or in an alternative, the cross-sectional area of ​​the cross-sectional profile of the flow field can be modified between the return manifold inlet 802 and one or more return manifold outlets 804. In various embodiments, the cross-sectional area can be increased, decreased, and / or maintained. The cross-sectional area of ​​the flow field can remain substantially equal between the return manifold inlet 802 and one or more return manifold outlets 804. In addition, or in an alternative, the amount by which the cross-sectional area can be reduced from the return manifold inlet 802 to one or more return manifold outlets 804 is, for example, about 5% to about 90%, for example, about 10% to about 80%, or, for example, about 25% to about 75%. The reduced cross-sectional area can provide a pressure increase and / or velocity increase in the flow field, which can result in good reception and discharge of process gas. The cross-sectional area of ​​the return manifold inlet 802 and the cross-sectional area of ​​one or more return manifold outlets 804 can be within about 25% of each other, such as within about 10% of each other, such as within about 5% of each other, or such as within about 1% of each other. In addition, or in an alternative, the cross-sectional area of ​​the return manifold inlet 802 and the cross-sectional area of ​​one or more return manifold outlets 804 can differ from each other by up to 125%, such as up to 100%, such as up to 50%, such as up to 25%. This pressure increase can be determined from pressure measurements obtained using one or more pressure sensors, one or more pressure sensors configured to determine upstream pressure and downstream pressure, and / or pressure differential. As an example, this pressure or pressure differential can be determined by a differential pressure sensor.

[0170] The one or more return manifold inlets 802 can have a proportional width and height such that the width exceeds the height by a factor of, for example, about 10:1 to 100:1, such as about 10:1 to about 50:1, or such as about 10:1 to about 20:1. The width of the lateral flow field for process gas discharged from the one or more return manifold outlets 804 can exceed the height of the lateral flow field. For example, the ratio of the width of the lateral flow field to the height of the lateral flow field can be about 10:1 to 100:1, such as about 10:1 to about 50:1, or such as about 10:1 to about 20:1.

[0171] The cross-sectional area of ​​the one or more return manifold inlets 802 may correspond to the cross-sectional area of ​​the one or more cross-flow manifold outlets 504 and / or the cross-sectional area of ​​the plurality of downflow manifold pathways 418. For example, the cross-sectional area of ​​the one or more return manifold inlets 802 may be configured to receive an amount of process gas corresponding to an amount of process gas from the one or more cross-flow manifold outlets 504 and / or from the one or more downflow manifold pathways 418. The cross-sectional area of ​​the one or more return manifold inlets 802 may be substantially equal to the cross-sectional area of ​​the one or more cross-flow manifold outlets 504 and / or the one or more downflow manifold pathways 418 from which the one or more return manifold inlets 802 are intended to receive process gas. For example, the cross-sectional area of ​​one or more return manifold inlets 802 may be within about 25% of the cross-sectional area of ​​one or more cross-flow manifold outlets 504 and / or one or more downflow manifold paths 418 from which the one or more return manifold inlets 802 are intended to receive process gases, such as within about 15% of the cross-sectional area of ​​one or more cross-flow manifold outlets 504 and / or one or more downflow manifold paths 418 from which the one or more return manifold inlets 802 are intended to receive process gases, such as within about 10% of the cross-sectional area of ​​one or more cross-flow manifold outlets 504 and / or one or more downflow manifold paths 418 from which the one or more return manifold inlets 802 are intended to receive process gases, or such as within about 5% of the cross-sectional area of ​​one or more cross-flow manifold outlets 504 and / or one or more downflow manifold paths 418 from which the one or more return manifold inlets 802 are intended to receive process gases. In addition, or in the alternative, the cross-sectional area of ​​one or more return manifold inlets 802 may be slightly larger, such as up to about 25% larger than the cross-sectional area of ​​one or more cross-flow manifold outlets 504 and / or one or more downflow manifold paths 418 from which one or more return manifold inlets 802 are intended to receive process gases, such as up to about 15% larger than the cross-sectional area of ​​one or more cross-flow manifold outlets 504 and / or one or more downflow manifold paths 418 from which one or more return manifold inlets 802 are intended to receive process gases, such as up to about 10% larger than the cross-sectional area of ​​one or more cross-flow manifold outlets 504 and / or one or more downflow manifold paths 418 from which one or more return manifold inlets 802 are intended to receive process gases, or such as up to about 5% larger than the cross-sectional area of ​​one or more cross-flow manifold outlets 504 and / or one or more downflow manifold paths 418 from which one or more return manifold inlets 802 are intended to receive process gases.

[0172] In addition to or in lieu of changing the cross-sectional profile of the flow field, the return manifold body 800 may be configured to change the direction vector of the flow field. The return manifold body 800 may include one or more return manifold inlets 802, which are respectively in fluid communication with the irradiation chamber 121 defined by the irradiation chamber 120, the cross-flow chamber 311 defined by the cross-flow chamber 310, and / or the downflow chamber 309 defined by the downflow chamber 308. The return manifold body 800 may be configured to change the direction vector of the flow field at the return manifold inlet 802 to the direction vector at one or more return manifold outlets 804. The return manifold body 800 may modify the lateral direction vector 262 at the return manifold inlet 802 to the upward direction vector 266 at one or more return manifold outlets 804. The return manifold body 800 may provide an upward acceleration direction vector 268. The modification of the direction vector from the return manifold inlet 802 to the one or more return manifold outlets 804 can be about 90 degrees, such as about 80 degrees to about 100 degrees, such as about 85 degrees to about 95 degrees. In addition, or in the alternative, the amount by which the direction vector of the flow field is modified from the return manifold inlet 802 to the one or more return manifold outlets 804 can be about 10 degrees to about 100 degrees, such as about 30 degrees to about 90 degrees, such as about 60 degrees to about 90 degrees, or about 10 degrees to about 45 degrees.

[0173] Lateral axis 812 of return manifold inlet 802 may be oriented parallel to build plane 225, or substantially parallel to build plane 225, such as within about 10 degrees parallel to build plane 225, such as within about 5 degrees parallel to build plane 225, or within about 1 degree parallel to build plane 225. Additionally, or in the alternative, lateral axis 812 of return manifold inlet 802 may be oriented oblique to build plane 225, such as from about 5 degrees to about 85 degrees relative to build plane 225, such as from about 30 degrees to about 85 degrees relative to build plane 225, such as from about 60 degrees to about 80 degrees relative to build plane 225, or such as from about 10 degrees to about 45 degrees relative to build plane 225. Additionally, or in the alternative, lateral axis 812 of return manifold inlet 802 can be oriented perpendicular to build plane 225, or substantially perpendicular to build plane 225, such as approximately 90 degrees relative to build plane 225, such as approximately 80 to 100 degrees relative to build plane 225, or such as approximately 85 to 95 degrees relative to the build plane.

[0174] In addition to or in lieu of the orientation of the lateral axis 812 of the return manifold inlet 802 relative to the build plane 225, the lateral axis 812 of the return manifold inlet 802 can be oriented perpendicular or substantially perpendicular to the longitudinal axis 424 of the downflow manifold body 400, for example within about 10 degrees of perpendicular to the longitudinal axis 424 of the downflow manifold body 400, for example within about 5 degrees of perpendicular to the longitudinal axis 424 of the downflow manifold body 400, or for example within about 1 degree of perpendicular to the longitudinal axis 424 of the downflow manifold body 400. In addition, or in the alternative, the lateral axis 812 of the return manifold inlet 802 can be oriented to be inclined relative to the longitudinal axis 424 of the downflow manifold body 400, for example, from about 5 degrees to about 85 degrees relative to the longitudinal axis 424 of the downflow manifold body 400, for example, from about 30 degrees to about 85 degrees relative to the longitudinal axis 424 of the downflow manifold body 400, for example, from about 60 degrees to about 80 degrees, for example, from about 10 degrees to about 45 degrees.

[0175] In addition, or in the alternative, the lateral axis 812 of the return manifold inlet 802 can be oriented perpendicular or substantially perpendicular to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross flow chamber 310, for example within about 10 degrees perpendicular to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross flow chamber 310, for example within about 5 degrees perpendicular to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross flow chamber 310, or within about 1 degree perpendicular to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross flow chamber 310. In addition, or in the alternative, the lateral axis 812 of the return manifold inlet 802 can be oriented to be inclined relative to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross flow chamber 310, for example, about 5 degrees to about 85 degrees relative to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross flow chamber 310, for example, about 30 degrees to about 85 degrees relative to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross flow chamber 310, for example, about 60 degrees to about 80 degrees relative to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross flow chamber 310, for example, about 10 degrees to about 45 degrees relative to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross flow chamber 310. In addition, or in the alternative, the lateral axis 812 of the return manifold inlet 802 can be oriented parallel to or substantially parallel to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross flow chamber 310, for example within about 10 degrees parallel to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross flow chamber 310, for example within about 5 degrees parallel to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross flow chamber 310, or within about 1 degree parallel to the longitudinal axis 316 of the irradiation chamber 120 and / or the cross flow chamber 310.

[0176] Longitudinal axis 810 of one or more return manifold outlets 804 may be oriented perpendicular to build plane 225, or substantially perpendicular to build plane 225, such as at about 90 degrees relative to build plane 225, such as within about 10 degrees perpendicular to build plane 225, such as within about 5 degrees perpendicular to build plane 225, or within about 1 degree perpendicular to build plane 225. One or more return manifold outlets 804 may discharge an upward flow field having an upward direction vector 266 oriented perpendicular to build plane 225, or substantially perpendicular to build plane 225, such as at about 90 degrees relative to build plane 225, such as within about 10 degrees perpendicular to build plane 225, such as within about 5 degrees perpendicular to build plane 225, or within about 1 degree perpendicular to build plane 225. Upward direction vector 266 may be oriented obliquely relative to build plane 225 , such as about 5 degrees to about 85 degrees relative to build plane 225 , such as about 30 degrees to about 60 degrees relative to build plane 225 , or such as about 45 degrees to about 85 degrees relative to build plane 225 .

[0177] Reference now Figure 8B , the return manifold 204 can include one or more narrowed regions 821 that represent a reduction in the cross-sectional height of the return manifold inlet 802 and / or a reduction in the cross-sectional height within the return manifold path 806. The one or more narrowed regions 821 can extend across all or a portion of the width of the return manifold inlet 802 and / or the return manifold path 806. The one or more narrowed regions 821 can be located upstream of the upward translation region 814 of the return manifold body 800. The reduction in cross-sectional height can be provided relative to a portion of the return manifold body 800 disposed above and / or below the return manifold inlet 802 and / or the return manifold path 806. The one or more narrowed regions 821 can provide a venturi effect that accelerates process gas into and / or through the return manifold inlet 802 and / or the return manifold path 806.

[0178] like Figure 8B As shown, in addition to or in lieu of one or more narrowed regions 821, the return manifold 204 may include one or more rib elements 822 that protrude into the return manifold inlet 802 and / or the return manifold path 806. The narrowed region 821 and / or one or more rib elements 822 may be disposed around the return manifold inlet 802 and / or within the return manifold path 806. For example, Figure 8BAs shown, the narrowed region 821 and / or rib element 822 can be disposed within the return manifold path 806 and downstream of the inlet edge 824 of the return manifold inlet 802. Additionally, or in the alternative, as shown, the narrowed region 821 and / or rib element 822 can be disposed within the return manifold path 806 and upstream of the upward translation region 814 of the return manifold body 800. One or more narrowed regions 821 and / or one or more rib elements 822 can be located anywhere around the return manifold inlet 802 and / or within the return manifold path 806. As shown, the narrowed region and / or rib element 822 can be disposed across a bottom portion of the return manifold path 806. Additionally, or in the alternative, one or more narrowed regions 821 and / or one or more rib elements 822 can be disposed across a top portion and / or side portion of the return manifold path 806. The narrowed regions 821 and / or rib elements 822 may extend across all or a portion of a bottom portion, a top portion, or a side portion of the return manifold path 806. The one or more narrowed regions 821 and / or the one or more rib elements 822 may be integrally formed as a part of the return manifold body 800. Additionally, or in the alternative, the one or more narrowed regions 821 and / or the one or more rib elements 822 may be fixedly coupled to the return manifold body 800 as a separate component.

[0179] One or more narrowed regions 821 and / or one or more rib elements 822 can provide a pressure reduction within the return manifold inlet 802 and / or within one or more return manifold paths 806, which accelerates the flow of process gas into the return manifold inlet 802 and / or through one or more return manifold paths 806. This pressure reduction can be determined from pressure measurements obtained using one or more pressure sensors, and one or more pressure sensors are configured to determine the upstream pressure and downstream pressure, and / or pressure differential relative to one or more narrowed regions 821 and / or one or more rib elements 822. As an example, such pressure or pressure differential can be determined by a differential pressure sensor. One or more narrowed regions 821 and / or one or more rib elements 822 can, for example, increase the efficiency of the return manifold 204 to recapture process gas by drawing process gas into the return manifold inlet 802. In addition, or in the alternative, one or more narrowed regions 821 and / or one or more rib elements 822 can reduce or prevent process gas loss. For example, a narrowed area 821 and / or rib elements 822 disposed across a bottom portion of the return manifold path may prevent process gas from flowing beneath the return manifold inlet 802 and / or the return manifold body 800 .

[0180] like Figure 8BAs shown, the return manifold body 800 may include one or more recapture paths 826 configured to receive process gas flowing through the return manifold inlet 802 into one or more return manifold paths 806. For example, the one or more recapture paths 826 may receive process gas flowing below the return manifold inlet 802. The one or more recapture paths 826 may be in the form of elongated slits; however, other path configurations, such as an array of orifices, an array of perforations, a grid, a grille, etc., are also contemplated. The one or more recapture paths 826 may be disposed across at least a portion of the return manifold path 806, such as across a bottom portion, a top portion, and / or a side portion of the return manifold path 806. For example, as shown, the recapture paths 826 may be disposed laterally across a bottom portion of the return manifold path 806. As shown, the one or more recapture paths 826 may be in fluid communication with the return manifold path 806 downstream of the inlet edge 824 of the return manifold inlet 802. Additionally, or in the alternative, one or more recapture paths 826 can be in fluid communication with the return manifold path 806 at the narrowed region and / or upstream of the rib element 822 (e.g., upstream of the foil edge 828 of the rib element 822). Additionally, or in the alternative, as shown, one or more recapture paths 826 can be disposed within the return manifold path 806 and upstream of the upward translation region 814 of the return manifold body 800.

[0181] One or more recapture paths 826 can recapture process gas flowing through the return manifold inlet 802. For example, Figure 8B As shown, process gas flowing below the return manifold inlet 802 and / or the return manifold body 800 may be recaptured by one or more recapture paths 826 and drawn into the return manifold path 806. When the one or more recapture paths 826 are disposed upstream of the one or more narrowed regions 821 and / or the one or more rib elements 822, the pressure reduction provided by the one or more narrowed regions 821 and / or the one or more rib elements 822 may accelerate the process gas through the one or more recapture paths 826 and into the return manifold path 806. For example, the recapture paths 826 followed by the narrowed regions 821 and / or the rib elements 822 arranged across the bottom portion of the return manifold path 806 may cooperate with each other to recapture process gas that may flow below the return manifold inlet 802.

[0182] Now turn to Figures 9A-9D , an exemplary cross-flow wall 314 of the cross-flow chamber 310 will be further described. Figures 9A-9DAs shown, the cross-flow wall 314 may include one or more flanges 900 having attachment points 901 configured to couple the cross-flow wall 314 to the cross-flow manifold 222, the return manifold 204, and / or the downflow wall 312. In addition, or in the alternative, the cross-flow wall 314 may be integrally formed with the cross-flow manifold 222, the return manifold 204, and / or the downflow wall 312 as a single component.

[0183] As shown, the cross-flow wall 314 may include a cross-flow manifold flange 902 having one or more attachment points 901 configured to couple the cross-flow wall 314 to the cross-flow manifold 222. Additionally, or in the alternative, the cross-flow wall 314 may include a return manifold flange 904 having one or more attachment points 901 configured to couple the cross-flow wall 314 to the return manifold 204. Further additionally or alternatively, the cross-flow wall 314 may include a downflow wall flange 906 having one or more attachment points 901 configured to couple the cross-flow wall 314 to the downflow wall 312.

[0184] The cross-flow wall 314 may include one or more chamfers 908 disposed between a face 910 of the cross-flow wall 314 and a corresponding flange in the one or more flanges 900. The one or more chamfers 908 may be inclined away from the corresponding flange 900, which may, for example, help prevent and / or reduce the accumulation of contaminants around the corresponding flange 900 where the flanges are attached to the cross-flow manifold 222, the return manifold 204, and / or the downflow wall 312, respectively. The corresponding attachment points 901 of the cross-flow manifold 222, the return manifold 204, and / or the downflow wall 312 may have corresponding chamfers (not shown) that are configured to match the corresponding chamfers 908 on the cross-flow wall 314.

[0185] As shown, the cross-flow wall 314 may include a cross-flow manifold chamfer 912 corresponding to the cross-flow manifold flange 902. Additionally, or in the alternative, the cross-flow wall 314 may include a return manifold chamfer 914 corresponding to the return manifold flange 904. Further additionally or alternatively, the cross-flow wall 314 may include a downflow wall chamfer 916 corresponding to the downflow wall flange 906.

[0186] like Fig.9D and 9E As shown, the cross-flow wall 314 may include a cross-flow ledge 918 disposed along a bottom portion of the cross-flow wall 314 (e.g., a bottom inward lateral edge of the cross-flow wall 314). The cross-flow ledge 918 may protrude laterally from the cross-flow wall 314, such as toward a lateral axis 318 (e.g., Figures 3A-3D) protrudes inwardly. Cross-flow ledge 918 can prevent process gas from escaping from below the bottom portion of cross-flow wall 314. For example, cross-flow ledge 918 can generate turbulence that lifts process gas flowing adjacent to cross-flow ledge 918 and redirects such process gas into the overall flow of the flow field flowing through cross-flow plenum 311 defined by cross-flow chamber 310.

[0187] like Fig.9E As shown, the cross-flow wall 314 may include an outward ledge 920, which is disposed along a bottom portion of the cross-flow wall 314 (e.g., a bottom outward lateral edge of the cross-flow wall 314). In addition to or in lieu of the cross-flow ledge 918, the cross-flow wall may include an outward ledge 920. The outward ledge 920 may extend from the cross-flow wall 314 (e.g., the cross-flow chamber 310 (e.g., Figures 3A-3D ) protrudes laterally from the outside of the cross flow wall 314. The outward ledge 920 can prevent process gas from escaping from below the bottom portion of the cross flow wall 314. For example, the outward ledge 920 can increase the distance that the process gas travels before escaping from below the bottom portion of the cross flow wall 314. The outward ledge 920 can function independently of the cross flow ledge 918 or in conjunction with the cross flow ledge 918. For example, the turbulence created by the cross flow ledge 918 can draw process gas from below the outward ledge and back into the cross flow chamber 310.

[0188] Now turn to Figures 10A-10F , an exemplary flow field will be described. Fig. 10A and 10B As shown, the process gas flowing through one or more process gas supply lines 206 to the cross-flow manifold 222 can have a downward direction vector 260. For example, when the directional flow of the process gas changes from a downward direction to a lateral direction, the process gas flowing from the cross-flow manifold 222 into the cross-flow plenum 311 can have a lateral acceleration direction vector 264. The process gas flowing through the cross-flow plenum 311 can have a lateral direction vector 262. The process gas can flow from the cross-flow plenum 311 into the return manifold 204 with a lateral direction vector. The process gas flowing through the return manifold 204 can have an upward acceleration direction vector 268. The process gas can leave the return manifold 204 and flow into one or more process gas exhaust lines 208 with an upward direction vector. In addition, or in the alternative, the process gas flowing into the irradiation plenum 121 and / or the downflow plenum 309 can have a downward direction vector 260. The process gas flowing from the irradiation plenum into the cross-flow plenum 311 and / or the return manifold 204 can have a lateral acceleration direction vector 264.

[0189] The flow field of the process gas may have different characteristics relative to different areas of the irradiation plenum 121, the crossflow plenum 311, and / or the downflow plenum 309. In addition, or in the alternative, multiple flow fields having one or more respectively different characteristics may be determined within the irradiation plenum 121, the crossflow plenum 311, and / or the downflow plenum 309. Fig. 10A As shown, the process gas flow through the crossflow plenum 311 can include, for example, a crossflow flow field 350 having a relatively high velocity compared to one or more other flow fields within the irradiation plenum 121 and / or the downflow plenum 309. The crossflow flow field 350 can occupy all or a portion of the crossflow plenum 311. The crossflow flow field 350 can represent the highest velocity in the irradiation plenum 121.

[0190] like Fig. 10A and 10B As shown, the process gas flow through the downflow chamber 309 may include a primary downflow flow field 352. The primary downflow flow field 352 may include a region of the downflow of the process gas, which has a relatively moderate velocity, for example, relative to the crossflow flow field 350. The primary downflow flow field 352 may occupy an annular or semi-annular region extending longitudinally below at least a portion of the downflow manifold 210. The process gas in the primary downflow flow field 352 may be supplied from the downflow manifold 210 (e.g., from a plurality of downflow manifold orifices 422 disposed around one or more walls of the downflow manifold 210). The process gas flow through the downflow chamber 309 may include a static downflow flow field 354. The static downflow flow field 354 may represent a region of the downflow chamber 309 that exhibits a relatively static process gas flow, such as a relatively latent, gentle and / or soft process gas flow. The static downflow flow field 354 can be disposed below one or more optical windows 234, which separate one or more optical elements 233 of the irradiation device 216 from the irradiation chamber 121. The static downflow flow field 354 can be at least partially surrounded by the primary downflow flow field 352. For example, at least a portion of the primary downflow flow field 352 can circumferentially surround at least a portion of the static downflow flow field 354. The static downflow flow field 354 can present a crossflow, for example, having a radially outward direction vector and / or a downward acceleration direction vector 360. Such a crossflow can be located in a region of the downflow chamber 309 adjacent to the one or more optical windows 234.

[0191] The process gas flow through the downflow plenum 309 may include an intermediate downflow flow field 356. The intermediate downflow flow field 356 may be disposed between the primary downflow flow field 352 and the stationary downflow flow field 354. The intermediate downflow flow field 356 may represent a translational region of the downflow plenum 309, such as a translation from the primary downflow flow field 352 to the stationary downflow flow field 354. The intermediate downflow flow field 356 may occupy an annular or semi-annular region of the downflow plenum 309, such as an annular or semi-annular region extending longitudinally below at least a portion of the downflow manifold 210 and / or at least a portion of the one or more optical windows 234, the one or more optical windows 234 separating the one or more optical elements 233 of the irradiation device 216 from the irradiation plenum 121.

[0192] The intermediate downstream flow field 356 may be at least partially surrounded by the primary downstream flow field 352. For example, at least a portion of the primary downstream flow field 352 may circumferentially surround at least a portion of the intermediate downstream flow field 356. In addition, or in the alternative, the intermediate downstream flow field 356 may at least partially surround the stationary downstream flow field 354. For example, at least a portion of the intermediate downstream flow field 356 may circumferentially surround at least a portion of the stationary downstream flow field 354. At least a portion of the intermediate downstream flow field 356 may occupy a radially inward region of the downflow plenum 309, such as a radially inward region that extends longitudinally below at least a portion of the stationary downstream flow field 354.

[0193] Still reference Fig. 10A and 10B , the process gas flow through the downflow plenum 309 may include a lateral acceleration flow field 358. The lateral acceleration flow field 358 may include a portion of the downflow plenum 309 in which the process gas is accelerated laterally, for example, due to acceleration and entrainment by the cross-flow flow field 350 and / or suction from the return manifold 204. The lateral acceleration flow field 358 may represent a translational region of the downflow plenum 309, such as a translation from the primary downflow flow field 352 to the cross-flow flow field 350. At least a portion of the lateral acceleration flow field 358 may be disposed between the primary downflow flow field 352 and the cross-flow flow field 350. In addition, or in the alternative, at least a portion of the lateral acceleration flow field 358 may be laterally offset toward the return manifold inlet 802 and / or relative to the longitudinal axis 316 of the irradiation chamber 120. The lateral acceleration flow field 358 can occupy a proximal region of the downflow chamber 309 relative to the build plane 225, such as a proximal region extending longitudinally below at least a portion of the downflow manifold 210 and / or at least a portion of one or more optical windows 234, wherein one or more optical windows 234 separate one or more optical elements 233 of the irradiation device 216 from the irradiation chamber 121.

[0194] The process gas flow through the downflow plenum 309 may include an intermediate lateral acceleration flow field 362. The intermediate lateral acceleration flow field 362 may include a portion of the downflow plenum 309 where the process gas is accelerated laterally at a relatively intermediate rate compared to the lateral acceleration flow field 358, such as entrainment through the crossflow flow field 350 and / or suction from the return manifold 204. The intermediate lateral acceleration flow field 362 may represent a translational region of the downflow plenum 309, such as a translation from the intermediate downflow flow field 356 to the crossflow flow field 350. At least a portion of the intermediate lateral acceleration flow field 362 may be disposed between the intermediate downflow flow field 356 and the crossflow flow field 350. In addition, or in the alternative, at least a portion of the intermediate lateral acceleration flow field 362 may be centrally offset relative to the longitudinal axis 316 of the irradiation chamber 120 and / or laterally offset toward the crossflow manifold outlet 504. Intermediate lateral acceleration flow field 362 can occupy a proximal region of downflow plenum 309 relative to build plane 225, such as a proximal region extending longitudinally below at least a portion of intermediate downflow flow field 356, and / or below at least a portion of downflow manifold 210 and / or at least a portion of one or more optical windows 234. At least a portion of lateral acceleration flow field 358 can be laterally disposed adjacent to at least a portion of intermediate lateral acceleration flow field 362. For example, lateral acceleration flow field 358 can be disposed laterally outward relative to longitudinal axis 316 of irradiation chamber 120, and / or intermediate lateral acceleration flow field 362 can be disposed laterally inward relative to longitudinal axis 316 of irradiation chamber 120.

[0195] The overall flow rate of the process gas in the downflow plenum 309 may be selected to appropriately capture contaminants that may propagate out of the crossflow plenum 311. The regional velocity of the process gas in the downflow plenum 309 may be different between different flow fields within the downflow plenum 309. As an example, in Fig. 10A and 10B An exemplary downstream velocity curve 364 showing different velocities between the various flow fields is shown in FIG. For example, a relatively high velocity may be present in the primary downstream flow field 352 compared to a relatively low velocity in the static downstream flow field 354. Additionally or in the alternative, a relatively intermediate velocity may be present in the intermediate downstream flow field 356. It should be understood that Fig. 10A and 10B The downflow velocity profile 364 shown in FIG. 3 is provided by way of example only and is not limiting. It should be understood that other velocity profiles are contemplated and within the scope of the present disclosure, and such other velocity profiles may be achieved through modification of various embodiments and / or features of the presently disclosed inerting system 200 .

[0196] Reference now Fig. 10C , showing that from Fig. 10AAn exemplary cross-flow plenum 311 taken through cross-section CC shown in . The cross-flow plenum 311 may present a cross-flow flow field 350. The process gas in the cross-flow flow field 350 may be supplied from the cross-flow manifold 222 (e.g., from the cross-flow manifold outlet 504). The lateral velocity of the process gas in the cross-flow flow field 350 flowing through the cross-flow plenum 311 may exceed the downward velocity of the process gas in the irradiation plenum 121 and / or the downflow plenum 309. For example, the velocity of the process gas in the cross-flow flow field 350 may be relatively higher than the velocity of the process gas in the primary downflow flow field 352, the intermediate downflow flow field 356, and / or the stationary downflow flow field 354.

[0197] The overall flow rate of the process gas in the crossflow plenum 311 can be selected to appropriately remove and / or exhaust contaminants from the irradiation plenum 121 (including the crossflow plenum 311 and / or the downflow plenum 309). The velocity of the process gas in the crossflow plenum 311 can be selected to quickly remove and / or exhaust contaminants without disturbing the powder material 114 in the powder bed 227. The regional velocity of the process gas in the crossflow plenum 311 can be relatively uniform across the crossflow plenum 311. As an example, the exemplary crossflow velocity curve 366 represents a relatively uniform velocity across the crossflow flow field 350. It should be understood that Fig. 10C The cross-flow velocity profile 366 shown in FIG. 3 is provided by way of example only and is not limiting. It should be understood that other velocity profiles are contemplated and within the scope of the present disclosure, and such other velocity profiles may be implemented through modification of various embodiments and / or features of the presently disclosed inerting system 200 .

[0198] Reference now Figures 10D-10F , exemplary irradiation chambers 120 and irradiation plenums 121, such as crossflow chambers 310 and crossflow plenums 311, and / or downflow chambers 308 and downflow plenums 309, will be further described. The irradiation chamber 120 can define an irradiation plenum 121 that includes an irradiation zone 370. In addition, or in the alternative, the downflow chamber 308 can define a downflow plenum 309 that includes the irradiation zone 370, and / or the crossflow chamber can define a crossflow plenum 311 that includes the irradiation zone 370. The irradiation zone 370 can represent a portion of the irradiation plenum 121, the downflow plenum 309, and / or the crossflow plenum 311 that is utilized by the energy beam 214 during additive manufacturing. The irradiation zone 370 can include one or more dimensions corresponding to one or more dimensions of the scan field 212 of the one or more energy beams 214. For example, the irradiation zone 370 and the scanning field 212 can have the same cross-sectional area at one or more locations along the longitudinal axis 316 of the irradiation chamber 120. In addition, or in the alternative, the irradiation zone 370 can have a smaller cross-sectional area than the scanning field 212 of the one or more energy beams 214, for example at one or more locations along the longitudinal axis 316 of the irradiation chamber 120.

[0199] The irradiation zone 370 may occupy all or a portion of the cross-flow plenum 311. The cross-flow plenum 311 may include an auxiliary zone 372. The auxiliary zone 372 may include a portion of the cross-flow plenum 311 that is not utilized by one or more energy beams 214 during additive manufacturing. The auxiliary zone 372 may represent a portion of the irradiation plenum 121, the downflow plenum 309, and / or the cross-flow plenum 311 that may remain unused by the energy beam 214 during additive manufacturing. The auxiliary zone 372 may represent an area outside the scanning field of one or more energy beams 214. For example, the auxiliary zone 372 may surround at least a portion of the irradiation zone 370.

[0200] like Figures 10D-10F As shown, the irradiation chamber 120 can define an irradiation chamber 121 including an auxiliary zone 372 circumferentially surrounding the irradiation zone 370. For example, the irradiation chamber 120 can have a rectangular cross-sectional profile. In addition, or in the alternative, the cross-flow chamber 310 can define a cross-flow chamber 311 having a rectangular cross-sectional profile, and / or the downflow chamber 308 can define a downflow chamber 309 having a rectangular cross-sectional profile. Fig. 10D As shown, the lateral flow field within the irradiation zone 370 and / or the auxiliary zone 372 may have a lateral direction vector 262 .

[0201] like Fig. 10D As shown, the overall flow 374 of the lateral flow field can be substantially perpendicular to the lateral axis 318 of the irradiation chamber 120, the crossflow chamber 310 and / or the downflow chamber 308. In addition, or in the alternative, as Fig.10E and 10F As shown, the overall flow 374 of the lateral flow field can converge toward the lateral axis 318 of the irradiation chamber 120, the cross flow chamber 310 and / or the downflow chamber 308. The convergent overall flow 374 can be achieved by the construction and arrangement of the cross flow manifold 222 (for example, the construction and arrangement of the cross flow manifold outlet 504). The cross flow manifold outlet 504 can be configured to provide a convergent overall flow 374 with a lateral direction vector 262, and the lateral direction vector 262 converges toward the lateral axis 318. For example, the cross flow manifold outlet 504 may include one or more cross flow manifold path walls 508 oriented relative to the normal line of the tangent line perpendicular to the curved cross flow plane 378. In addition, or in the alternative, the cross flow manifold outlet 504 may include an outlet flow regulator 700, which is configured to provide a convergent overall flow 374. The outlet flow regulator 700 may include a plurality of outlet flow regulating channels 704 oriented relative to the normal line of the tangent line perpendicular to the curved cross flow plane 378.

[0202] The convergence of the bulk flow 374 toward the lateral axis 318 may orient the process gas flow relative to the irradiation zone 370, for example, to favor the auxiliary zone 372. Fig.10EAs shown, by converging the bulk flow 374 toward the lateral axis 318, a portion of the auxiliary region 372 may not be traversed by the bulk flow 374. In addition, or in the alternative, a boundary layer 376 of the bulk flow 374 may intersect the auxiliary region 372. The converging bulk flow 374 may help the return manifold 204 recapture the process gas. For example, the converging bulk flow 374 may direct the process gas into the return manifold inlet 802. In addition, or in the alternative, the converging bulk flow 374 may reduce or minimize eddies along the boundary layer 376 of the bulk flow 374, and / or the converging bulk flow 374 may reduce disturbances in the boundary layer 376, for example, by interaction from eddies and / or by interaction with the cross-flow wall 314.

[0203] The irradiation chamber 120, the downflow chamber 308, and / or the crossflow chamber 310 may include one or more crossflow walls 314 that are substantially aligned with the boundary layer 376 of the converging bulk flow 374 of the process gas. Fig.10F As shown, the irradiation chamber 120, the downflow chamber 308 and / or the cross-flow chamber 310 can have a trapezoidal cross-sectional profile. In addition, or in the alternative, one or more cross-flow walls 314 can be oriented convergingly toward the lateral axis 318. Since one or more cross-flow walls 314 are oriented convergingly toward the lateral axis 318, the return manifold can present improved recapture of process gas. For example, the converging cross-flow wall 314 can guide the process gas into the return manifold inlet 802. In addition, or in the alternative, the converging cross-flow wall 314 can reduce or minimize the vortex of the boundary layer 376 along the bulk flow 374, and / or the converging cross-flow wall 314 can, for example, reduce the disturbance of the boundary layer 376 by interaction from the vortex and / or by interaction between the bulk flow 374 and the cross-flow wall 314.

[0204] For example, Fig.10F , the return manifold 204 can be configured to receive the converging bulk flow 374. For example, the return manifold inlet 802 can be configured to receive the converging bulk flow 374. The return manifold inlet 802 can include one or more return manifold path walls 808 that are oriented relative to a normal perpendicular to a tangent to the curvilinear discharge plane 380. The normal perpendicular to the tangent to the curvilinear discharge plane 380 can coincide with a normal perpendicular to a tangent to the curvilinear cross-flow plane 378 of the cross-flow manifold outlet 504 and / or the outlet flow conditioner 700.

[0205] Now turn to Fig.11, an exemplary control system for an additive manufacturing machine 102 or additive manufacturing system 100 will be described. The control system 104 can be configured to perform one or more control operations. The control system 104 can be configured to output one or more control commands associated with the additive manufacturing machine 102. The control commands can be configured to control one or more controllable components of the additive manufacturing machine 102.

[0206] like Fig.11 As shown, the exemplary control system 104 includes a controller 1100. The controller may include one or more control modules 1102 configured to cause the controller 1100 to perform one or more control operations. The one or more control modules 1102 may include control logic executable to determine one or more operating parameters of the additive manufacturing machine 102, such as set points of one or more build units 110 and / or set points of one or more inerting systems 200 for performing operations according to the present disclosure. In addition, or in the alternative, the one or more control modules 1102 may include control logic executable to provide control commands configured to control one or more controllable components associated with the additive manufacturing machine 102, such as controllable components associated with one or more build units 110 and / or one or more inerting systems 200. For example, the control module 1102 may be configured to provide one or more control commands based at least in part on one or more set points for performing operations according to the present disclosure.

[0207] The controller 1100 may be communicatively coupled to the additive manufacturing machine 102. The controller 1100 may be communicatively coupled to one or more components of the additive manufacturing machine 102, such as the energy beam system 118 and / or one or more components of the monitoring system 254. The controller 1100 may also be communicatively coupled to the management system 106 and / or the user interface 108.

[0208] The controller 1100 may include one or more computing devices 1104, which may be located locally or remotely relative to the additive manufacturing machine 102 and / or the monitoring system 254. The one or more computing devices 1104 may include one or more processors 1106 and one or more memory devices 1108. The one or more processors 1106 may include any suitable processing device, such as a microprocessor, a microcontroller, an integrated circuit, a logic device, and / or other suitable processing device. The one or more memory devices 1108 may include one or more computer-readable media, including but not limited to non-transitory computer-readable media, RAM, ROM, hard drives, flash drives, and / or other memory devices 1108.

[0209] As used herein, the terms "processor" and "computer" and related terms (e.g., "processing device" and "computing device") are not limited to those integrated circuits known in the art as computers, but refer generally to microcontrollers, microcomputers, programmable logic controllers (PLCs), application specific integrated circuits, and other programmable circuits, and these terms may be used interchangeably herein. Memory device 1108 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, a floppy disk, a compact disk read only memory (CD-ROM), a magneto-optical disk (MOD), and / or a digital versatile disk (DVD) may also be used.

[0210] As used herein, the term "non-transitory computer-readable medium" is intended to mean any tangible computer-based device implemented in any method or technology for short-term and long-term storage of information (e.g., computer-readable instructions, data structures, program modules and submodules, or other data in any device). The methods described herein may be encoded as executable instructions embodied in a tangible non-transitory computer-readable medium (including, but not limited to, a storage device and / or a memory device). When executed by a processor, such instructions cause the processor to perform at least a portion of the methods described herein. In addition, 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, and removable and non-removable media, such as firmware, physical and virtual storage devices, CD-ROMs, DVDs, and any other digital source, such as a network or the Internet, as well as digital means yet to be developed, with the sole exception of transient propagation signals.

[0211] The one or more memory devices 1108 may store information accessible by the one or more processors 1106, including computer executable instructions 1110 executable by the one or more processors 1106. The instructions 1110 may include any set of instructions that, when executed by the one or more processors 1106, cause the one or more processors 1106 to perform operations, including optical element monitoring operations, maintenance operations, cleaning operations, calibration operations, and / or additive manufacturing operations.

[0212] The memory device 1108 may store data 1112 accessible by the one or more processors 1106. The data 1112 may include current or real-time data 1112, past data 1112, or a combination thereof. The data 1112 may be stored in a database 1114. As an example, the data 1112 may include data 1112 associated with or generated by the additive manufacturing system 100 and / or the additive manufacturing machine 102, including data 1112 associated with or generated by the controller 1100, the additive manufacturing machine 102, the energy beam system 118, the monitoring system 254, the management system 106, the user interface 108, and / or the computing device 1104. Such data 1112 may be related to the operation of one or more build units 110 and / or one or more inerting systems 200. The data 1112 may also include other data sets, parameters, outputs, information associated with the additive manufacturing system 100 and / or the additive manufacturing machine 102.

[0213] The one or more computing devices 1104 may also include a communication interface 1116 that may be used to communicate with a communication network 1118 via a wired or wireless communication link 1120. The communication interface 1116 may include any suitable components for interfacing with one or more networks, including, for example, a transmitter, a receiver, a port, a controller, an antenna, and / or other suitable components. The communication interface 1116 may allow the computing device 1104 to communicate with various nodes on the communication network 1118 (e.g., nodes associated with the additive manufacturing machine 102, one or more build units 110, one or more inerting systems 200, the management system 106, and / or the user interface 108). The communication network 1118 may include, for example, a local area network (LAN), a wide area network (WAN), a SATCOM network, a VHF network, a HF network, a Wi-Fi network, a WiMAX network, a gatelink network, and / or any other suitable communication network 1118 for transmitting messages to and / or from the controller 1100 across the communication link 1120. The communication links 1120 of the communication network 1118 may include a data bus or a combination of wired and / or wireless communication links.

[0214] The communication interface 1116 may allow the computing device 1104 to communicate with various components of the additive manufacturing system 100 and / or the additive manufacturing machine 102 that are communicatively coupled to the communication interface 1116 and / or to each other, including one or more build units 110 and / or one or more inerting systems 200. The communication interface 1116 may additionally or alternatively allow the computing device 1104 to communicate with the management system 106 and / or the user interface 108. The management system 106 may include a server 1122 and / or a data repository 1124. As an example, at least a portion of the data 1112 may be stored in the data repository 1124, and the server 1122 may be configured to transmit the data 1112 from the data repository 1124 to the computing device 1104, and / or receive the data 1112 from the computing device 1104 and store the received data 1112 in the data repository 1124 for further purposes. The server 1122 and / or the data repository 1124 may be implemented as part of the control system 104 and / or as part of the management system 106 .

[0215] Now turn to Fig.12 , an exemplary method for additive manufacturing of a three-dimensional object will be described. As shown, exemplary method 1200 may include positioning build unit 110 above an area of ​​powder bed 227 at block 1202. The area of ​​powder bed 227 may include a portion of powder bed 227 intended to be irradiated. Positioning build unit 110 may include, for example, moving build unit 110 using build unit positioning system 124. In addition, or in the alternative, moving build unit 110 may include, for example, moving build container 112 using build container positioning system 128, build container 112 being configured to support powder bed 227 below build unit 110. Build unit 110 may include energy beam system 118 and inerting system 200. Energy beam system 118 may include one or more irradiation devices 216, each of which is configured to direct one or more energy beams 214 to an area of ​​powder bed 227 corresponding to a corresponding scan field 212 of one or more energy beams 214. The inerting system 200 may include an irradiation chamber 120 defining an irradiation chamber 121. The inerting system 200 may additionally or alternatively include one or more supply manifolds 202 configured to supply process gas to the irradiation chamber 121, and / or return manifolds 204 configured to receive and / or exhaust process gas from the irradiation chamber.

[0216] The exemplary method 1200 may include, at block 1204, irradiating an area of ​​the powder bed 227 with a build unit 110 positioned above the area of ​​the powder bed 227 intended to be irradiated. At block 1206, the exemplary method 1200 may include flowing a process gas through one or more supply manifolds 202 and into an irradiation chamber 121 while irradiating the powder bed 227. The one or more supply manifolds 202 may include a downflow manifold 210 configured to provide a downward flow of a process gas through at least a portion of the irradiation chamber 121 defined by the irradiation chamber 120. Additionally, or in the alternative, the one or more supply manifolds 202 may include a crossflow manifold 222 configured to provide a lateral flow of a process gas through at least a portion of the irradiation chamber 121 defined by the irradiation chamber 120.

[0217] Flowing the process gas through the one or more supply manifolds 202 and into the irradiation gas chamber 121 may include flowing the process gas through a plurality of downflow manifold orifices 422 disposed within one or more inward downflow manifold walls 412. The plurality of downflow manifold orifices 422 may be in fluid communication between the one or more downflow manifold paths 418 and the optical gas chamber 235. The one or more downflow manifold paths 418 may be defined by a downflow manifold body 400. The downflow manifold body 400 may include one or more inward downflow manifold walls 412 that define the optical gas chamber 235. The optical gas chamber may include a distal portion of the irradiation gas chamber 121 relative to the powder bed 227. The plurality of downflow manifold orifices 422 may be oriented parallel to the longitudinal axis 424 of the downflow manifold body 400, or within 10 degrees of being parallel to the longitudinal axis 424 of the downflow manifold body 400.

[0218] In addition, or in the alternative, flowing the process gas through the one or more supply manifolds 202 and into the irradiation gas chamber 121 may include laterally expanding the process gas at a lateral expansion region 514 of a corresponding cross-flow manifold body in a plurality of cross-flow manifold bodies 500 of the cross-flow manifold 222, and then laterally translating the process gas at a lateral translation region 516 of a corresponding cross-flow manifold body in the plurality of cross-flow manifold bodies 500. The lateral expansion region 514 may be located downstream of the cross-flow manifold inlet 502 of the corresponding cross-flow manifold body 500. The lateral translation region 516 may be located downstream of the lateral expansion region 514 and upstream of the cross-flow manifold outlet 504 of the cross-flow manifold 222. The lateral expansion region 514 may exhibit a lateral expansion relative to the longitudinal axis 510 of the corresponding cross-flow manifold inlet 502 and / or relative to the lateral axis 512 of the cross-flow manifold outlet 504. The lateral translation region 516 may exhibit lateral translation relative to the longitudinal axis 510 of the corresponding cross flow manifold inlet 502 and / or relative to the lateral axis 512 of the cross flow manifold outlet 504 in an axial orientation of the corresponding cross flow manifold body 500 .

[0219] The exemplary method 1200 may include, at block 1208, exhausting process gas from the irradiation plenum 121 through the return manifold body 800 while irradiating the powder bed 227. Exhausting the process gas from the irradiation plenum 121 may include accelerating the process gas into the return manifold inlet 802 of the return manifold 204, and / or through one or more return manifold paths 806 defined by the corresponding one or more return manifold bodies 800. The process gas may be accelerated by a pressure reduction within the return manifold inlet 802 and / or within the one or more return manifold paths 806. The pressure reduction may be provided by one or more narrowed regions 821 and / or one or more rib elements 822 disposed about the return manifold inlet 802 and / or within the one or more return manifold paths 806.

[0220] Further aspects of the presently disclosed subject matter are provided by the following clauses:

[0221] 1. A building unit for additive manufacturing of three-dimensional objects, the building unit comprising: an energy beam system, the energy beam system comprising one or more irradiation devices respectively constructed to direct one or more energy beams onto an area of ​​a powder bed; and an inerting system, the inerting system comprising an irradiation chamber defining an irradiation chamber, one or more supply manifolds and a return manifold; wherein the one or more supply manifolds include a downflow manifold constructed to provide a downward flow of process gas through at least a portion of the irradiation chamber defined by the irradiation chamber, and a cross-flow manifold constructed to provide a lateral flow of the process gas through at least a portion of the irradiation chamber defined by the irradiation chamber.

[0222] 2. A construction unit according to any of the clauses herein, wherein the downflow manifold is constructed and arranged to interchangeably accommodate a selected one of a plurality of different energy beam systems, and / or interchangeably accommodate a selected one of a plurality of different irradiation devices and / or monitoring devices, and / or interchangeably accommodate a selected one of a plurality of different optical elements that can be included in the selected one of a plurality of different irradiation devices and / or monitoring devices.

[0223] 3. A construction unit according to any of the clauses herein, wherein the downflow manifold comprises one or more inward downflow manifold walls, wherein the one or more inward downflow manifold walls define an optical gas chamber constructed to receive one or more irradiation devices; and wherein the optical gas chamber is constructed and arranged to interchangeably accommodate a selected one of a plurality of different energy beam systems, and / or interchangeably accommodate a selected one of a plurality of different irradiation devices and / or monitoring devices, and / or interchangeably accommodate a selected one of a plurality of different optical elements that can be included in the selected one of a plurality of different irradiation devices and / or monitoring devices.

[0224] 4. A building unit according to any clause herein, wherein the downflow manifold comprises a downflow manifold body, the downflow manifold body defining one or more downflow manifold paths within the downflow manifold body.

[0225] 5. A building unit according to any item described herein, wherein the downflow manifold body includes one or more inward downflow manifold walls, and the one or more inward downflow manifold walls define an optical gas chamber that coincides with a distal portion of the irradiation gas chamber relative to the powder bed.

[0226] 6. A building unit according to any item described herein, wherein the one or more inward downstream manifold walls diverge from the longitudinal axis of the downstream manifold body at a divergence angle in a proximal direction relative to the powder bed, and the divergence angle allows the one or more energy beams from the energy beam system to approach a portion of the powder bed corresponding to the scanning field of the one or more energy beams.

[0227] 7. A building unit according to any item described herein, wherein the one or more inward downflow manifold walls include a plurality of downflow manifold orifices, and the plurality of downflow manifold orifices are oriented parallel to the longitudinal axis of the downflow manifold body, or within 10 degrees of parallel to the longitudinal axis of the downflow manifold body.

[0228] 8. A building unit according to any item described in the present invention, wherein the cross-flow manifold includes a plurality of cross-flow manifold bodies arranged along the width of the cross-flow manifold, and the plurality of cross-flow manifold bodies are respectively connected to each other or define corresponding integrally formed parts of the cross-flow manifold.

[0229] 9. A construction unit according to any item described herein, wherein a corresponding cross-flow manifold body among the multiple cross-flow manifold bodies includes a cross-flow manifold inlet fluidically connected to a process gas supply line and a plurality of cross-flow manifold paths defined by a corresponding cross-flow manifold body among the multiple cross-flow manifold bodies.

[0230] 10. A construction unit according to any item described herein, wherein the cross-flow manifold includes a cross-flow manifold outlet at least partially defined by a corresponding cross-flow manifold body among the multiple cross-flow manifold bodies, and the cross-flow manifold outlet is fluidly connected to the irradiation air chamber defined by the irradiation chamber and the multiple cross-flow manifold path fluids of the corresponding cross-flow manifold bodies among the multiple cross-flow manifold bodies.

[0231] 11. A construction unit according to any item herein, wherein the cross-flow manifold outlet has an elongated cross-sectional profile, and wherein a corresponding cross-flow manifold body among the plurality of cross-flow manifold bodies includes a lateral expansion region and a lateral translation region, wherein the lateral expansion region presents a lateral expansion of the corresponding cross-flow manifold body relative to the longitudinal axis of the corresponding cross-flow manifold inlet and / or relative to the lateral axis of the cross-flow manifold outlet, and the lateral translation region presents a lateral translation relative to the longitudinal axis of the corresponding cross-flow manifold inlet and / or relative to the lateral axis of the cross-flow manifold outlet in the axial orientation of the corresponding cross-flow manifold body.

[0232] 12. A building unit according to any item described herein, wherein the lateral expansion region is located downstream of the corresponding cross-flow manifold inlet, and the lateral translation region is located downstream of the lateral expansion region and upstream of the cross-flow manifold outlet.

[0233] 13. A building unit according to any clause herein, wherein the return manifold is configured to receive and / or exhaust process gas from the irradiation chamber while irradiating the powder bed, the process gas flowing through the irradiation chamber and into the return manifold.

[0234] 14. A building unit according to any clause herein, wherein the return manifold comprises a plurality of exhaust manifold bodies arranged along the width of the return manifold, the plurality of exhaust manifold bodies being respectively coupled to each other or defining respective integrally formed portions of the return manifold.

[0235] 15. A construction unit according to any of the clauses herein, wherein the return manifold includes a return manifold inlet and one or more exhaust manifold paths at least partially defined by corresponding exhaust manifold bodies among the multiple exhaust manifold bodies, and the return manifold inlet is fluidly connected to the irradiation air chamber defined by the irradiation chamber and the one or more exhaust manifold paths defined by corresponding exhaust manifold bodies among the multiple exhaust manifold bodies.

[0236] 16. A building unit according to any clause herein, wherein a respective one of the plurality of exhaust manifold bodies comprises a return manifold outlet in fluid communication with the one or more exhaust manifold paths of the respective exhaust manifold body and a process gas exhaust line.

[0237] 17. A building unit according to any item described herein, wherein the return manifold inlet has an elongated cross-sectional profile, and wherein the return manifold includes one or more narrowed areas and / or one or more rib elements arranged around the return manifold inlet and / or within the one or more exhaust manifold paths.

[0238] 18. A construction unit according to any of the clauses herein, wherein the one or more narrowed regions and / or the one or more rib elements are configured to provide a pressure reduction within the return manifold inlet and / or within the one or more exhaust manifold paths, the pressure reduction accelerating the flow of the process gas into the return manifold inlet and / or through the one or more exhaust manifold paths.

[0239] 19. A building unit according to any clause herein, wherein the return manifold is configured to receive a lateral flow of the process gas from at least a portion of an irradiation plenum defined by the irradiation chamber.

[0240] 20. A building unit for additive manufacturing of three-dimensional objects, the building unit comprising: an energy beam system, the energy beam system comprising one or more irradiation devices respectively constructed to direct one or more energy beams onto an area of ​​a powder bed; and an inerting system, the inerting system comprising an irradiation chamber defining an irradiation gas chamber and one or more supply manifolds, the one or more supply manifolds being constructed to supply process gas to the irradiation gas chamber while irradiating the area of ​​the powder bed using the building unit located above the area of ​​the powder bed, the process gas flowing through the one or more supply manifolds and entering the irradiation gas chamber while irradiating the area of ​​the powder bed; wherein the one or more supply manifolds include a downflow manifold, the downflow manifold being constructed to provide a downward flow of the process gas through at least a portion of the irradiation gas chamber defined by the irradiation chamber; wherein the downflow manifold includes a downflow manifold body, the downflow manifold body being disposed in the One or more downflow manifold paths are defined in a downflow manifold body, the downflow manifold body including one or more inward downflow manifold walls, the one or more inward downflow manifold walls defining an optical gas chamber coinciding with a distal portion of the irradiation gas chamber relative to the powder bed; and wherein the one or more inward downflow manifold walls diverge from the longitudinal axis of the downflow manifold body in a proximal direction relative to the powder bed at a divergence angle, the divergence angle allowing the one or more energy beams of the energy beam system to approach a portion of the powder bed corresponding to a scanning field of the one or more energy beams; wherein the one or more inward downflow manifold walls include a plurality of downflow manifold orifices, the plurality of downflow manifold orifices being fluidly connected between the optical gas chamber and one or more downflow manifold paths defined by the downflow manifold body, the plurality of downflow manifold orifices being oriented parallel to the longitudinal axis of the downflow manifold body, or within 10 degrees of being parallel to the longitudinal axis of the downflow manifold body.

[0241] 21. A building unit according to any clause herein, wherein said one or more inward downflow manifold walls comprise a second plurality of downflow manifold apertures oriented obliquely and / or perpendicularly to said longitudinal axis of said downflow manifold body.

[0242] 22. A building block according to any of the clauses herein, comprising: an optical window, which separates one or more optical elements of the energy beam system from the optical gas cell, and the optical window defines a top portion of the optical gas cell.

[0243] 23. A construction unit according to any of the clauses herein, wherein the downflow manifold and / or the optical gas chamber are constructed and arranged to interchangeably accommodate a plurality of different energy beam systems, and / or interchangeably accommodate a plurality of different irradiation devices and / or monitoring devices, and / or interchangeably accommodate a plurality of different optical elements that can be included in an irradiation device or a measuring device.

[0244] 24. A building unit according to any item described herein, wherein the irradiation gas chamber has an elongated cross-sectional area, and the elongated cross-sectional area is configured to accommodate a plurality of adjacently arranged optical elements utilized by the energy beam system.

[0245] 25. A building unit according to any item described herein, wherein the downflow manifold body includes one or more bottom downflow manifold walls, which define a distal portion of the irradiation chamber relative to the powder bed; and wherein the one or more bottom downflow manifold walls include a second plurality of downflow manifold orifices, which are fluidly connected between the irradiation chamber and the one or more downflow manifold paths defined by the downflow manifold body, and the plurality of downflow manifold orifices are oriented parallel to the longitudinal axis of the downflow manifold body, or within 10 degrees of being parallel to the longitudinal axis of the downflow manifold body.

[0246] 26. A building unit according to any item herein, wherein the one or more bottom downflow manifold walls include a third plurality of downflow manifold apertures, the third plurality of downflow manifold apertures being oriented obliquely and / or perpendicularly to the longitudinal axis of the downflow manifold body.

[0247] 27. A building unit according to any clause herein, wherein the downflow manifold body comprises one or more downflow manifold baffles disposed within the one or more downflow manifold paths.

[0248] 28. A building unit according to any clause herein, wherein the energy beam system comprises an energy beam housing coupled to the downflow manifold and / or defining a portion of the downflow manifold.

[0249] 29. A building unit according to any clause herein, wherein the irradiation chamber comprises one or more downflow walls that can be oriented parallel and / or oblique to a longitudinal axis of the irradiation chamber.

[0250] 30. A building unit according to any clause herein, comprising: a supply manifold header configured to distribute the process gas to the one or more supply manifolds, the supply manifold header comprising a plurality of supply manifold distribution elements.

[0251] 31. A building unit according to any clause herein, wherein the supply manifold header comprises one or more supply manifold connection elements, the one or more supply manifold connection elements providing fluid communication between at least some of the plurality of supply manifold distribution elements.

[0252] 32. A building unit according to any item described herein, wherein the one or more supply manifolds include a cross-flow manifold configured to provide a lateral flow of the process gas through at least a portion of the irradiation chamber defined by the irradiation chamber.

[0253] 33. A building unit according to any clause herein, comprising: a return manifold configured to receive and / or exhaust the process gas from the irradiation chamber.

[0254] 34. A building unit for additive manufacturing of three-dimensional objects, the building unit comprising: an energy beam system, the energy beam system comprising one or more irradiation devices respectively configured to direct one or more energy beams onto an area of ​​a powder bed; and an inerting system, the inerting system comprising an irradiation chamber defining an irradiation gas chamber and one or more supply manifolds, the one or more supply manifolds being configured to supply process gas to the irradiation gas chamber while irradiating the area of ​​the powder bed using the building unit located above the area of ​​the powder bed, and irradiating the area of ​​the powder bed. while the process gas flows through the one or more supply manifolds and enters the irradiation gas chamber; wherein the one or more supply manifolds include a cross-flow manifold, the cross-flow manifold being configured to provide a lateral flow of the process gas through at least a portion of the irradiation gas chamber defined by the irradiation chamber; wherein the cross-flow manifold includes a plurality of cross-flow manifold bodies arranged along the width of the cross-flow manifold, the plurality of cross-flow manifold bodies being respectively connected to each other or defining corresponding integrally formed portions of the cross-flow manifold, and corresponding cross-flow manifold bodies among the plurality of cross-flow manifold bodies including a cross-flow manifold having a cross-flow manifold body that is connected to the process gas The cross-flow manifold is provided with a cross-flow manifold inlet fluidly connected to a body supply line and a plurality of cross-flow manifold paths defined by corresponding cross-flow manifold bodies, and the cross-flow manifold includes a cross-flow manifold outlet at least partially defined by a corresponding cross-flow manifold body among the multiple cross-flow manifold bodies, and the cross-flow manifold outlet is fluidly connected to the irradiation gas chamber defined by the irradiation chamber and the plurality of cross-flow manifold paths of the corresponding cross-flow manifold bodies among the multiple cross-flow manifold bodies; and wherein the cross-flow manifold outlet has an elongated cross-sectional profile, and wherein the corresponding cross-flow manifold body among the multiple cross-flow manifold bodies includes a lateral expansion A region and a lateral translation region, wherein the lateral expansion region is located downstream of the corresponding cross-flow manifold inlet, and the lateral translation region is located downstream of the lateral expansion region and upstream of the cross-flow manifold outlet, the lateral expansion region presents a lateral expansion of the corresponding cross-flow manifold body relative to the longitudinal axis of the corresponding cross-flow manifold inlet and / or relative to the lateral axis of the cross-flow manifold outlet, and the lateral translation region presents a lateral translation in the axial orientation of the corresponding cross-flow manifold body relative to the longitudinal axis of the corresponding cross-flow manifold inlet and / or relative to the lateral axis of the cross-flow manifold outlet.

[0255] 35. A building unit according to any item described herein, wherein the cross-flow manifold includes a plurality of cross-flow manifold path walls, and the plurality of cross-flow manifold path walls respectively define at least a portion of a corresponding cross-flow manifold path in the plurality of cross-flow manifold paths.

[0256] 36. A building unit according to any item described herein, wherein a corresponding cross-flow manifold body among the multiple cross-flow manifold bodies includes a longitudinal extension region, which is arranged between at least a portion of the lateral expansion region and at least a portion of the lateral translation region, and the longitudinal extension region presents a longitudinal extension relative to the longitudinal axis of the corresponding cross-flow manifold inlet in the corresponding cross-flow manifold body.

[0257] 37. A construction unit according to any item described herein, wherein a corresponding cross-flow manifold body among the multiple cross-flow manifold bodies includes a lateral contour area, which coincides with the position of at least a portion of the lateral expansion area and / or at least a portion of the lateral translation area, and the lateral contour area presents a lateral change in the cross-sectional profile of the corresponding cross-flow manifold body relative to the cross-sectional profile of the corresponding cross-flow manifold inlet.

[0258] 38. A building unit according to any item described herein, wherein the cross-flow manifold includes a plurality of inlet flow regulators, and corresponding inlet flow regulators of the plurality of inlet flow regulators are arranged in corresponding cross-flow manifold inlets.

[0259] 39. A building unit according to any item described herein, wherein a corresponding inlet flow regulator among the multiple inlet flow regulators includes a grid defining a plurality of inlet flow regulation channels, and a corresponding inlet flow regulation channel among the multiple inlet flow regulation channels includes a polygonal cross-sectional profile, an elliptical cross-sectional profile and / or a curved cross-sectional profile.

[0260] 40. A building unit according to any item described herein, wherein a corresponding inlet flow regulator among the multiple inlet flow regulators is removably and / or fixedly inserted into the inlet of the corresponding cross-flow manifold, or wherein a corresponding inlet flow regulator among the multiple inlet flow regulators is integrally formed as a part of the corresponding cross-flow manifold body defining the inlet of the corresponding cross-flow manifold.

[0261] 41. A building block according to any item described herein, wherein the cross-flow manifold includes an outlet flow regulator arranged in the outlet of the cross-flow manifold.

[0262] 42. A building unit according to any item described herein, wherein the outlet flow regulator includes a grid defining a plurality of outlet flow regulating channels, and corresponding outlet flow regulating channels in the plurality of outlet flow regulating channels include a polygonal cross-sectional profile, an elliptical cross-sectional profile and / or a curved cross-sectional profile.

[0263] 43. A building unit according to any item described herein, wherein at least some of the plurality of outlet flow conditioning channels have an inclined orientation that converges toward a lateral axis of the cross-flow manifold outlet in the direction of process gas flow through the plurality of outlet flow conditioning channels.

[0264] 44. A building block according to any clause herein, wherein at least some of the plurality of outlet flow conditioning channels are oriented relative to a normal perpendicular to a tangent to a curvilinear plane corresponding to a portion of a sphere or an oval.

[0265] 45. A building unit according to any item described herein, wherein the outlet flow regulator is removably and / or fixedly inserted into the cross-flow manifold outlet, or wherein the outlet flow regulator is integrally formed as a part of the multiple cross-flow manifold bodies that define the cross-flow manifold outlet.

[0266] 46. ​​A building unit according to any item described herein, wherein the plurality of cross-flow manifold bodies include one or more cross-flow manifold side walls, and the one or more cross-flow manifold side walls have an outlet flow regulator access port configured to receive the outlet flow regulator.

[0267] 47. A building unit according to any item described herein, wherein the multiple cross-flow manifold bodies include one or more outlet flow regulator grooves configured to receive outflow regulators, and the one or more outlet flow regulator grooves extend laterally through the multiple cross-flow manifold bodies adjacent to the cross-flow manifold outlet and / or upstream of the cross-flow manifold outlet.

[0268] 48. A construction unit according to any of the clauses herein, comprising: a supply manifold header, which is constructed to distribute process gas to the one or more supply manifolds; and a plurality of process gas supply pipelines, corresponding process gas supply pipelines in which are fluidly connected between the supply manifold header and the corresponding cross-flow manifold inlets.

[0269] 49. A construction unit according to any of the clauses herein, comprising: one or more supply manifold connecting elements, corresponding ones of the one or more supply manifold connecting elements being fluidly connected between corresponding first and second process gas supply pipelines in the plurality of process gas supply pipelines, and the one or more supply manifold connecting elements being constructed to allow the process gas flow to be proportionally distributed among the plurality of process gas supply pipelines.

[0270] 50. A build unit according to any item described herein, wherein the inerting system includes a return manifold, which is constructed to receive and / or exhaust process gas from the irradiation chamber while irradiating the area of ​​the powder bed using the build unit located above the area of ​​the powder bed, and the process gas flows through the irradiation chamber and enters the return manifold while irradiating the area of ​​the powder bed.

[0271] 51. A building unit according to any clause herein, wherein the one or more supply manifolds include a downflow manifold configured to provide a downward flow of the process gas through at least a portion of the irradiation plenum defined by the irradiation chamber.

[0272] 52. A construction unit according to any item described herein, wherein the irradiation chamber includes a cross-flow chamber, which defines a cross-flow chamber that occupies at least a portion of the irradiation chamber, wherein the cross-flow manifold is configured to provide a lateral flow of the process gas through the cross-flow chamber, and wherein the cross-flow chamber includes one or more cross-flow walls oriented parallel to or inclined to a lateral axis of the cross-flow chamber.

[0273] 53. A building unit for additive manufacturing of three-dimensional objects, the building unit comprising: an energy beam system, the energy beam system comprising one or more irradiation devices respectively constructed to direct one or more energy beams onto an area of ​​a powder bed; and an inerting system, the inerting system comprising an irradiation chamber defining an irradiation chamber and a return manifold, the return manifold being constructed to receive and / or discharge process gas from the irradiation chamber while irradiating the area of ​​the powder bed using the building unit located above the area of ​​the powder bed, the process gas flowing through the irradiation chamber and entering the return manifold while irradiating the area of ​​the powder bed; wherein the return manifold comprises a plurality of return manifold bodies arranged along the width of the return manifold, the plurality of return manifold bodies being respectively connected to each other or defining corresponding integrally formed portions of the return manifold, the return manifold comprising a plurality of return manifold bodies at least partially formed by the plurality of return manifold bodies. a return manifold inlet defined by a corresponding return manifold body among the return manifold bodies, a corresponding return manifold body among the multiple return manifold bodies including one or more return manifold paths and a return manifold outlet, the return manifold outlet being fluidly connected to the one or more return manifold paths and the process gas exhaust line of the return manifold body, and the return manifold inlet being fluidly connected to the irradiation gas chamber defined by the irradiation chamber and the one or more return manifold paths defined by the corresponding return manifold body among the multiple return manifold bodies; wherein the return manifold is constructed to receive a lateral flow of the process gas from at least a portion of the irradiation gas chamber defined by the irradiation chamber, wherein the return manifold inlet has an elongated cross-sectional profile, and wherein the return manifold includes one or more narrowed areas and / or one or more rib elements arranged around the return manifold inlet and / or within the one or more return manifold paths.

[0274] 54. A building unit according to any item described herein, wherein the plurality of return manifold bodies include one or more recapture paths arranged around a bottom portion of the one or more return manifold paths, and the one or more recapture paths are constructed to receive the process gas flowing through the return manifold inlet into the one or more return manifold paths.

[0275] 55. A building block according to any clause herein, wherein the one or more recapture paths comprise an elongated slit disposed laterally across a bottom portion of the one or more return manifold paths.

[0276] 56. A building block according to any clause herein, wherein the one or more recapture paths are in fluid communication with the one or more return manifold paths downstream of an inlet edge of a return manifold inlet.

[0277] 57. A building block according to any item herein, wherein the one or more recapture paths are in fluid communication with the one or more return manifold paths upstream of at least one of the one or more narrowing elements and / or at least one of the one or more rib elements.

[0278] 58. A building block according to any item herein, wherein the one or more recapture paths include slits, a perforated array, a grid or a grille, and the one or more recapture paths are arranged around at least a portion of the one or more return manifold paths.

[0279] 59. A construction unit according to any item described herein, wherein a corresponding return manifold body among the multiple return manifold bodies includes an upward translation region located downstream of the return manifold inlet, and the upward translation region presents an upward translation in the axial orientation of the corresponding cross-flow manifold body relative to the longitudinal axis of the corresponding cross-flow manifold inlet and / or relative to the lateral axis of the corresponding return manifold outlet.

[0280] 60. A building unit according to any item described herein, wherein a corresponding return manifold body among the multiple return manifold bodies includes a lateral contraction region, which is located downstream of the corresponding upward translation region and upstream of the corresponding return manifold outlet, and the lateral contraction region presents a lateral contraction in the corresponding return manifold body relative to the lateral axis of the return manifold inlet and / or relative to the longitudinal axis of the corresponding return manifold outlet.

[0281] 61. A construction unit according to any item described herein, wherein a corresponding return manifold body among the multiple return manifold bodies includes a lateral contour area, which coincides with the position of at least a portion of the lateral contraction area and / or at least a portion of the upward translation area, and the lateral contour area presents a lateral change in the cross-sectional profile of the corresponding return manifold body relative to the cross-sectional profile of the corresponding cross-flow manifold inlet.

[0282] 62. A building unit according to any item described herein, wherein a corresponding return manifold body among the multiple return manifold bodies includes a longitudinal extension region, which is arranged between at least a portion of the upward translation region and at least a portion of the lateral contraction region, and the longitudinal extension region presents a longitudinal extension of the corresponding return manifold body relative to the longitudinal axis of the corresponding return manifold outlet.

[0283] 63. A build unit according to any item described herein, wherein the inerting system includes: one or more supply manifolds, wherein the one or more supply manifolds are configured to supply the process gas to the irradiation chamber while the area of ​​the powder bed is irradiated using the build unit located above the area of ​​the powder bed, and the process gas flows through the one or more supply manifolds and enters the irradiation chamber while the area of ​​the powder bed is irradiated.

[0284] 64. A building unit according to any item described herein, wherein the one or more supply manifolds include a cross-flow manifold configured to provide a lateral flow of the process gas through at least a portion of the irradiation gas chamber defined by the irradiation chamber.

[0285] 65. A building unit according to any clause herein, wherein the one or more supply manifolds include a downflow manifold configured to provide a downward flow of the process gas through at least a portion of the irradiation plenum defined by the irradiation chamber.

[0286] 66. A building unit according to any item described herein, wherein the return manifold is configured to receive the lateral flow of the process gas from the cross-flow manifold and / or the downward flow of the process gas from the downflow manifold.

[0287] 67. A construction unit according to any item described herein, wherein the irradiation chamber includes a cross-flow chamber, which defines a cross-flow chamber that occupies at least a portion of the irradiation chamber, wherein the cross-flow manifold is configured to provide a lateral flow of the process gas through the cross-flow chamber, and wherein the cross-flow chamber includes one or more cross-flow walls oriented parallel to or inclined to a lateral axis of the cross-flow chamber.

[0288] 68. A construction unit according to any item described herein, wherein a corresponding cross-flow wall among the one or more cross-flow walls comprises: one or more flanges, the one or more flanges having attachment points, the attachment points being configured to connect the corresponding cross-flow wall to a cross-flow manifold, a return manifold and / or a downstream wall of the irradiation chamber; and one or more slopes, a corresponding slope among the one or more slopes being arranged between a surface of the corresponding cross-flow wall and a corresponding flange among the one or more flanges, the corresponding slope among the one or more slopes being inclined away from one of the one or more flanges.

[0289] 69. A construction unit according to any item described herein, wherein the irradiation chamber includes a downflow chamber, the downflow chamber defining a downflow chamber occupying at least a portion of the irradiation chamber, wherein the downflow manifold is constructed to provide a downward flow of the process gas through the downflow chamber, and wherein the downflow chamber includes one or more downflow walls oriented parallel to or inclined to the longitudinal axis of the downflow chamber.

[0290] 70. An additive manufacturing system, comprising: a build unit; a build container; a build unit positioning system and / or a build container positioning system; and wherein the build unit comprises: an energy beam system, the energy beam system comprising one or more irradiation devices respectively configured to direct one or more energy beams onto an area of ​​a powder bed; and an inerting system, the inerting system comprising an irradiation chamber defining an irradiation chamber, one or more supply manifolds and a return manifold; wherein the one or more supply manifolds comprise a downflow manifold configured to provide a downward flow of process gas through at least a portion of the irradiation chamber defined by the irradiation chamber, and a cross-flow manifold configured to provide a lateral flow of process gas through at least a portion of the irradiation chamber defined by the irradiation chamber.

[0291] 71. An additive manufacturing system according to any item herein, wherein the build unit positioning system is configured to move the build unit to a specified build coordinate and / or move the build unit along a specified build vector.

[0292] 72. An additive manufacturing system according to any item described herein, wherein the build container positioning system is configured to move the build container to a specified build coordinate and / or move the build container along a specified build vector.

[0293] 73. An additive manufacturing system according to any clause herein, comprising:

[0294] A control system configured to control one or more operations of the additive manufacturing system.

[0295] 74. An additive manufacturing system according to any of the clauses herein, comprising a building unit as described in any of the clauses herein.

[0296] 75. A method for additive manufacturing of three-dimensional objects, the method comprising: irradiating a powder bed using a building unit located above a powder bed, the building unit comprising an energy beam system and an inerting system, wherein the inerting system comprises: an irradiation chamber defining an irradiation chamber, one or more supply manifolds configured to supply process gas to the irradiation chamber, and a return manifold configured to receive and / or discharge process gas from the irradiation chamber; causing process gas to flow through the one or more supply manifolds and into the irradiation chamber while irradiating the powder bed, wherein the one or more supply manifolds comprise a downflow manifold configured to provide a downward flow of the process gas through at least a portion of the irradiation chamber defined by the irradiation chamber, and a crossflow manifold configured to provide a lateral flow of the process gas through at least a portion of the irradiation chamber defined by the irradiation chamber; and discharging the process gas from the irradiation chamber through the return manifold while irradiating the powder bed.

[0297] 76. A method according to any item herein, wherein causing the process gas to flow through the one or more supply manifolds and into the irradiation gas chamber includes causing the process gas to flow through a plurality of downflow manifold orifices disposed within one or more inward downflow manifold walls of the downflow manifold.

[0298] 77. A method according to any item herein, wherein causing the process gas to flow through the one or more supply manifolds and into the irradiation gas chamber includes laterally expanding the process gas at a lateral expansion region of a corresponding cross-flow manifold body among a plurality of cross-flow manifold bodies, and then laterally translating the process gas at a lateral translation region of a corresponding cross-flow manifold body among the plurality of cross-flow manifold bodies, wherein the lateral expansion region is located downstream of the corresponding cross-flow manifold inlet, and the lateral translation region is located downstream of the lateral expansion region and upstream of the cross-flow manifold outlet, the lateral expansion region exhibits a lateral expansion relative to the longitudinal axis of the corresponding cross-flow manifold inlet and / or relative to the lateral axis of the cross-flow manifold outlet, and the lateral translation region exhibits a lateral translation relative to the longitudinal axis of the corresponding cross-flow manifold inlet and / or relative to the lateral axis of the cross-flow manifold outlet in the axial orientation of the corresponding cross-flow manifold body.

[0299] 78. A method according to any item herein, wherein exhausting the process gas from the irradiation gas chamber includes accelerating the flow of process gas into the return manifold inlet and / or through one or more exhaust manifold paths by a pressure reduction within the return manifold inlet and / or within the one or more exhaust manifold paths, wherein the pressure reduction is provided by one or more narrowed areas and / or one or more rib elements arranged around the return manifold inlet and / or within the one or more exhaust manifold paths.

[0300] 79. A method for additive manufacturing of a three-dimensional object, the method comprising: irradiating the area of ​​the powder bed using a building unit located above the area of ​​the powder bed, the building unit comprising an energy beam system and an inerting system, the energy beam system comprising one or more irradiation devices respectively constructed to direct one or more energy beams onto the area of ​​the powder bed, and the inerting system comprising an irradiation chamber defining an irradiation chamber and one or more supply manifolds constructed to supply process gas to the irradiation chamber; and causing the process gas to flow through the one or more supply manifolds and into the irradiation chamber while irradiating the powder bed, wherein the one or more supply manifolds comprise a downflow manifold, the downflow manifold being constructed to provide a downward flow of the process gas through at least a portion of the irradiation chamber defined by the irradiation chamber; wherein the downflow manifold comprises a downflow manifold body, the downflow manifold body defining one or more downflow manifold paths within the downflow manifold body, the downflow manifold body It includes one or more inward downflow manifold walls defining an optical gas chamber, the optical gas chamber including a distal portion of the irradiation gas chamber relative to the powder bed; and wherein the one or more inward downflow manifold walls diverge from the longitudinal axis of the downflow manifold body at a divergence angle in a proximal direction relative to the powder bed, and the divergence angle allows the one or more energy beams of the energy beam system to approach a portion of the powder bed corresponding to a scanning field of the one or more energy beams; wherein causing the process gas to flow through the one or more supply manifolds and into the irradiation gas chamber includes causing the process gas to flow through a plurality of downflow manifold orifices disposed within the one or more inward downflow manifold walls, the plurality of downflow manifold orifices being fluidly connected between the optical gas chamber and the one or more downflow manifold paths defined by the downflow manifold body, and the plurality of downflow manifold orifices being oriented parallel to the longitudinal axis of the downflow manifold body, or within 10 degrees of being parallel to the longitudinal axis of the downflow manifold body.

[0301] 80. A method according to any of the clauses herein, comprising: positioning the build unit above the area of ​​the powder bed at least in part by moving the build unit using a build unit positioning system and / or by moving a build container, wherein the build container is constructed to support the powder bed below the build unit, and the build container is moved at least in part by the build container positioning system.

[0302] 81. A method according to any item herein, wherein the irradiation gas chamber includes a downflow gas chamber, the downward flow of the process gas flows through the downflow gas chamber, wherein the downward flow of the process gas includes a primary downflow flow field and a stationary downflow flow field at least partially surrounded by the primary downflow flow field, the primary downflow flow field occupies an annular or semi-annular area extending longitudinally below at least a portion of the downflow manifold, and the stationary downflow flow field occupies at least a portion of the optical gas chamber.

[0303] 82. A method according to any item herein, wherein causing the process gas to flow through the one or more supply manifolds and into the irradiation gas chamber includes causing the process gas to flow through a cross-flow manifold, which is constructed to provide a lateral flow of the process gas through at least a portion of the irradiation gas chamber defined by the irradiation chamber.

[0304] 83. A method according to any item herein, wherein the irradiation chamber includes a cross-flow chamber, wherein the lateral flow of the process gas flowing through the cross-flow chamber has a lateral velocity that exceeds the downward velocity of the downward flow of the process gas flowing through the irradiation chamber.

[0305] 84. A method according to any clause herein, comprising exhausting the process gas from the irradiation chamber through a return manifold while irradiating the powder bed.

[0306] 85. A method for additive manufacturing of a three-dimensional object, the method comprising: irradiating the area of ​​the powder bed using a building unit located above the area of ​​the powder bed, the building unit comprising an energy beam system and an inerting system, the energy beam system comprising one or more irradiation devices respectively configured to direct one or more energy beams onto the area of ​​the powder bed, and the inerting system comprising an irradiation chamber defining an irradiation gas chamber and one or more supply manifolds configured to supply process gas to the irradiation gas chamber; and causing the process gas to flow through the one or more supply manifolds and into the irradiation gas chamber while irradiating the powder bed. The invention relates to a process gas supply chamber, wherein the one or more supply manifolds include a cross-flow manifold configured to provide a lateral flow of the process gas through at least a portion of the irradiation gas chamber defined by the irradiation chamber; wherein the cross-flow manifold includes a plurality of cross-flow manifold bodies arranged along the width of the cross-flow manifold, the plurality of cross-flow manifold bodies being respectively connected to each other or defining corresponding integrally formed portions of the cross-flow manifold, a corresponding cross-flow manifold body among the plurality of cross-flow manifold bodies including a cross-flow manifold inlet fluidly connected to a process gas supply line and a plurality of cross-flow manifold paths defined by the corresponding cross-flow manifold body, and the cross-flow manifold body comprises a plurality of cross-flow manifold bodies arranged along the width of the cross-flow manifold, the plurality of cross-flow manifold bodies being respectively connected to each other or defining corresponding integrally formed portions of the cross-flow manifold, the corresponding cross-flow manifold bodies among the plurality of cross-flow manifold bodies comprising a cross-flow manifold inlet fluidly connected to a process gas supply line and a plurality of cross-flow manifold paths defined by the corresponding cross-flow manifold bodies, and the cross-flow manifold body comprises a plurality of cross-flow manifold bodies arranged along the width of the cross-flow manifold, the plurality of cross-flow manifold bodies being respectively connected to each other or defining corresponding integrally formed portions of the cross-flow manifold, the corresponding ... The manifold includes a cross-flow manifold outlet at least partially defined by a corresponding cross-flow manifold body among the plurality of cross-flow manifold bodies, the cross-flow manifold outlet having an elongated cross-sectional profile, and the cross-flow manifold outlet is fluidly connected to the irradiation gas chamber defined by the irradiation chamber and the plurality of cross-flow manifold path fluids of the corresponding cross-flow manifold bodies among the plurality of cross-flow manifold bodies; wherein causing the process gas to flow through the one or more supply manifolds and into the irradiation gas chamber includes laterally expanding the process gas at a lateral expansion region of a corresponding cross-flow manifold body among the plurality of cross-flow manifold bodies, and then in the plurality of cross-flow manifold bodies The process gas is laterally translated at a lateral translation region of a corresponding cross-flow manifold body, the lateral expansion region is located downstream of the corresponding cross-flow manifold inlet, and the lateral translation region is located downstream of the lateral expansion region and upstream of the cross-flow manifold outlet, the lateral expansion region exhibits a lateral expansion relative to the longitudinal axis of the corresponding cross-flow manifold inlet and / or relative to the lateral axis of the cross-flow manifold outlet, and the lateral translation region exhibits a lateral translation relative to the longitudinal axis of the corresponding cross-flow manifold inlet and / or relative to the lateral axis of the cross-flow manifold outlet in the axial orientation of the corresponding cross-flow manifold body.

[0307] 86. A method for additive manufacturing of a three-dimensional object, the method comprising: irradiating the area of ​​the powder bed using a building unit located above the area of ​​the powder bed, the building unit comprising an energy beam system and an inerting system, the energy beam system comprising one or more irradiation devices respectively constructed to direct one or more energy beams onto the area of ​​the powder bed, and the inerting system comprising an irradiation chamber defining an irradiation chamber and a return manifold constructed to receive and / or discharge process gas from the irradiation chamber; and discharging the process gas from the irradiation chamber through the return manifold while irradiating the powder bed, wherein the return manifold comprises a plurality of return manifold bodies arranged along the width of the return manifold, the plurality of return manifold bodies being respectively connected to each other or defining corresponding integrally formed parts of the return manifold, the return manifold comprising a return manifold inlet at least partially defined by corresponding return manifold bodies among the plurality of return manifold bodies, the plurality of return manifold bodies comprising a plurality of return manifold bodies, and the plurality of return manifold bodies comprising a plurality of return manifold bodies. A corresponding return manifold body in each return manifold body includes one or more return manifold paths and a return manifold outlet, wherein the return manifold outlet is fluidly connected to the one or more return manifold paths and the process gas exhaust pipeline of the corresponding return manifold body, the return manifold inlet has a slender cross-sectional profile, and the return manifold inlet is fluidly connected to the irradiation air chamber defined by the irradiation chamber and the one or more return manifold paths defined by the corresponding return manifold body in the multiple return manifold bodies; wherein discharging the process gas from the irradiation air chamber includes accelerating the process gas to flow into the return manifold inlet and / or through the one or more return manifold paths by reducing the pressure in the return manifold inlet and / or in the one or more return manifold paths, and the pressure reduction is provided by one or more narrowed areas and / or one or more rib elements arranged around the return manifold inlet and / or in the one or more return manifold paths.

[0308] 87. A method according to any item herein, comprising: causing the process gas to flow through the one or more supply manifolds and into the irradiation chamber while irradiating the powder bed, wherein the one or more supply manifolds include a downflow manifold constructed to provide a downward flow of the process gas through at least a portion of the irradiation chamber defined by the irradiation chamber, and a cross-flow manifold constructed to provide a lateral flow of the process gas through at least a portion of the irradiation chamber defined by the irradiation chamber.

[0309] 88. A method according to any item herein, comprising: positioning the build unit above the area of ​​the powder bed at least in part by moving the build unit using a build unit positioning system and / or by moving a build container, the build container being constructed to support the powder bed below the build unit, the build container being moved at least in part by a build container positioning system; and wherein exhausting the process gas from the irradiation chamber through the return manifold while irradiating the powder bed includes exhausting the lateral flow of the process gas through the return manifold and the downward flow of the process gas.

[0310] 89. A method according to any of the clauses herein, wherein the method is performed using an additive manufacturing system as described in any of the clauses herein, and / or wherein the method is performed using a building block as described in any of the clauses herein.

[0311] 90. A computer-readable medium comprising computer-executable instructions, which, when executed by a processor associated with an additive manufacturing machine, cause the additive manufacturing machine to perform a method for additively manufacturing a three-dimensional object, the method comprising: irradiating a powder bed using a building unit located above the powder bed, the building unit comprising an energy beam system and an inerting system, wherein the inerting system comprises: an irradiation chamber defining an irradiation chamber, one or more supply manifolds configured to supply process gas to the irradiation chamber, and a manifold configured to receive and / or discharge process gas from the irradiation chamber. a return manifold for discharging process gas from the irradiation chamber; flowing process gas through the one or more supply manifolds and into the irradiation chamber while irradiating the powder bed, wherein the one or more supply manifolds include a downflow manifold configured to provide a downward flow of the process gas through at least a portion of the irradiation chamber defined by the irradiation chamber, and a crossflow manifold configured to provide a lateral flow of the process gas through at least a portion of the irradiation chamber defined by the irradiation chamber; and exhausting process gas from the irradiation chamber through the return manifold while irradiating the powder bed. The computer readable medium can be configured to cause the additive manufacturing machine to perform the method described in any clause herein.

[0312] This written description uses exemplary embodiments to describe the subject matter of the present invention, including the best mode, and also to enable any person skilled in the art to practice such subject matter, including making and using any device or system and performing any combined method. The patentable scope of the subject matter of the present invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to fall within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims.

Claims

1. A building unit for additive manufacturing of a three-dimensional object, characterized in that The building block comprises: an energy beam system comprising one or more irradiation devices each configured to direct one or more energy beams toward the build plane and onto a region of the powder bed; and an inerting system, the inerting system comprising an irradiation chamber and a return manifold, the irradiation chamber defining an irradiation chamber, the return manifold being configured to receive and / or exhaust process gas from the irradiation chamber while irradiating the region of the powder bed with the build unit located above the region of the powder bed, the process gas flowing through the irradiation chamber and into the return manifold while irradiating the region of the powder bed; wherein the return manifold comprises a plurality of return manifold bodies arranged along the width of the return manifold, each of the plurality of return manifold bodies defining a corresponding one of a plurality of return manifold outlets of the return manifold, the plurality of return manifold bodies being respectively coupled to one another or defining corresponding integrally formed portions of the return manifold, the return manifold comprising a return manifold inlet, the return manifold inlet being disposed at a bottom portion of the irradiation chamber and being at least partially defined by each of the plurality of return manifold bodies, a respective return manifold body of the plurality of return manifold bodies comprising one or more return manifold paths downstream of the return manifold inlet, the one or more return manifold paths fluidly connecting the return manifold inlet to a respective return manifold outlet of the plurality of return manifold outlets and a process gas exhaust line, and the return manifold inlet being in fluid communication with the irradiation gas chamber defined by the irradiation chamber and the one or more return manifold paths defined by the respective return manifold bodies of the plurality of return manifold bodies; Wherein the plurality of return manifold bodies include one or more recapture paths positioned to receive the process gas flowing through the return manifold inlet into the one or more return manifold paths.

2. The building unit according to claim 1, characterized in that Wherein the one or more recapture paths are disposed around a bottom portion of the one or more return manifold paths.

3. The building unit according to claim 1, characterized in that Wherein the one or more recapture paths include an elongated slit disposed laterally across a bottom portion of the one or more return manifold paths.

4. The building unit according to claim 1, characterized in that Wherein the one or more recapture paths are in fluid communication with the one or more return manifold paths downstream of an inlet edge of the return manifold inlet.

5. The building unit according to claim 1, characterized in that Wherein the one or more recapture pathways comprise slits, a perforated array or a grid.

6. A method for additive manufacturing of a three-dimensional object, characterized in that: The method comprises: irradiating the region of the powder bed with a build unit located above the region of the powder bed, the build unit comprising an energy beam system and an inerting system, the energy beam system comprising one or more irradiation devices, the one or more irradiation devices being respectively configured to direct one or more energy beams onto the region of the powder bed, and the inerting system comprising an irradiation chamber and a return manifold, the irradiation chamber defining an irradiation gas chamber, the return manifold being configured to receive and / or exhaust process gas from the irradiation gas chamber; and exhausting the process gas from the irradiation chamber through the return manifold while irradiating the powder bed, wherein the return manifold includes a plurality of return manifold bodies arranged along a width of the return manifold, each of the plurality of return manifold bodies defining a respective one of a plurality of return manifold outlets of the return manifold, the plurality of return manifold bodies being respectively coupled to one another or defining respective integrally formed portions of the return manifold, the return manifold including a return manifold inlet disposed at a bottom portion of the irradiation chamber and at least partially defined by each of the plurality of return manifold bodies, a respective one of the plurality of return manifold bodies including one or more return manifold paths downstream of the return manifold inlet, the one or more return manifold paths fluidly connecting the return manifold inlet to a respective one of the plurality of return manifold outlets and a process gas exhaust line, and the return manifold inlet being in fluid communication with the irradiation chamber defined by the irradiation chamber and the one or more return manifold paths defined by the respective one of the plurality of return manifold bodies; Wherein exhausting the process gas from the irradiation plenum further comprises exhausting the process gas flowing through the return manifold inlet into the one or more return manifold paths via one or more recapture paths disposed on the plurality of return manifold bodies.

7. A building unit for additive manufacturing of a three-dimensional object, characterized in that The building block comprises: an energy beam system comprising one or more irradiation devices, each of which is configured to direct one or more energy beams onto a region of the powder bed; and an inerting system, the inerting system comprising an irradiation chamber and a return manifold, the irradiation chamber defining an irradiation chamber, the return manifold being configured to receive and / or exhaust process gas from the irradiation chamber while irradiating the region of the powder bed with the build unit located above the region of the powder bed, the process gas flowing through the irradiation chamber and into the return manifold while irradiating the region of the powder bed; wherein the return manifold comprises a plurality of return manifold bodies arranged along a width of the return manifold, the plurality of return manifold bodies being respectively coupled to each other or defining respective integrally formed portions of the return manifold, the return manifold comprising one or more return manifold inlets, the one or more return manifold inlets being at least partially defined by respective return manifold bodies of the plurality of return manifold bodies, the respective return manifold bodies of the plurality of return manifold bodies comprising one or more return manifold paths and a plurality of return manifold outlets, the plurality of return manifold outlets being in fluid communication with the one or more return manifold paths of the return manifold bodies and a process gas exhaust line, and the one or more return manifold inlets being in fluid communication with the irradiation gas chamber defined by the irradiation chamber and the one or more return manifold paths defined by the respective return manifold bodies of the plurality of return manifold bodies; wherein the return manifold inlet is configured to receive a lateral flow of the process gas from at least a portion of an irradiation plenum defined by the irradiation chamber, and wherein the plurality of return manifold outlets outnumber the one or more return manifold inlets.

8. The building unit according to claim 7, characterized in that Wherein a corresponding return manifold body among the multiple return manifold bodies includes an upward translation region located downstream of the one or more return manifold inlets, and the upward translation region presents an upward translation in the axial orientation of the corresponding return manifold body relative to the longitudinal axis of the corresponding one or more return manifold inlets and / or relative to the lateral axis of the corresponding multiple return manifold outlets.

9. The building unit according to claim 8, characterized in that A corresponding return manifold body among the multiple return manifold bodies includes a lateral contraction region, which is located downstream of the corresponding upward translation region and upstream of the corresponding multiple return manifold outlets, and the lateral contraction region presents a lateral contraction in the corresponding return manifold body relative to the lateral axis of the corresponding one or more return manifold inlets and / or relative to the longitudinal axis of the corresponding multiple return manifold outlets.

10. The building unit according to claim 9, characterized in that Wherein a corresponding return manifold body among the multiple return manifold bodies includes a lateral contour area, which coincides with the position of at least a portion of the lateral contraction area and / or at least a portion of the upward translation area, and the lateral contour area presents a lateral change in the cross-sectional profile of the corresponding return manifold body relative to the cross-sectional profile of the corresponding one or more return manifold inlets.

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