Controlling irradiation parameters for additive manufacturing machines

Abstract

A method of additive manufacturing of a three-dimensional object, the method comprising determining a plurality of scan segments of a build plane and / or one or more object layers respectively corresponding to one or more regions of a powder bed defining the build plane, and determining an irradiation vector for irradiating the scan segments with an energy beam. The irradiation vector determined for each scan segment may include a shadow line vector and / or a plurality of scan vectors defining the shadow line vector. The shadow line vectors and / or scan vectors defining the shadow line vectors may be oriented away from normal points on the build plane. The method may include outputting an irradiation control command to the energy beam system based on the scan segment and / or an irradiation vector for irradiating the scan segment.

Description

[0001] This application is a divisional application of the invention patent application with application number 202111096396.0 filed on September 16, 2021, and invention name “Controlling irradiation parameters of additive manufacturing machines”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims priority to U.S. Provisional Application Serial No. 63 / 079,545, filed on September 17, 2020, the contents of which are incorporated herein by reference in their entirety as if set forth verbatim. Technical Field

[0004] The present disclosure generally relates to additive manufacturing of three-dimensional objects and systems and methods related to operating additive manufacturing machines. Background Art

[0005] An additive manufacturing machine for performing powder bed fusion typically has an energy beam system configured to selectively scan an energy beam across a build plane to irradiate successive layers of the powder bed. The energy beam melts and / or sinters the selectively irradiated portions of the powder bed and / or the bottom layers of the additively manufactured object, thereby forming a three-dimensional object as successive layers selectively fuse and / or sinter to each other.

[0006] The melting and / or sintering behavior of the powder bed may depend on one or more irradiation parameters, including beam parameters related to the energy beam and / or scanning parameters related to the way the energy beam is scanned across the powder bed. For example, the melting and / or sintering behavior of the powder bed may depend on the intensity distribution of the energy beam and / or the power density distribution of the beam spot from the energy beam incident on the build plane. This intensity distribution of the energy beam and / or this power density distribution of the beam spot may depend on the angle of incidence of the energy beam and / or the position of the beam spot relative to the normal point on the build plane. In addition, the melting and / or sintering behavior of the powder bed may depend on the irradiation vector of the energy beam, including, for example, the orientation of the irradiation vector relative to the normal point on the build plane and / or relative to the previous irradiation beam path. Differences in melting and / or sintering behavior may affect the quality of the object being additively manufactured, including the physical properties of the object.

[0007] Therefore, there is a need for improved additive manufacturing systems and methods of controlling irradiation parameters of additive manufacturing machines. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] 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:

[0009] Figure 1 An exemplary additive manufacturing system is schematically depicted;

[0010] Figure 2A and 2B An energy beam incident on a construction plane and a corresponding beam spot on the construction plane are schematically depicted, respectively, indicating an energy beam perpendicular to the construction plane;

[0011] Figure 3A and 3B Another energy beam incident on the construction plane and a corresponding beam spot on the construction plane are schematically depicted, respectively, indicating an energy beam tilted to the construction plane;

[0012] Figures 4A-4F schematically depicts an exemplary scan vector of an energy beam across a build plane;

[0013] Figures 5A-5F schematically depicts exemplary hatch vectors corresponding to a plurality of hatches applied to a construction plane according to a corresponding plurality of scan vectors;

[0014] Figure 5G schematically depicts exemplary contour vectors corresponding to one or more contours applied to a construction plane according to corresponding one or more scan vectors;

[0015] Figure 6 schematically depicts an exemplary construction plane divided into a plurality of scan segments;

[0016] Figure 7 schematically depicts another exemplary construction plane divided into a plurality of scan segments;

[0017] Figures 8A-8C schematically depicts exemplary irradiation vectors assigned to various scan segments;

[0018] Fig.9A and 9B schematically depicts an exemplary scan segment corresponding to an object layer;

[0019] Figures 10A-10H schematically depicts exemplary irradiance vectors corresponding to various objects in an object layer;

[0020] Fig.11 schematically depicts irradiation vectors corresponding to beam spots having increasing size and / or ellipticity with increasing distance from a normal point on a build plane;

[0021] Fig.12 An exemplary control system is schematically depicted, comprising an irradiation controller configured to control one or more irradiation parameters;

[0022] Fig.13A and 13B schematically depicts an exemplary control module including an irradiation control model;

[0023] Fig.14 schematically depicts an exemplary training computing device for training a machine learning model; and

[0024] Fig.15 A flow chart depicting an exemplary method of additively manufacturing a three-dimensional object is shown.

[0025] 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

[0026] Reference will now be made in detail to exemplary embodiments of the subject matter of the present disclosure, one or more examples of which are shown in the accompanying drawings. Each example is provided by way of explanation and should not be construed as limiting the present disclosure. In fact, it will be 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 as part of one embodiment may be used together with another embodiment to produce yet another embodiment. Therefore, the present disclosure is intended to cover such modifications and variations that fall within the scope of the appended claims and their equivalents.

[0027] It should be understood that the terms "upstream" and "downstream" refer to the relative direction of the fluid flow in the 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" and the like are convenient words and should not be interpreted as restrictive terms. As used herein, the terms "first", "second" and "third" are used interchangeably to distinguish one component from another component and are not intended to represent the position or importance of each component. The terms "one" and "a" do not represent a limitation of quantity, but rather represent the presence of at least one referenced item.

[0028] Approximate language, as used throughout the specification and claims, 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 one or more terms, such as "about," "substantially," and "approximately," are not limited to the precise values ​​specified. In at least some cases, approximate 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, approximate language may mean within 10%.

[0029] 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 disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other.

[0030] As described herein, exemplary embodiments of the present subject matter involve the use of an additive manufacturing machine or method. As used herein, the term "additive manufacturing" generally refers to a manufacturing technique that manufactures a component in a layer-by-layer manner. An exemplary additive manufacturing machine can be configured to utilize any desired additive manufacturing technology. In an exemplary embodiment, the additive manufacturing machine can utilize additive manufacturing technology, including 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 sequentially 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 typically monolithic in nature and may have multiple integral sub-components.

[0031] Additionally or alternatively, suitable additive manufacturing techniques include, for example, 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 techniques utilizing energy beams.

[0032] Additive manufacturing techniques can generally be described as being able to manufacture complex objects by building objects point by point, layer by layer, usually in a vertical direction; however, other manufacturing methods are also contemplated and within the scope of the present disclosure. For example, although the discussion herein relates to adding materials to form successive layers, the subject matter of the present disclosure can be practiced with any additive manufacturing technique or other manufacturing technique, including additive layer processing, subtractive layer processing, or hybrid processing.

[0033] The additive manufacturing processes described herein may be used to form parts using any suitable material. For example, the material may be a metal, a ceramic, a polymer, an epoxy resin, a photopolymer resin, a plastic, concrete, or any other suitable material that may be in a solid, liquid, powder, sheet, wire, or any other suitable form. Each successive layer may be, for example, between about 10 μm and 200 μm, but according to alternative embodiments, the thickness may be selected based on any number of parameters and may be of any suitable size.

[0034] The present disclosure generally provides systems and methods for controlling additive manufacturing machines (including controlling energy beam systems for additive manufacturing of three-dimensional objects). Exemplary systems and methods for controlling additive manufacturing machines and / or energy beam systems may include providing irradiation vectors (e.g., scan vectors, hatch vectors, and / or contour vectors) for irradiating one or more regions of a build plane. Exemplary systems and methods may include controlling one or more irradiation parameters that may affect the melting and / or sintering behavior of a powder bed, including systems and methods for controlling beam parameters related to actual or potential effects on melting and / or sintering behavior. Such effects on melting and / or sintering behavior may be at least partially attributed to the intensity distribution, angle of incidence, and / or one or more irradiation vectors (e.g., scan vectors, hatch vectors, and / or contour vectors) of the energy beam. Advantageously, the currently disclosed systems and methods may provide improved controllability of melting and / or sintering behavior, which in turn may improve the quality, uniformity, and / or repeatability of objects manufactured by additive manufacturing, reduce object defects and / or abort builds, and / or improve the operability of the machine.

[0035] As described herein, the energy imparted to the build plane by the energy beam can depend on a number of beam parameters, including, for example, the intensity or power of the energy beam, the intensity distribution or power density distribution of the energy beam, the spot size of the energy beam, the spot shape of the energy beam, the angle of incidence θ of the energy beam, and the energy beam. i and the scanning speed of the energy beam. These and / or other beam parameters may affect the melting and / or sintering behavior of the powder bed. Additionally or alternatively, the melting and / or sintering behavior of the powder bed may depend on, for example, the irradiation vector of the energy beam related to the beam source and / or the features of the build plane.

[0036] The incident angle of the energy beam is θ i The power density distribution of the resulting beam spot from the energy beam incident on the construction plane may depend on the incident angle θ of the energy beam. i and / or the position on the build plane to which the energy beam is directed. For example, an exemplary energy beam may have a Gaussian intensity distribution in a transverse plane that may be described by a Gaussian function. In the case of a circular Gaussian beam oriented perpendicular to the build plane, the energy imparted to the build plane may be similarly described by a Gaussian function. The radially inward portion of the Gaussian beam spot may have a higher energy density than the radially outward portion of the Gaussian beam spot. The energy density may increase according to the Gaussian function in the radially inward direction. Similarly, the energy imparted to the build plane may be described by other nonlinear functions corresponding to the respective beam intensity distributions.

[0037] In some embodiments, the surface area of ​​the beam spot incident on the construction plane may depend on the incident angle θ of the energy beam. i For example, from a Gaussian intensity distribution and an oblique incident angle θ iThe energy imparted to the construction plane by the energy beam may have an elliptical Gaussian energy density distribution. Therefore, in some embodiments, the energy density imparted to the construction plane may depend on the beam intensity distribution in the transverse plane and / or the incident angle θ of the energy beam. i Additionally or alternatively, at an oblique incident angle θ relative to the construction plane i In the case of a Gaussian beam, the energy imparted to the build plane can be described by an elliptical Gaussian function, where the energy density is biased towards the normal points corresponding to the positions on the build plane where the beam will be oriented perpendicular to the build plane.

[0038] Therefore, the melting and / or sintering behavior of the powder bed may depend on the position of the build plane irradiated by the energy beam, including the corresponding incident angle θ of the energy beam. i and / or the power density distribution of the resulting beam spot from the energy beam. For example, the melting and / or sintering behavior of the powder bed may depend on the coordinates of the beam spot and the resulting power density distribution. Additionally or alternatively, the melting and / or sintering behavior of the powder bed may depend on the coordinates of the beam spot associated with other features of the build plane (e.g., associated with previously irradiated portions of the powder bed). The melting and / or sintering behavior of the powder bed may additionally or alternatively depend at least in part on the orientation of one or more irradiation vectors corresponding to one or more beam paths of the energy beam (e.g., associated with a normal point and / or associated with such other features of the build plane). For example, the melting and / or sintering behavior of the powder bed may depend at least in part on the orientation of one or more irradiation vectors (e.g., one or more scan vectors, one or more shadow vectors, and / or one or more contour vectors), including the direction and / or amplitude of one or more such irradiation vectors.

[0039] As used herein, the term "build plane" refers to a plane defined by a surface on 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 powder material across build modules typically defines the build plane.

[0040] As used herein, the term "normal point" refers to a location on a build plane corresponding to an energy beam where the energy beam would be oriented perpendicular to the build plane when incident on the build plane.

[0041] As used herein, the term "irradiation vector" or "irradiation vectors" may refer individually or collectively to one or more scan vectors, one or more hatch vectors, and / or one or more contour vectors, as the case may be.

[0042] As used herein, the term "scan vector" or "scan vectors" may refer, individually or collectively, to the propagation entity of a beam path imparted by an energy beam across a build plane, as the case may be. The orientation of a scan vector includes a magnitude component and a direction component. Typically, an additive manufacturing machine may form successive layers of an object by directing an energy beam across a build plane, thereby defining a plurality of beam paths according to a corresponding plurality of scan vectors corresponding to regions of the build plane where the respective layers of the object are located.

[0043] In some embodiments, the energy beam may propagate across the build plane according to a plurality of scan vectors corresponding to a series of beam paths that may be arranged in one or more groups of hatches occupying a congruent area of ​​the build plane. Additionally or alternatively, the energy beam may propagate across the build plane according to one or more scan vectors corresponding to one or more beam paths that may be arranged to respectively define a contour of at least a portion of a perimeter around at least a portion of a congruent area of ​​the build plane (e.g., a congruent area of ​​the build plane occupied by a plurality of hatches).

[0044] As used herein, the term "hatching" or "a plurality of hatches" may refer, singly or in plurality, to one or more beam paths from a plurality of adjacent and / or partially overlapping beam paths that solidify a congruent region (e.g., a powder bed) defining a build plane. For example, a layer of an object may be formed at least in part by selectively solidifying a plurality of hatches of corresponding congruent regions of a powder bed.

[0045] As used herein, the term "shadow vector" refers to a propagation entity of multiple shadows imparted by corresponding multiple beam paths across a build plane. The orientation of a shadow vector includes an amplitude component and a direction component. Each individual shadow can be applied according to a corresponding scan vector. For example, a series of shadows can be defined by multiple scan vectors oriented with relative direction components, and such a series of shadows can be propagated across a build plane according to the shadow vector. Such a shadow vector can have a direction component that is inclined to the corresponding multiple scan vectors (e.g., transversely or perpendicular to the corresponding multiple scan vectors).

[0046] As used herein, the term "contour" or "contours" may refer, individually or in plurality, to one or more beam paths that define at least a portion of a peripheral region surrounding at least a portion of a congruent region of a build plane (e.g., a perimeter of a congruent region defined by a plurality of hatches). Multiple beam paths that define a contour or contours, respectively, may be adjacent or overlapping. For example, a peripheral region of an object may be formed, at least in part, by one or more contours of a corresponding peripheral region of a selectively solidified powder bed.

[0047] As used herein, the term "contour vector" refers to a propagation entity of one or more contours imparted by corresponding one or more beam paths across a build plane. The orientation of a contour vector includes an amplitude component and a direction component. Each individual contour can be applied according to a corresponding scan vector. For example, one or more contours can be defined by one or more scan vectors and such one or more contours can be propagated across a build plane according to the contour vector. Such a contour vector can have a direction component that is parallel or oblique to the corresponding one or more scan vectors. For example, a contour vector of a contour defined by a single beam path can be substantially equivalent to a scan vector of such a single beam path.

[0048] For purposes of convention, components of an irradiation vector (e.g., a scan vector, a hatch vector, and / or a profile vector) may be described relative to X and Y coordinates. A directional component of an irradiation vector (e.g., a scan vector, a hatch vector, and / or a profile vector) may include an X-directional component, a Y-directional component, or both an X-directional component and a Y-directional component. An amplitude component of an irradiation vector (e.g., a scan vector, a hatch vector, and / or a profile vector) may include an X-amplitude component, a Y-amplitude component, or both an X-amplitude component and a Y-amplitude component. As used herein, the term "orientation" with respect to an irradiation vector (e.g., a scan vector, a hatch vector, and / or a profile vector) includes both the amplitude and the direction of the vector.

[0049] In some embodiments, improvements in the quality, uniformity, and / or repeatability of additively manufactured objects may be at least partially attributed to selectively irradiating successive layers of an object using one or more irradiation vectors (e.g., scan vectors, hatch vectors, and / or contour vectors) oriented away from a normal point to a build plane, as compared to corresponding irradiation vectors oriented toward a normal point. For example, in some embodiments, regions of an object irradiated using irradiation vectors (e.g., scan vectors, hatch vectors, and / or contour vectors) oriented away from a normal point may exhibit improvements in material properties (e.g., porosity, tensile strength, and / or elastic modulus) as compared to irradiation using such irradiation vectors oriented toward the normal point. Such improvements in the quality, uniformity, and / or repeatability of additively manufactured objects may include improved absolute values ​​and / or reduced variations. Exemplary embodiments may include at least one directional component of such irradiation vectors (e.g., scan vectors, hatch vectors, and / or contour vectors) that may be oriented away from a normal point to a build plane. Additionally or alternatively, exemplary embodiments may include increasing the directional component of such irradiation vectors (e.g., scan vectors, hatch vectors, and / or contour vectors) as the angle of incidence θ increases. i An irradiation vector (e.g., a scan vector, a hatch vector, and / or a contour vector) propagates with an increase in irradiation.

[0050] Such material properties of the additively manufactured object may additionally or alternatively be attributed to selecting one or more irradiation vectors (e.g., scan vectors, hatch vectors, and / or contour vectors) based at least in part on the location of the build plane in which the object or a portion of the object is located. The orientation of such irradiation vectors (e.g., scan vectors, hatch vectors, and / or contour vectors) may be selected based at least in part on the location of the build plane in which the object or a portion of the object is located, the orientation including a corresponding direction component and / or magnitude component corresponding to the object or a region of the object. The irradiation vectors (e.g., scan vectors, hatch vectors, and / or contour vectors) may be determined for a corresponding layer or one or more corresponding layers of the object based at least in part on the location of the irradiated build plane relative to the normal point. For example, one or more irradiation vectors (e.g., one or more scan vectors, one or more hatch vectors, and / or one or more contour vectors) may be determined such that the corresponding location of the build plane is irradiated using one or more such irradiation vectors that are respectively oriented away from the normal point. In some embodiments, multiple segments of a construction plane can be defined and each scan segment can be irradiated according to one or more irradiation vectors (e.g., multiple scan vectors, one or more hatch vectors, and / or one or more contour vectors) that are respectively oriented away from the normal point. The directional component of the irradiation vector (including multiple scan vectors, one or more hatch vectors, and / or one or more contour vectors) of the corresponding region of the construction plane corresponding to the corresponding region can depend at least in part on the position of the corresponding region on the construction plane. In addition to or in lieu of the directional vector component, a corresponding amplitude component can be determined for one or more irradiation vectors (e.g., scan vectors, hatch vectors, and / or contour vectors) based at least in part on the position of the construction plane relative to the normal point.

[0051] In some embodiments, each scan segment of the construction plane can be irradiated with a hatch vector oriented away from the normal point. The hatch vector may include at least one directional component oriented away from the normal point. The orientation of the hatch vector may be defined by a plurality of scan vectors. In some embodiments, the plurality of scan vectors defining the hatch vector may include at least one directional component oriented away from the normal point. Additionally or alternatively, one or more scan vectors defining the hatch vector may include at least one directional component oriented obliquely to the hatch vector (e.g., transversely or perpendicular to the hatch vector).

[0052] Additionally or alternatively, individual scan segments of the construction plane may be irradiated with a profile vector oriented away from the normal point. The profile vector may include at least one directional component oriented away from the normal point. The orientation of the profile vector may be defined by one or more scan vectors. In some embodiments, one or more scan vectors defining the profile vector may include a directional component oriented away from the normal point. Additionally or alternatively, one or more scan vectors defining the profile vector may include at least one directional component oriented obliquely to the profile vector (e.g., transversely or perpendicular to the profile vector).

[0053] Additionally or alternatively, one or more irradiation vectors (e.g., scan vectors, hatch vectors, and / or contour vectors) may be determined for a corresponding layer or one or more corresponding layers of the object based at least in part on the position of the irradiated construction plane relative to one or more previously irradiated portions of the construction plane. For example, one or more irradiation vectors (e.g., scan vectors, hatch vectors, and / or contour vectors) may be determined such that respective positions of the construction plane are irradiated by one or more irradiation vectors (e.g., scan vectors, hatch vectors, and / or contour vectors) that are respectively oriented away from a previously irradiated portion of the construction plane (e.g., a previously irradiated adjacent beam path and / or an adjacent overlapping beam path). In some embodiments, a plurality of segments of the construction plane may be defined and each scan segment may include a plurality of scan vectors, one or more hatch vectors, and / or one or more contour vectors that are respectively oriented away from a previously irradiated portion of the construction plane (e.g., a previously irradiated adjacent beam path and / or an adjacent overlapping beam path).

[0054] In some embodiments, individual scan segments of a construction plane may be irradiated with a hatch vector including a directional component oriented away from a normal point, wherein the direction of the hatch vector is defined by a plurality of scan vectors including a directional component oriented away from a previously irradiated portion of the construction plane (e.g., a previously irradiated adjacent beam path and / or an adjacent overlapping beam path). Additionally or alternatively, individual scan segments of a construction plane may be irradiated with a profile vector including a directional component oriented away from a normal point, wherein the direction of the profile vector is defined by one or more scan vectors including a directional component oriented away from a previously irradiated portion of the construction plane (e.g., a previously irradiated adjacent beam path and / or an adjacent overlapping beam path).

[0055] Additionally or alternatively, one or more irradiation vectors (e.g., one or more scan vectors, hatch vectors, and / or contour vectors) can be determined based at least in part on a position of the construction plane irradiated relative to one or more previously irradiated portions of the construction plane. For example, the irradiation vectors (e.g., scan vectors, hatch vectors, and / or contour vectors) can be determined such that respective positions of the construction plane are irradiated with a direction component and / or a magnitude component of such irradiation vectors (e.g., scan vectors, hatch vectors, and / or contour vectors) determined at least in part based on such position of the construction plane relative to one or more previously irradiated portions of the construction plane.

[0056] Exemplary embodiments of the present disclosure will now be described in more detail. Figure 1 An exemplary 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 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.

[0057] 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 associated with the additive manufacturing system 100. Such enterprise-level operations may include transmitting data from the management system 106 to the control system 104 and / or transmitting 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.

[0058] As shown, the additive manufacturing machine 102 may include a build module 110 including a build chamber 112 within which one or more objects 114 may be additively manufactured. In some embodiments, the additive manufacturing machine 102 may include a powder module 116 and / or an overflow module 118. The build module 110, the powder module 116, and / or the overflow module 118 may be provided in the form of a modular container that is configured to be installed to and removed from the additive manufacturing machine 102, for example, in an assembly line process. In addition, or alternatively, the build module 110, the powder module 116, and / or the overflow module 118 may define a fixed component of the additive manufacturing machine 102.

[0059] Powder module 116 includes a powder material supply 120 housed within a supply chamber 122. Powder module 116 includes a powder piston 124 that raises a powder base plate 126 during operation of additive manufacturing machine 102. As powder base plate 126 is raised, a portion of powder material 120 is pressed out of powder module 116. A recoater 128, such as a blade or roller, sequentially distributes thin layers of powder material 120 on a build plane 130 above build module 110. Build platform 132 supports the successive layers of powder material 120 distributed on build plane 130.

[0060] The additive manufacturing machine 102 includes an energy beam system 134 that is configured to generate a plurality of energy beams, such as laser beams or electron beams, and direct respective energy beams onto the build plane 130 to selectively consolidate respective portions of a powder bed 136 defining the build plane 130. As the respective energy beams selectively melt or fuse successive layers of the powder material 120 defining the powder bed 136, the object 114 begins to take shape. Typically for a DMLM, EBM, or SLM system, the powder material 120 is completely melted, and the respective layers are melted or re-melted as the energy beams pass through them. In contrast, for a DMLS or SLS system, typically the layers of the powder material 120 are sintered, causing the particles of the powder material 120 to fuse to each other, typically without reaching the melting point of the powder material 120. The energy beam system 134 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.

[0061] Energy beam system 134 may include one or more irradiation devices configured to generate a plurality of energy beams and direct the energy beams onto construction plane 130. The irradiation devices may each have an energy beam source, a galvanometer scanner, and an optical component configured to direct the energy beams onto construction plane 130. Figure 1In the illustrated embodiment, the energy beam system 134 includes a first irradiation device 138 and a second irradiation device 140. In other embodiments, the energy beam system 134 may include three, four, six, eight, ten or more irradiation devices. The plurality of irradiation devices may be configured to generate one or more energy beams, respectively, which may scan within a scanning field incident on at least a portion of the construction plane 130. For example, the first irradiation device 138 may generate a first energy beam 142, which may scan within a first scanning field 144 incident on at least a first construction plane area 146. The second irradiation device 140 may generate a second energy beam 148, which may scan within a second scanning field 150 incident on at least a second construction plane area 152. The first scanning field 144 and the second scanning field 150 may overlap, so that the first construction plane area 146 scanned by the first energy beam 142 overlaps with the second construction plane area 152 scanned by the second energy beam 148. The overlapping portion of first build plane region 146 and second build plane region 152 may sometimes be referred to as staggered region 154. Portions of powder bed 136 to be irradiated within staggered region 154 may be irradiated by first energy beam 142 and / or second energy beam 148 in accordance with the present disclosure.

[0062] To irradiate a layer of powder bed 136, one or more irradiators (e.g., first irradiator 138 and second irradiator 140) respectively direct a plurality of energy beams (e.g., first energy beam 142 and second energy beam 148) through respective portions of build plane 130 (e.g., first build plane region 146 and second build plane region 152) to melt or fuse portions 114 of powder material 120 that will become part of object 114. A first layer or series of layers of powder bed 136 are typically melted or fused to build platform 132, and successive layers of powder bed 136 are then melted or fused to each other to additively manufacture object 114.

[0063] As successive layers of powder bed 136 melt or fuse to one another, build piston 156 gradually lowers build platform 132 to make room for recoater 128 to distribute successive layers of powder material 120. As build piston 156 gradually lowers and successive layers of powder material 120 are applied to build plane 130, the next successive layer of powder material 120 defines a surface of powder bed 136 that coincides with build plane 130. Successive layers of powder bed 136 may be selectively melted or fused until a completed object 114 has been additively manufactured.

[0064] In some embodiments, the additive manufacturing machine may utilize an overflow module 118 to capture excess powder material 120 in an overflow chamber 158. The overflow module 118 may include an overflow piston 160 that gradually lowers to make room for additional excess powder material 120 within the overflow chamber 158.

[0065] It should be understood that in some embodiments, the additive manufacturing machine may not use the powder module 116 and / or the overflow module 118, and other systems for handling the powder material 120, including different powder supply systems and / or excess powder recovery systems, may be provided. However, the subject matter of the present disclosure may be practiced with any suitable additive manufacturing machine without departing from its scope.

[0066] Still reference Figure 1 In some embodiments, additive manufacturing machine 102 may include monitoring system 162. Monitoring system 162 may be configured to detect a monitoring beam (not shown), such as an infrared beam and / or a reflected portion of an energy beam from a laser diode, and determine one or more parameters associated with irradiating successive layers of powder bed 136 based at least in part on the detected monitoring beam. For example, one or more parameters associated with irradiating successive layers of powder bed 136 may include irradiation parameters and / or object parameters, such as melt pool monitoring parameters. One or more parameters determined by monitoring system 162 may be utilized, 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 162 may be configured to project a monitoring beam (not shown) and detect a portion of the monitoring beam reflected from build plane 130. In addition, and / or alternatively, monitoring system 162 can be configured to detect a monitoring beam including radiation emitted from the build plane, such as radiation from the energy beam reflected from powder bed 136 and / or radiation emitted from a molten pool in powder bed 136 produced by the energy beam and / or radiation emitted from a portion of powder bed 136 adjacent to the molten pool.

[0067] The monitoring system 162 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. For example, the monitoring system 162 may include components that are integrated as part of the energy beam system 134. Additionally, or alternatively, the monitoring system 162 may include separate components, such as in the form of an assembly, that may be installed as part of the energy beam system 134 and / or as part of the additive manufacturing machine 102.

[0068] Reference now Figure 2A and 2B 3A and 3B, exemplary energy beam intensity distributions and corresponding energy density distributions imparted to build plane 130 will be described. Figure 2A and 3A Energy beam 200 is shown incident on build plane 130 . Figure 2A The energy beam is shown as being perpendicular to build plane 130 . Figure 3AThe energy beam shown in FIG. 200 is tilted toward the build plane. Energy beam 200 may be an energy beam from additive manufacturing machine 102, such as from Figure 1 The energy beam system 134 of the additive manufacturing machine 102 is shown emitting a first energy beam 142 or a second energy beam 148 . Figure 2B and 3B The energy density distribution of beam spot 300 from energy beam 200 imparted to build plane 130 is shown. Figure 2B The beam spot 300 in corresponds to Figure 2A The energy beam in 200, and Figure 3B The beam spot 300 in corresponds to Figure 3A Energy beam 200 in.

[0069] The energy beam 200 has an intensity distribution 202 in a transverse plane 204 that can be described by a nonlinear function. As used herein, the term "transverse plane" refers to a plane perpendicular to the propagation direction of the energy beam 200. For example, the energy beam 200 can have a Gaussian intensity distribution in the transverse plane 204 that can be described by a Gaussian function. Other intensity distributions are also contemplated, including super-Gaussian intensity distributions, astigmatic intensity distributions, "top hat" intensity distributions, Laguerre-Gaussian intensity distributions, bimodal or multimodal intensity distributions, etc., which can be described by corresponding functions, respectively.

[0070] Energy beam 200 is incident at an angle θ relative to a normal N perpendicular to construction plane 130. i It is incident on the construction plane 130. Figure 2A As shown, energy beam 200 is perpendicular to build plane 130 and therefore has an incident angle θ of zero (0). i .like Figure 3A As shown, the energy beam 200 is inclined with respect to the normal line N, and thus has an inclined incident angle θ i When energy beam system 134 scans energy beam 200 across construction plane 130, incident angle θ i For example, when energy beam 200 is incident on construction plane 130 at a point that is aligned (e.g., in the X, Y plane) with an optical center of an optical component of an irradiation device (e.g., first irradiation device 138 or second irradiation device 140) that generates energy beam 200, energy beam 200 may be perpendicular to construction plane 130. Such a point on construction plane 130 corresponding to energy beam 200 that is perpendicular to construction plane 130 is sometimes referred to as a normal point 206. As energy beam 200 scans across points on construction plane 130 that are gradually offset (e.g., in the X, Y plane) from the optical center of an optical component of an irradiation device that generates energy beam 200, energy beam 200 may have an increasing angle of incidence θ i .

[0071] like Figure 3AAs shown, when the energy beam is perpendicular to the construction plane 130, corresponding to the energy beam 200 having a circular cross-section in the transverse plane 204, the energy beam 200 imparts a circular beam spot 300 on the construction plane 130. However, it should be understood that other beam cross-sections are also contemplated, including elliptical cross-sections and polygonal cross-sections. Figure 3B As shown, when energy beam 200 is tilted to construction plane 130, energy beam 200 imparts an elliptical beam spot 300 in construction plane 130. The energy density of beam spot 300 has an energy density distribution 302 across construction plane 130, which can be described by a nonlinear function. Figure 2B The beam spot 300 shown in FIG. 3 has a Gaussian energy density distribution 302 which can be described by a Gaussian function. Figure 2B The energy density of the beam spot 300 shown in FIG. 3 has a substantially annular distribution according to a Gaussian function, with the gradually inner annular region of the beam spot 300 having an increased energy density and the gradually outer annular region of the beam spot 300 having a reduced energy density.

[0072] When the energy beam 200 has an oblique incident angle θ i When Figure 3A As shown, the energy beam imparts an elliptical beam spot 300, such as Figure 3B shown. Figure 3B The elliptical beam spot 300 shown in FIG. 3 has an elliptical Gaussian energy density distribution 302 , which can be described by an elliptical Gaussian function that is skewed toward the normal point 206 . Figure 3B The beam spot 300 shown in FIG. 3 has a substantially elliptical annular distribution biased toward the beam source, with an increasing energy density at an annular region of the beam spot 300 that gradually tilts inward, and a decreasing energy density at an annular region of the beam spot 300 that gradually tilts outward. It should be understood that other energy density distributions 302 are also contemplated, including super-Gaussian energy density distributions, astigmatic energy density distributions, "top hat" energy density distributions, Laguerre-Gaussian energy density distributions, bimodal or multi-modal energy density distributions, etc., which can be described by corresponding functions, respectively.

[0073] By comparison, reference Figure 2B and 3B , will realize that from Figure 2A and 3B The beam spot 300 of the circular energy beam 200 shown in FIG. 3 may become increasingly larger and / or increasingly elliptical, with increasingly larger incident angles θ. i Additionally or alternatively, from Figure 2A and 3B The energy density imparted to the construction plane 130 by the circular energy beam 200 shown in FIG. 1 can vary with the incident angle θ. iAs the angle θ of the energy beam 200 increases, the melting and / or sintering behavior of the powder bed 136 may depend on the incident angle θ of the energy beam 200. i For example, corresponding to the incident angle θ of the energy beam 200 i , the melting and / or sintering behavior of the powder bed 136 may depend on the shape of the beam spot 300, such as the ellipticity of the beam spot 300. Additionally or alternatively, the melting and / or sintering behavior of the powder bed 136 may depend on the energy density of the beam spot 300 and / or the energy density distribution 302 of the beam spot 300, such as the ellipticity and / or the skewness of the energy density distribution 302.

[0074] Reference now Figures 4A-4F , an exemplary scan vector 400 of energy beam 200 will be described. In some embodiments, the melting and / or sintering behavior of build plane 130 and / or powder bed 136 may depend on the orientation of scan vector 400 of energy beam 200 across build plane 130 and / or powder bed 136. Figures 4A-4F An energy beam 200 and resulting beam path 402 propagating according to a corresponding scan vector 400 oriented relative to a normal point 206 is shown. Figure 4A Energy beam 200 is shown having a scan vector 400 oriented toward normal point 206 . Figure 4B A construction plane 130 is shown, where the Figure 4A The beam spot 300 of the energy beam 200 is based on Figure 4A The scan vector 400 shown in FIG. propagates across the powder bed 136. Figure 4A and 4B The scanning vector 400 is shown, and the incident angle θ of the energy beam 200 is i As the energy beam 200 propagates along the scan vector 400 and toward the normal point 206 . Figure 4C An energy beam having a scan vector 400 directed away from the normal point 206 is shown. Figure 4D A construction plane 130 is shown, where the Figure 4C The beam spot 300 of the energy beam 200 is based on Figure 4C The scan vector 400 is shown propagating across the powder bed 136. Figure 4C and 4D The scanning vector 400 is shown, and the incident angle θ of the energy beam 200 is i Increases as the energy beam 200 propagates along the scan vector 400 and away from the normal point 206. Figure 4E An energy beam is shown having a scan vector 400 oriented substantially equidistant from the normal point 206. For example, Figure 4E The scan vector 400 shown in FIG. 200 may be oriented at a tangent or substantially tangent relative to the normal point 206. Additionally or alternatively, Figure 4EThe scan vector 400 shown in FIG. 4 may follow a circular or semi-circular path around a normal point. Figure 4F A construction plane 130 is shown, where the Figure 4E The beam spot 300 of the energy beam 200 is based on Figure 4E The scan vector 400 is shown propagating across the powder bed 136. Figure 4E and 4F The scanning vector 400 shown in FIG. 4 and the incident angle θ of the energy beam 200 are i Remains substantially constant as the energy beam 200 propagates along a scan vector 400 that is substantially equidistant from the normal point 206 .

[0075] like Figures 4A-4F As shown, when the energy beam 200 propagates along the scan vector 400, the energy density distribution 302 of the beam spot 300 may be biased toward the normal point 206. When the energy beam 200 follows the scan vector 400, energy may be imparted to the powder bed 136 according to a power density distribution 404 oriented perpendicular to the scan vector 400, which may be described by a nonlinear function. For example, the power density distribution 404 may have a Gaussian power density distribution that may be described by a Gaussian function. Other power density distributions 404 are also contemplated, including super-Gaussian power density distributions, astigmatic power density distributions, "top hat" power density distributions, Laguerre-Gaussian power density distributions, bimodal or multi-modal power density distributions, etc., which may be described by corresponding functions, respectively.

[0076] The power density distribution 404 may depend at least in part on the intensity distribution 202 ( Figure 2A and 3A ), the energy density distribution 302 of the beam spot 300, the incident angle θ of the energy beam 200 i , the scanning speed of the energy beam 200 and / or the orientation of the scanning vector 400 relative to the normal point 206. For example, Figures 4A-4F As depicted in , energy may be imparted to powder bed 136 using a power density distribution 404 according to an elliptical Gaussian function that is skewed toward normal point 206 .

[0077] When the energy beam 200 propagates along the scan vector 400 directed toward the normal point 206, as shown in FIG. Figure 4A and 4B As shown, power density distribution 404 may be oriented toward normal point 206. For example, due to the orientation of scan vector 400 and / or the orientation of power density distribution 404 toward normal point 206, following Figure 4A and 4BEnergy beam 200 of scan vector 400 shown in FIG. 4 may impart more energy to a central portion of beam path 402. Additionally or alternatively, energy density distribution 302 of beam spot 300 may be biased toward the direction of scan vector 400. As a result, a leading portion of beam spot 300 may expose build plane 130 and / or powder bed 136 to a relatively higher intensity and / or power density than a trailing portion of beam spot 300. Figure 4B As shown, for example, when the energy beam 200 propagates along the scan vector 400 oriented toward the normal point 206, the ellipticity of the beam spot 300 may vary with the incident angle θ of the energy beam 200. i The skewness of the energy density distribution 302 can be adjusted as the incident angle θ of the energy beam 200 decreases. i The reduction in the beam spot 300 and / or the reduction in the ellipticity of the beam spot 300 are correspondingly reduced.

[0078] When the energy beam 200 propagates along a scan vector 400 directed away from the normal point 206, as Figure 4C and 4D As shown, power density distribution 404 may be oriented away from normal point 206. For example, due to the orientation of scan vector 400 and / or the orientation of power density distribution 404 away from normal point 206, following Figure 4C and 4D Energy beam 200 of scan vector 400 shown in FIG. 4 may impart more energy to a central portion of beam path 402. Additionally or alternatively, energy density distribution 302 of beam spot 300 may be skewed away from the direction of scan vector 400. As a result, a leading portion of beam spot 300 may expose build plane 130 and / or powder bed 136 to a relatively lower intensity and / or power density than a trailing portion of beam spot 300. Thus, as shown in FIG. Figure 4A and 4B Compared to the energy beam 200 shown following a scan vector 400 directed toward the normal point 206, as shown Figure 4C and 4D Energy beam 200 shown following scan vector 400 directed away from normal point 206 may impart a relatively more gradual transition in intensity and / or power density as beam spot 300 passes through points on build plane 130 and / or powder bed 136. Figure 4D As shown, for example, when the energy beam 200 propagates along a scan vector 400 directed away from the normal point 206, the ellipticity of the beam spot 300 may vary with the incident angle θ of the energy beam 200. i The skewness of the energy density distribution 302 can be increased with the increase of the incident angle θ of the energy beam 200. i The increase in and / or the increase in the ellipticity of the beam spot 300 increases accordingly.

[0079] like Figure 4E and4F As shown, when the energy beam 200 propagates along the scan vector 400 oriented substantially equidistant from the normal point 206, the power density distribution 404 can be oriented transverse to the normal point 206 and / or biased toward the normal point 206. For example, the peak of the power density distribution 404 can be oriented transverse to the normal point 206. Additionally or alternatively, the median power density of the power density distribution 404 can be biased toward the normal point 206. For example, due to the orientation of the scan vector 400 and / or the orientation of the power density distribution 404 transverse to the normal point 206, following Figure 4E and 4F Energy beam 200 of scan vector 400 shown in FIG. 4 may impart more energy to an eccentric portion of beam path 402, toward normal point 206. Additionally or alternatively, energy density distribution 302 of beam spot 300 may be biased toward the direction of scan vector 400. As a result, the inwardly directed side of beam spot 300 may expose build plane 130 and / or powder bed 136 to a relatively higher intensity and / or power density than the outwardly directed portion of beam spot 300. Figure 4E and 4F As shown, when the energy beam 200 propagates along the scanning vector 400 that is substantially equidistant from the normal point 206, the elliptical angle θ of the beam spot 300 e The incident angle θ of the energy beam 200 may be changed due to the change in the coordinates of the beam spot 300 relative to the normal point 206. When the beam spot 300 and the normal point 206 are kept substantially equidistant, the incident angle θ of the energy beam 200 i For example, when the skewness remains substantially constant, the skewness of energy density distribution 302 may be rotated accordingly such that energy density distribution 302 remains biased toward normal point 206. Additionally or alternatively, for example, when the skewness of the median power density of power density distribution 404 remains substantially constant, power density distribution 404 may be rotated accordingly such that power density distribution 404 remains oriented transversely to normal point 206 and / or such that the median power density of power density distribution 404 remains biased toward normal point 206.

[0080] Now turn to Figure 5A-5G , an exemplary hatch vector 500 ( Figures 5A-5F ) and contour vector 550( Figure 5G). As will be described, the melting and / or sintering behavior of build plane 130 and / or powder bed 136 may depend on the orientation of the shadow vector 500 of energy beam 200 across build plane 130 and / or powder bed 136. Additionally or alternatively, the melting and / or sintering behavior of build plane 130 and / or powder bed 136 may depend on the orientation of the profile vector 550 of energy beam 200 across build plane 130 and / or powder bed 136. One or more shadow lines 502, respectively formed by multiple adjacent and / or partially overlapping beam paths 402, may define a solidified congruent region of build plane 130, such as a layer of object 114. One or more shadow lines 502 may propagate across build plane 130 (e.g., a layer of object 114), respectively, in a propagation direction according to the shadow line vector 500. Each individual shadow line 502 may be applied according to a corresponding scan vector 400. In some embodiments, the shadow line vector 500 may be transverse to the corresponding plurality of scan vectors 400 defining the plurality of shadow lines. In the depicted embodiment, a plurality of hatches 502 may be formed, for example, by corresponding scan vectors 400 oriented in a series of alternating directions, wherein the hatch vectors 500 propagate transversely to the hatches. However, it should be understood that other hatching methods are contemplated with corresponding other scan vectors 400 and / or hatch vectors 500.

[0081] One or more contours 552, respectively formed by one or more beam paths 402, may define a cured perimeter region around at least a portion of a congruent region of build plane 130 (e.g., a perimeter of object 114). For example, one or more contours 552 may define a cured perimeter around at least a portion of a congruent region of build plane 130 that has been and / or subsequently cured by multiple hatches 502. One or more contours may be respectively propagated across build plane 130 (e.g., a layer of object 114) in a propagation direction according to contour vectors 550. Each individual contour 552 may be applied according to a corresponding scan vector 400. In some embodiments, contour vectors 550 may be perpendicular (e.g., adjacent and / or overlapping) to the corresponding one or more scan vectors 400 defining the one or more contours 552. Additionally or alternatively, contour vectors 550 may be transverse to the corresponding one or more scan vectors 400 defining the plurality of contours 552. In the depicted embodiment, one or more contours 552 may be formed by corresponding one or more scan vectors 400, wherein contour vectors 550 propagate perpendicular (e.g., adjacent and / or overlapping) to the one or more scan vectors 400. In the case of multiple profiles 552 , the corresponding multiple scan vectors 400 may be oriented, for example, in the same direction or in alternating directions. However, it should be understood that other irradiation methods are contemplated with corresponding other scan vectors 400 and / or profile vectors 550 .

[0082] In some embodiments, the melting and / or sintering behavior of powder bed 136 may depend on the orientation of shadow vector 500 of energy beam 200 across build plane 130. Additionally or alternatively, the melting and / or sintering behavior of powder bed 136 may depend on the orientation of profile vector 550 of energy beam 200 across build plane 130. Figures 5A-5F Energy beam 200 is shown propagating according to scan vector 400 to apply a series of hatches 502. Series of hatches 502 provide corresponding hatch vectors 500 that propagate across build plane 130 and / or powder bed 136 relative to normal point 206.

[0083] Figure 5A and 5B A hatch vector 500 is shown oriented toward the normal point 206 . Figure 5A and 5B The hatch vectors 500 shown in FIG. 5 correspond to a series of hatches 502 applied according to corresponding scan vectors 400 that are oriented substantially equidistant from the normal point 206. The scan vectors 400 and resulting hatches 502 may be linear (indicated by the linear hatches 502 shown) and / or curved (indicated by the scan vectors 400 shown). For example, Figure 5A and 5B The scan vector 400 of the series of hatches 502 shown in FIG. 4 can be oriented at a tangent or substantially tangent line relative to the normal point 206. Figure 5A and 5B The hatching vector 500 is shown, and the incident angle θ of the energy beam 200 is i As the shadow vector 500 propagates towards the normal point 206 , it decreases.

[0084] Figure 5C and 5D A hatch vector 500 is shown oriented away from the normal point 206 . Figure 5C and 5D The hatch vectors 500 shown in FIG. 5 correspond to a series of hatches 502 applied according to corresponding scan vectors 400 that are oriented substantially equidistant from the normal point 206. The scan vectors 400 and resulting hatches 502 may be linear (indicated by the linear hatches 502 shown) and / or curved (indicated by the scan vectors 400 shown). For example, Figure 5C and 5D The scan vector 400 of the series of hatches 502 shown in FIG. 4 can be oriented at a tangent or substantially tangent line relative to the normal point 206. Figure 5C and 5D The hatch vector 500 shown in FIG. 5 and the incident angle θ of the energy beam 200 are i Increases as the shadow vector 500 propagates away from the normal point 206 .

[0085] Figure 5Eand 5F The hatch vector 500 is shown to be oriented substantially equidistant from the normal point 206. For example, Figure 5E and 5F The hatch vectors 500 shown in can be oriented at a tangent or substantially tangent to the normal point 206. The scan vectors 400 and the resulting hatch lines 502 can be oriented toward or substantially toward the normal point 206. In some embodiments, the scan vectors 400 and the resulting hatch lines 502 can be oriented radially or substantially radially relative to the normal point 206. For example, at least one hatch line 502 and corresponding scan vector 400 can be oriented toward or away from the normal point 206, and adjacent hatch lines 502 and corresponding scan vectors 400 can be laterally offset by a distance corresponding to the hatch width, which can include an overlap or offset. Figure 5E and 5F As shown in FIG. 5 , when the shadow vector 500 propagates substantially equidistant from the normal point 206, the incident angle θ of the energy beam 200 is i Keep it basically consistent.

[0086] like Figures 5A-5F As shown, when the energy beam 200 propagates along the scan vector 400 corresponding to a given shadow line 502 and / or when the corresponding shadow line 502 propagates along the shadow line vector 500, the ellipticity of the beam spot 300 can be due to the incident angle θ of the energy beam 200. i Additionally or alternatively, when the energy beam 200 propagates along the scan vector 400 corresponding to a given shadow line 502 and / or when the corresponding shadow line 502 propagates along the shadow line vector 500, the elliptical angle θ of the beam spot 300 is e The energy density distribution 302 and / or the power density distribution 404 of the beam spot 300 may change due to a change in the coordinates of the beam spot 300 relative to the normal point 206. Therefore, when the energy beam 200 propagates along the scan vector 400 corresponding to a given shadow line 502 and / or when the corresponding shadow line 502 propagates along the shadow line vector 500, the energy density distribution 302 and / or the power density distribution 404 of the beam spot 300 may change. Additionally or alternatively, when the energy beam 200 propagates along the scan vector 400 corresponding to a given shadow line 502 and / or when the corresponding shadow line 502 propagates along the shadow line vector 500, the melting and / or sintering behavior of each shadow line 502 and / or the powder bed 136 may change. For example, the melting and / or sintering behavior of each shadow line 502 and / or the powder bed may depend at least in part on the incident angle θ of the energy beam 200 corresponding to the previous shadow line 502 and / or one or more previous shadow lines 502 (e.g., previous shadow lines 502 overlapping the current shadow line 502). i and / or the ellipse angle θ of the beam spot 300 e .

[0087] for Figure 5BAs shown in the shadow line 502, the ellipticity of the beam spot 300 decreases as the shadow line 502 propagates along the shadow line vector 500 toward the normal point 206, and the elliptic angle θ of the beam spot 300 e As each shadow line 502 propagates along the corresponding scan vector 400, the energy density and / or power density imparted by the energy beam 200 may increase as each shadow line propagates along the shadow line vector 500 toward the normal point 206. Figure 5B As shown in , a portion of the beam spot 300 that overlaps the previous shadow line 502 may have a lower power density than a portion of the beam spot 300 that is incident on the powder bed 136. Additionally or alternatively, the energy density imparted to the portion of the previous shadow line 502 that is overlapped by the beam spot 300 may be greater than the energy density of the portion of the beam spot 300 that overlaps the previous shadow line 502. As the shadow line 502 propagates along the shadow line vector 500 and the incident angle θ of the energy beam 200 is i Accordingly, the difference in energy density and / or power density between the portion of the previous hatch line 502 overlapped by the beam spot 300 and the portion of the beam spot 300 overlapping with the previous hatch line 502 may become less noticeable.

[0088] for Figure 5D As shown in the shadow line 502 in FIG. 1 , the ellipticity of the beam spot 300 increases as the shadow line 502 propagates away from the normal point 206 along the shadow line vector 502, and the elliptic angle θ of the beam spot 300 increases. e As each shadow line 502 propagates along the corresponding scan vector 400, the energy density and / or power density imparted by the energy beam 200 may decrease as each shadow line propagates along the shadow line vector 500 away from the normal point 206. Figure 5D As shown, a portion of the beam spot 300 that overlaps the previous shadow line 502 can have a greater power density than a portion of the beam spot 300 that is incident on the powder bed 136. Additionally or alternatively, the energy density imparted to the portion of the previous shadow line 502 that is overlapped by the beam spot 300 can be lower than the energy density of the portion of the beam spot 300 that overlaps the previous shadow line 502. As the shadow line 502 propagates along the shadow line vector 500 and the incident angle θ of the energy beam 200 is i Accordingly, the difference in energy density and / or power density between the portion of the previous hatch line 502 overlapped by the beam spot 300 and the portion of the beam spot 300 overlapping with the previous hatch line 502 may become more pronounced.

[0089] for Fig. 5F The shadow line 502 shown in FIG. 1 shows the ellipse angle θ of the beam spot 300. eAs the shadow line 502 propagates along the shadow line vector 500, the ellipticity of the beam spot 300 changes as each shadow line 502 propagates along the corresponding scan vector 400. Therefore, the energy density and / or power density imparted by the energy beam 200 can change as each shadow line 502 propagates away from and / or toward the normal point 206 along each scan vector 400. Fig. 5F As shown, a portion of the beam spot 300 that overlaps the previous shadow line 502 can have a greater power density than a portion of the beam spot 300 that is incident on the powder bed 136. Additionally or alternatively, the energy density imparted to the portion of the previous shadow line 502 that is overlapped by the beam spot 300 can be lower than the energy density of the portion of the beam spot 300 that overlaps the previous shadow line 502. As the shadow line 502 propagates along the shadow line vector 500 and the incident angle θ of the energy beam 200 increases, the energy density of the beam spot 300 increases. i Accordingly, the difference in energy density and / or power density between the portion of the previous hatch line 502 overlapped by the beam spot 300 and the portion of the beam spot 300 overlapping with the previous hatch line 502 may become more pronounced.

[0090] Figure 5G Contour vectors 550 and corresponding contours 552 are shown at least partially surrounding the perimeter of a layer of object 114. Figure 5G The profile vector 550 is shown, and the incident angle θ of the energy beam 200 is i As the contour vector 550 propagates around the perimeter of the layer of the object 114, it changes continuously. Figure 5G As shown, when the energy beam 200 propagates along the scan vector 400 corresponding to a given profile 552 and / or when the corresponding profile 552 propagates along the profile vector 550, the ellipticity of the beam spot 300 may be due to the incident angle θ of the energy beam 200. i Additionally or alternatively, when the energy beam 200 propagates along the scan vector 400 corresponding to the given profile 552 and / or when the corresponding profile 552 propagates along the profile vector 550, the elliptical angle θ of the beam spot 300 is eThe beam spot 300 may change due to the change in coordinates of the beam spot 300 relative to the normal point 206. Therefore, the energy density distribution 302 and / or the power density distribution 404 of the beam spot 300 may change as the energy beam 200 propagates along the scan vector 400 corresponding to the given contour 552 and / or as the corresponding contour 552 propagates along the contour vector 550. Additionally or alternatively, the melting and / or sintering behavior of each contour 552, the shadow lines 502 adjacent to the contour 552, and / or the powder bed 136 may change as the energy beam 200 propagates along the scan vector 400 corresponding to the given contour 552 and / or as the corresponding contour 552 propagates along the contour vector 550. For example, the melting and / or sintering behavior of each contour 552, the shadow lines 502 adjacent to the contour 552, and / or the powder bed 136 may depend at least in part on the incident angle θ of the energy beam 200 corresponding to the current contour 552 and / or one or more previous contours 552 and / or one or more previous shadow lines 502 (e.g., previous contours 552 and / or shadow lines 502 overlapped by the current contour 552). i and / or the ellipse angle θ of the beam spot 300 e .

[0091] Reference now Figure 6 , Figure 7 , Figures 8A-8C , Fig.9A and 9B , Figures 10A-10H and Fig.11 , exemplary scan segments and exemplary irradiation vectors corresponding to such scan segments will be described. Figure 6 and Figure 7 A construction plane 130 divided into a plurality of scan segments is shown respectively. Figures 8A-8C Exemplary irradiation vectors that may be used for various scan segments are shown. Fig.9A and 9B An exemplary scan segment is shown superimposed on a layer of multiple objects 114 to be irradiated. Figures 10A-10H Exemplary irradiation vectors are shown that may be used to irradiate layers of corresponding objects in plurality of objects 114, for example, according to respective scan segments corresponding to such layers. One or more scan segments and / or one or more irradiation vectors may be determined for one or more layers of object 114 based at least in part on a location of at least a portion of a layer of object 114 on a construction plane. Additionally or alternatively, one or more irradiation parameters for at least a portion of a layer of object 114 may be determined based at least in part on such a location on construction plane 130 and / or based at least in part on scan segments and / or irradiation vectors, respectively, corresponding to such a location on construction plane 130.

[0092] Figure 6 An exemplary construction plane 130 is shown, corresponding to, for example, Figure 11. Build plane 130 of additive manufacturing machine 102 shown in FIG. Build plane 130 may include first build plane region 146 corresponding to first energy beam 142 and / or second build plane region 152 corresponding to second energy beam 148. As shown, multiple scan segments 600 of build plane 130 may be defined. Multiple scan segments 600 may be about normal points 206 corresponding to corresponding energy beams 200 and / or about incident angle θ of energy beam 200 corresponding to normal point 206. i For example, as shown with respect to first construction plane region 146, a plurality of segments may extend radially from normal point 206. A plurality of scan segments 600 may be arranged radially adjacent to one another. In some embodiments, construction plane 130 may be divided into a plurality of radial segments 602, for example, respective radial segments of plurality of radial segments 602 being radially adjacent to one another.

[0093] Additionally or alternatively, as shown with respect to second construction plane region 152, multiple scan segments 600 may extend annularly or semi-annularly from normal point 206. In some embodiments, construction plane 130 may be divided into multiple annular segments 604, for example, respective ones of multiple annular segments 604 are circumferentially adjacent to each other. Additionally or alternatively, construction plane 130 may be divided into multiple semi-annular segments 606, for example, respective ones of multiple semi-annular segments 606 are circumferentially adjacent to each other and / or radially adjacent to each other. In some embodiments, the construction plane may be divided radially and annularly, thereby defining multiple semi-annular segments 606 that are radially and semi-annularly bounded relative to normal point 206. The boundaries of each scan segment 600 may be determined by reference to coordinates of the construction plane (e.g., X and Y coordinates associated with normal point 206). Additionally or alternatively, the boundaries of each scan segment 600 may be determined by reference to an incident angle θ of energy beam 200 corresponding to normal point 206. i to be sure.

[0094] Figure 7 Another exemplary construction plane 130 is shown divided into a plurality of scan segments 600, for example corresponding to Figure 1 The build plane 130 of the additive manufacturing machine 102 is shown in FIG. Figure 7 As shown, in some embodiments, the number of scan segments 600 per unit area of ​​build plane 130 to be irradiated and / or the number of scan segments 600 per unit area of ​​one or more layers of object 114 may depend at least in part on the distance from normal point 206 and / or the angle of incidence θ of energy beam 200 corresponding to normal point 206. i For example, as shown, the number of scan segments 600 per unit area may increase with increasing distance from the normal point 206 and / or the incident angle θ of the energy beam 200 corresponding to the normal point 206. iAdditionally or alternatively, the area of ​​a given segment may depend at least in part on the distance from the normal point 206 and / or the incident angle θ of the energy beam 200 corresponding to the normal point 206. i For example, the area of ​​each scanning segment 600 may increase with the distance from the normal point 206 and / or the incident angle θ of the energy beam 200 corresponding to the normal point 206. i This reduction in area of ​​each scan segment 600 may be determined with reference to an average area of ​​each scan segment within radially inward and radially outward co-annular portions of construction plane 130 disposed about normal point 206.

[0095] like Figure 7 As shown, one or more segment boundaries 700 corresponding to a given scan segment 600 may be based at least in part on an incident angle θ of the energy beam 200 when incident on the corresponding scan segment 600. i An exemplary segment may include a radial boundary 702, an annular boundary 704, and / or a semi-annular boundary 706. In some embodiments, the number of segment boundaries 700 including radial boundaries 702 and / or annular boundaries 704 may increase with increasing distance from the normal point 206 and / or the incident angle θ of the energy beam 200 corresponding to the normal point 206. i increases with the increase of .

[0096] The energy may be based at least in part on the incident angle θ which may depend at least in part on the energy i One or more beam parameters are used to determine one or more segment boundaries 700 for the corresponding one or more scan segments 600. For example, the one or more segment boundaries 700 can be determined at least in part based on the one or more beam parameters, which can be determined based on the incident angle θ of the energy beam 200. i In some embodiments, one or more segment boundaries 700 may be determined for one or more corresponding scanning segments 600 so that the incident angle θ of the energy beam 200 incident on the corresponding scanning segment 600 is i Remain within a defined range at all points within the respective scan segment 600 and / or at all points along one or more segment boundaries 700 defining the respective scan segment 600 .

[0097] The incident angle θ of the energy beam 200 i The defined range and / or number of segment boundaries 700 (eg, the number of annular boundaries 704 and / or radial boundaries 702) may be based at least in part on the incident angle θ of the energy beam 200. i The actual or potential effect of one or more beam parameters (e.g., the incident angle θ attributable to the energy beam 200) i The actual or potential influence of the melting and / or sintering behavior of the

[0098] For example, one or more annular boundaries 704 may be determined for corresponding one or more scan segments 600 such that the incident angle θ i 704 to the outer annular boundary 704. For example, in some embodiments, the plurality of scan segments 600 can be constructed and arranged relative to the normal point 206 so that between any two points within the corresponding scan segment 600, and / or between any two points along any one or more segment boundaries 700 corresponding to the segment, the incident angle θ of the energy beam 200 corresponding to the normal point 206 incident on the corresponding scan segment 600 is i The difference is within a limited range of 20 degrees or less (e.g., 15 degrees or less, e.g., 10 degrees or less, e.g., 5 degrees or less, or e.g., 2.5 degrees or less). In some embodiments, the incident angle θ of the energy beam 200 is i The limit range can be changed with the incident angle θ i For example, in some embodiments, the defined range of the radially inward segment 600 may exceed the defined range of the radially outward segment 600 by at least 5%, such as at least 10%, such as at least 20%, such as at least 25%, such as at least 35%, such as at least 50%, such as at least 75%, such as at least 100%, such as at least 150%, such as at least 200%.

[0099] Additionally or alternatively, in some embodiments, the number of radial boundaries 702 and / or the number of annular or semi-annular scan segments 600 may be based at least in part on the angle of incidence θ of the energy beam 200 incident on the corresponding scan segment 600. i For example, the number of radial boundaries 702 and / or the number of annular or semi-annular scan segments 600 may vary with the incident angle θ. i For example, in some embodiments, the number of radial boundaries 702 of the radially outer portion of build plane 130 may exceed the number of radial boundaries 702 of the radially inner portion of build plane 130, and / or the number of annular or semi-annular sweep segments 600 of the radially outer portion of build plane 130 may exceed the number of annular or semi-annular sweep segments 600 of the radially inner portion of build plane 130 by a factor of at least 3:2, such as at least 2:1, such as at least 3:1, such as at least 4:1, such as at least 8:1, such as at least 16:1, such as at least 32:1, such as at least 64:1. Figure 7As shown, with respect to first build plane region 146, first radially inward portion 708 of build plane 130 may have one annular segment 604, and first radially outward portion 710 of build plane 130 may have 16 semi-annular segments 606. As another example, with respect to second build plane region 152, second radially inward portion 712 may have a plurality of radial boundaries 702 distributed in 45 degree increments about normal point 206, and second radially outward portion 714 may have a plurality of radial boundaries 702 distributed in 22.5 degree increments about normal point 206. The plurality of radial boundaries 702 at second radially inward portion 712 may define eight (8) semi-annular segments 606. The plurality of radial boundaries 702 at second radially outward portion 714 may define sixteen (16) semi-annular segments 606.

[0100] Reference now Figures 8A-8C , an exemplary irradiation vector will be described. The irradiation vector may be assigned to each scan segment 600. The scan segment 600 may correspond to a build plane 130, a powder bed 136 defining the build plane 130, or an object layer including one or more objects to be irradiated by the energy beam 200. Figures 8A-8C As shown, the construction plane 130 can be divided into a plurality of scanning segments 600, such as a plurality of radial segments 602. As an illustration, Figures 8A-8C 6. The construction plane 130 shown in FIG. 1 is divided into eight (8) radial segments; however, it should be understood that the construction plane 130 may be divided into any number of scanning segments 600, including radial segments 602, annular segments 604, and / or semi-annular segments 606. In some embodiments, the annular segments 604 may surround the normal point 206. The annular segments 604 surrounding the normal point 206 may have an incident angle θ corresponding to the corresponding energy beam. i For example, the incident angle θ i can be at least less than a threshold value, below which the incident angle θ i The one or more irradiation vectors (e.g., one or more scan vectors, one or more hatch vectors, and / or one or more contour vectors) may be assigned to at least some of the plurality of scan segments 600 based at least in part on the position of the segment 600 on the build plane 130 (e.g., based at least in part on the position of the segment 600 relative to the normal point 206). At least some of the one or more irradiation vectors (e.g., one or more scan vectors, one or more hatch vectors, and / or one or more contour vectors) assigned to the respective scan segments 600 may be oriented away from the normal point 206.

[0101] like Figures 8A-8CAs shown, one or more shadow vectors 500 may be assigned to one or more scan segments 600 of the construction plane 130, such as one or more radial segments 602 of the construction plane 130. The one or more shadow vectors 500 assigned to the corresponding scan segment 600 may be oriented away from the normal point 206. An object 114 and / or a portion of an object 114 located within a given scan segment 600 (e.g., radial segment 602) may be irradiated at least in part based on such shadow vectors 500 assigned to the given segment. In some embodiments, each segment 600 (e.g., each radial segment 602) may include one or more shadow vectors 500 oriented away from the normal point 206. The one or more shadow vectors 500 may be determined at least in part based on the position of the corresponding scan segment 600 on the construction plane 130, for example, such that each shadow vector 500 may be oriented away from the normal point 206. Each shadow vector 500 may include at least one directional component oriented away from the normal point 206, such as at least one X-direction component and / or at least one Y-direction component oriented away from the normal point 206. Each hatch vector 500 may be defined by a corresponding plurality of scan vectors 400. In some embodiments, at least some of the scan vectors 400 may be oriented away from the normal point 206. For example, a hatch vector 500 may be assigned to a segment 600 of a construction plane 130, and the hatch vector 500 and the plurality of scan vectors 400 defining the hatch vector 500 may be oriented away from the normal point 206.

[0102] like Fig. 8A As shown, in some embodiments, the plurality of scan vectors 400 may be oriented away from the normal point 206 in a substantially radial direction relative to the normal point 206. Such hatch vectors 500 may have a directional component oriented away from the normal point 206 in a substantially radial direction. The plurality of scan vectors 400 defining the respective hatch vectors 500 may be oriented perpendicular to a radial line extending from the normal point 206 (e.g., perpendicular to the respective hatch vectors 500). Fig. 8A As shown in relation to first construction plane region 146, at least some of scan vectors 400 defining hatch vectors 500 may be oriented in alternating directions. Additionally or alternatively, as Figure 8B As shown in relation to second construction plane region 152 , at least some of scan vectors 400 defining hatch vectors 500 may be oriented in a common direction. For example, at least some of scan vectors 400 may be oriented counter-flow to air flow direction 800 .

[0103] like Figure 8BAs shown, in some embodiments, multiple scan vectors 400 can be oriented away from the normal point 206 in a substantially radial direction relative to the normal point 206. Such scan vectors 400 can have a directional component oriented away from the normal point 206 in a substantially radial direction. Multiple scan vectors 400 in a corresponding scan segment 600 (e.g., radial segment 602) can define a hatch vector 500, which can be oriented perpendicular to a radial line extending from the normal point 206 (e.g., perpendicular to the corresponding scan vector 400 defining the hatch vector 500). Figure 8B As shown in FIG. 1 with respect to first construction plane region 146, at least some of scan vectors 400 defining hatch vectors 500 may be oriented in alternating directions. At least some of hatch vectors 500 defined by scan vectors 400 may be oriented countercurrent to airflow direction 800. Additionally or alternatively, as Figure 8B As shown in relation to second construction plane region 152, at least some of the scan vectors 400 defining hatch vectors 500 may be oriented in a common direction. For example, at least some of the hatch vectors 500 may be defined by a plurality of scan vectors 400 that are oriented parallel to radial lines extending from normal point 206 (e.g., perpendicular to respective hatch vectors 500).

[0104] Any number of orientations of hatch vectors 500 and corresponding scan vectors 400 may be provided. As another example, Figure 8C As shown in relation to first construction plane region 146, a plurality of scan vectors 400 may be oriented away from normal point 206 in a substantially radial direction relative to normal point 206, and a plurality of scan vectors 400 defining respective hatch vectors 500 may be oriented non-perpendicular to a radial line extending from normal point 206 (e.g., non-perpendicular to respective hatch vectors 500). Hatch vectors 500 defined by such scan vectors 400 may be oriented away from normal point 206 in a substantially radial direction. At least some of scan vectors 400 may be oriented counter-current to airflow direction 800. In some embodiments, scan vectors located upstream of the normal point 206 relative to airflow direction 800 may have at least one directional component oriented counter-current to the airflow direction. Additionally or alternatively, scan vectors located downstream of the normal point 206 may have at least one directional component oriented downstream to airflow direction 800.

[0105] like Figure 8CAs shown in relation to second construction plane region 152, a plurality of scan vectors 400 may be oriented away from normal point 206 in a substantially perpendicular direction relative to airflow direction 800. At least some of the hatch vectors 500 defined by such scan vectors 400 may be oriented away from normal point 206 in a substantially radial direction. Additionally or alternatively, at least some of the hatch vectors 500 defined by such scan vectors 400 may be oriented counter-current to airflow direction 800. For example, in some embodiments, one or more scan segments 600 (e.g., one or more radial segments 602) located upstream of normal point 206 relative to airflow direction 800 may include hatch vectors 500 having at least one directional component oriented counter-current to airflow direction 800. One or more scan segments 600 (e.g., one or more radial segments 602) located downstream of normal point 206 relative to airflow direction 800 may include hatch vectors 500 having at least one directional component oriented downstream to airflow direction 800. One or more scan segments 600 (e.g., one or more radial segments 602) located in the middle portion of build plane 130 relative to air flow direction 800 may include a plurality of scan vectors 400 having at least one directional component oriented transverse to air flow direction 800. A hatch vector 500 defined by such scan vectors 400 may include at least one directional component oriented countercurrent to air flow direction 800.

[0106] Now turn to Fig.9A and 9B , an exemplary scan segment corresponding to an object layer including a plurality of objects 114 to be irradiated will be described. Fig.9A 1 and 12. Construction plane 130 is shown, which defines object layers 900 of multiple objects 114 to be irradiated by one or more energy beams. Object layer 900 may include a first object layer 902 at a first construction plane region 146 to be irradiated by a first energy beam 142 and / or a first object layer 902 at a first construction plane region 146 to be irradiated by a second energy beam 148 ( Figure 1 ) irradiated second object layer 904 at second construction plane region 152. Construction plane 130 has been segmented into a plurality of scan segments 600. For example, Fig.9A As shown, the plurality of scanning segments 600 may include a plurality of radial segments 602 , a plurality of annular segments 604 , and / or a plurality of semi-annular segments 606 .

[0107] like Fig.9A As shown, construction plane 130 may be segmented into a plurality of scanning segments 600, such as a plurality of radial segments 602, a plurality of annular segments 604, and / or a plurality of semi-annular segments 606. Depending on the position of each object 114 on construction plane 130, plurality of scanning segments 600 may intersect each of plurality of objects 114 in object layer 900 at a different position of the corresponding object 114. For example, Fig.9A As shown, radial segment 602 shown in first construction plane area 146 includes radial boundary 702 that intersects first object 906 at or near a middle region of first object 906, and the same radial boundary 702 intersects second object 908 at or near an edge region of second object 908. Additionally or alternatively, for Fig.9A In the scan segment 600 shown in FIG. 1 , the first object 906 and the second object 908 may intersect one radial boundary 702, while the third object 910 may intersect three radial boundaries 702. The slopes of the radial boundaries 702 intersecting the respective objects 114 may differ depending on the location of the respective objects 114. For example, the radial boundaries 702 intersecting the first object 906 and / or the second object 908 may have a slope of approximately 11.25 degrees, while the radial boundaries intersecting the third object 910 may have a slope of approximately 22.5 degrees and / or approximately 33.75 degrees.

[0108] As another example, Fig.9A Annular segment 604 shown in second construction plane region 152 may include annular boundary 704 that intersects fourth object 912 at or near a radially inward region of fourth object 912, while the same annular boundary 704 may not intersect fifth object 914. Additionally or alternatively, for Fig.9A In the scan segment 600 shown in FIG. 1 , the annular boundary 704 may intersect the fourth object 912 but may not intersect the fifth object 914. The arc lengths of the annular boundary 704 and / or the semi-annular boundary 706 intersecting the respective objects 114 may differ depending on the locations of the respective objects 114. For example, the portion of the annular boundary 704 intersecting the fifth object 914 may have an arc length from about 11.25 degrees to less than 22.5 degrees, while the portion of the annular boundary 704 intersecting the sixth object 916 may have an arc length from about 22.5 degrees to less than 33.75 degrees.

[0109] In some embodiments, one or more irradiation parameters may be determined based at least in part on the position of object 114 (e.g., the position of a layer of object 114 in object layer 900). i and / or the ellipse angle θ of the beam spot 300 e , and / or based at least in part on the melting and / or sintering behavior and the incident angle θ of the energy beam 200 i and / or the ellipse angle θ of the beam spot 300 eThe one or more irradiation parameters may be determined with respect to one or more scan segments 600 (e.g., with respect to one or more scan segments 600 corresponding to object layer 900). The one or more irradiation parameters may be different between at least some scan segments 600 and / or between at least some objects 114 in object layer 900.

[0110] In some embodiments, the configuration and / or arrangement of one or more scan segments 600 may be determined at least in part based on the location of a layer of object 114 in object layer 900 on construction plane 130. For example, Fig. 9B An object layer 900 is shown of a plurality of objects 114, each including one or more scan segments 600, the configuration and / or arrangement of the one or more scan segments 600 being determined at least in part based on the position of the corresponding object 114. The configuration and / or arrangement of the one or more scan segments 600 corresponding to each object 114 in the object layer 900 may be based at least in part on the incident angle θ of the energy beam 200 at one or more positions of the corresponding object 114 in the object layer 900. i and / or the ellipse angle θ of the beam spot 300 e Additionally or alternatively, the configuration and / or arrangement of one or more scanning segments 600 may be based at least in part on the melting and / or sintering behavior and the incident angle θ of the energy beam 200 corresponding to such one or more locations of the corresponding object 114 in the object layer 900. i and / or the ellipse angle θ of the beam spot 300 e The configuration and / or arrangement of one or more scan segments 600 may be determined with respect to one or more objects 114 in object layer 900. The configuration and / or arrangement of one or more scan segments 600 may be different between at least some scan segments 600 and / or between at least some objects 114 in object layer 900.

[0111] like Fig. 9BAs shown in relation to first construction plane region 146, in some embodiments, a configuration and / or arrangement of one or more segment boundaries 700 (e.g., one or more radial boundaries 702) may be determined for one or more objects 114 in object layer 900 based at least in part on the location of objects 114 in object layer 900 on construction plane 130. For example, as shown, a location and / or slope of radial boundaries 702 may be determined for one or more objects 114 in object layer 900 based at least in part on the location of corresponding objects 114 in object layer 900 on construction plane 130. In some embodiments, as shown in relation to first construction plane region 146, a location and / or slope of radial boundaries 702 may be determined to substantially coincide with a middle portion of the object. As shown in relation to second construction plane region 152, a location and / or slope of radial boundaries 702 may be determined to be substantially the same between respective objects in a plurality of objects 114 in object layer 900. For example, radial boundary 702 that intersects object 114 located at a radially inward portion of object layer 900 may have a position and / or slope that coincides with normal point 206, while radial boundary 702 that intersects object 114 located at a radially outward portion of object layer 900 may have a position and / or slope that deviates from normal point 206.

[0112] Additionally or alternatively, such as Fig. 9B As shown in relation to second construction plane region 152, in some embodiments, a configuration and / or arrangement of one or more annular boundaries 704 and / or one or more semi-annular boundaries 706 may be determined for one or more objects 114 in object layer 900 based at least in part on the location of objects 114 in object layer 900 on construction plane 130. For example, as shown, a location, radius of curvature, and / or slope of annular boundaries 704 and / or semi-annular boundaries 706 may be determined for one or more objects 114 in object layer 900 based at least in part on the location of corresponding objects 114 in object layer 900 on construction plane 130. In some embodiments, as shown in relation to second construction plane region 152, the location and / or slope of annular boundaries 704 and / or semi-annular boundaries 706 may be determined to be substantially the same between respective objects in a plurality of objects 114 in object layer 900. For example, an annular boundary 704 and / or semi-annular boundary 706 that intersects object 114 located at a radially inward portion of object layer 900 may have a position, radius of curvature, and / or slope that coincides with normal point 206, while annular boundary 704 and / or semi-annular boundary 706 that intersects object 114 located at a radially outward portion of object layer 900 may have a position, radius of curvature, and / or slope that deviates from normal point 206.

[0113] Reference now Figures 10A-10H, exemplary irradiance vectors corresponding to various objects 114 in object layer 900 will be described. Figures 10A-10H Slices of individual objects 114 from object layer 900 are shown respectively, with exemplary irradiance vectors that may be utilized. Figures 10A-10H The exemplary irradiance vectors for individual objects 114 shown in FIG. 1 may be used for one or more objects 114 in object layer 900. Such exemplary irradiance vectors may be used alone or in combination for one or more objects 114 in object layer 900. For example, Fig. 10A The irradiance vectors shown in FIG. 1 may be used for multiple objects 114 in object layer 900, for example Fig.9A or Fig. 9B 900. Additionally or alternatively, such exemplary irradiance vectors may be used for multiple objects in object layer 900 in any combination. For example, Fig. 10A The irradiance vectors shown in FIG. 1 may be used for first plurality of objects 114 in object layer 900, and Fig. 10B The irradiance vectors shown in FIG. 1 may be used for second plurality of objects 114 in object layer 900, for example, for Fig.9A or Fig. 9B 1 and 2. The first and second pluralities of objects 114 in object layer 900 are shown in FIG. Figures 10C-10H The irradiance vectors shown in can similarly be used alone or in conjunction with Figures 10A-10H can be used in conjunction with any of the irradiance vectors shown in .

[0114] Fig. 10A and 10B Objects 114 from object layer 900 are each shown, including radial boundaries 702 that intersect respective objects 114 . Fig. 10A The object 114 shown in FIG. 1 may correspond to Fig. 9B The seventh object 918 is shown in . Fig. 10B The object 114 shown in FIG. 1 may correspond to Fig. 9B The eighth object 920 shown in FIG. Fig. 10A and 10B As shown in the reference Fig. 9B In some embodiments, object 114 may be irradiated according to shadow vector 500 oriented substantially radially relative to normal point 206 . Fig. 10A and 10B The substantially radial orientation of hatch vector 500 shown in is illustrated by hatch vector 500 and radial boundary 702, respectively, being aligned with radial lines that intersect at a point (eg, at normal point 206).

[0115] like Fig. 10A and 10BAs shown, object 114 from object layer 900 may include a first portion and a second portion separated by radial boundary 702. A first hatch vector 500 passing through the first portion of object 114 may have a first orientation, such as a first direction component and / or a magnitude component. For example, a first hatch vector 500 passing through the first portion of object 114 may have a first slope. A second hatch vector 500 passing through the second portion of object 114 may have a second orientation, such as a second direction component and / or a magnitude component. For example, a second hatch vector 500 passing through the second portion of object 114 may have a second slope. The orientation of the first hatch vector 500 passing through the first portion of object 114 may be different from the orientation of the second hatch vector 500 passing through the second portion of object 114. For example, the first hatch vector 500 and / or the second hatch vector 500 may differ in direction component, magnitude component, and / or slope.

[0116] Fig. 10C and 10D An object 114 from the object layer 900 is shown separately, and the object layer 900 includes a semi-annular boundary 706 that intersects the corresponding object 114. The object 114 from the object layer 900 may additionally or alternatively include annular boundary 704. Fig. 10C The object 114 shown in FIG. 1 may correspond to Fig. 9B The ninth object 922 shown in . Fig. 10D The object 114 shown in FIG. 1 may correspond to Fig. 9B The tenth object 924 shown in FIG. Fig. 10C and 10D As shown in the reference Fig. 9B In some embodiments, the object 114 may be irradiated according to a shadow vector 500 that is oriented substantially circularly or semi-circularly relative to the normal point 206. For example, the shadow vector 500 may pass through an arc length relative to the normal point. Fig. 10A and 10B The substantially circular or semi-circular orientation of hatch vectors 500 shown in is illustrated by each hatch vector 500 being oriented co-circularly with each semi-circular boundary 706. The semi-circular boundary 706 and hatch vectors 500 may additionally or alternatively be oriented co-circularly with respect to a point (eg, normal point 206).

[0117] like Fig. 10C and 10DAs shown, an object 114 from the object layer 900 may include a first portion and a second portion separated by a semi-circular boundary 706. A first hatch vector 500 passing through the first portion of the object 114 may have a first orientation, such as a first direction component and / or a magnitude component. For example, a first hatch vector 500 passing through the first portion of the object 114 may have a first slope and / or a radius of curvature. A second hatch vector 500 passing through the second portion of the object 114 may have a second orientation, such as a second direction component and / or a magnitude component. For example, a second hatch vector 500 passing through the second portion of the object 114 may have a second slope and / or a radius of curvature. The orientation of the first hatch vector 500 passing through the first portion of the object 114 may be different from the orientation of the second hatch vector 500 passing through the second portion of the object 114. For example, the first hatch vector 500 and / or the second hatch vector 500 may differ in direction component, magnitude component, radius of curvature, and / or slope.

[0118] Reference again Fig. 10A and 10B , and still refer to Fig. 10C and 10D In some embodiments, each object 114 in the object layer 900 may be irradiated according to each shadow vector 500, and each shadow vector 500 may have a different orientation between each object 114. For example, the first object 114 (e.g. Fig. 10A At least a portion of the first object 114 (e.g., shown in FIG. 1 ) may be irradiated according to a first hatch vector 500 having a first orientation (e.g., a first direction component and / or a magnitude component). For example, the first hatch vector 500 passing through at least a portion of the first object 114 may have a first slope and / or radius of curvature. The second object 114 (e.g., Fig. 10B At least a portion of the first object 114 (shown in FIG. 1 ) may be irradiated according to a second shadow vector 500 having a second orientation (e.g., a second direction component and / or magnitude component). For example, the second shadow vector 500 passing through at least a portion of the second object 114 may have a second slope and / or radius of curvature. The orientation of the first shadow vector 500 passing through at least a portion of the first object 114 may be different from the orientation of the second shadow vector 500 passing through at least a portion of the second object 114. For example, the first shadow vector 500 and / or the second shadow vector 500 may differ in direction component, magnitude component, and / or slope. In some embodiments, at least a portion of the first object may be irradiated according to a shadow vector 500 (e.g., a second direction component and / or magnitude component) oriented substantially radially relative to the normal point 206. Fig. 10A and 10B ) is irradiated, and at least a portion of the second object can be irradiated according to a shadow vector 500 ( Fig. 10C and 10D ) was irradiated.

[0119] Reference now Figures 10E-10H , a further exemplary slice of object 114 from object layer 900 is shown. Fig.10E The object 114 shown in FIG. 1 may correspond to Fig. 9B An eleventh object 926 is shown in FIG. Fig.10F The object 114 shown in FIG. 1 may correspond to Fig. 9B The twelfth object 928 is shown in FIG. Figure 10G The object 114 shown in FIG. 1 may correspond to Fig. 9B A thirteenth object 930 is shown in FIG. Fig. 10H The object 114 shown in FIG. 1 may correspond to Fig. 9B The fourteenth object 932 is shown in FIG. Figures 10E-10H As shown, reference Fig. 9B In some embodiments, the objects 114 may be irradiated according to a plurality of hatch vectors 500 oriented substantially parallel to one another. For example, a plurality of hatch vectors 500 corresponding to the respective objects 114 may be oriented substantially parallel to an orientation line 1000 that intersects the respective objects 114. In some embodiments, the orientation line 1000 may correspond to the radial boundary 702. The substantially parallel hatch vectors 500 corresponding to the respective objects 114 may include one or more hatch vectors 500 adjacent to the orientation line 1000 and / or one or more hatch vectors adjacent to the orientation line 1000. Figures 10E-10H The substantially parallel orientation of the hatch vectors 500 shown in is illustrated by the hatch vectors 500 being oriented substantially parallel to an orientation line 1000 that intersects the corresponding object 114 .

[0120] like Figures 10E-10H As shown, an object 114 from the object layer 900 may include a first portion and a second portion intersected by an orientation line 1000 (e.g., radial boundary 702). The orientation line 1000 corresponding to the object may be determined based at least in part on a radial line intersecting a middle portion of the object. The orientation line may extend from a point (e.g., normal point 206). The orientation line 1000 may be used to determine all or part of the shadow vectors 500 corresponding to the object 114 from the object layer 900. In some embodiments, the orientation line 1000 may be different between corresponding objects in a plurality of objects 114 from the object layer 900. Each object 114 in the object layer 900 may be irradiated according to a corresponding plurality of shadow vectors 500 having different orientations between the respective objects 114. For example, the shadow vectors 500 corresponding to the respective objects 114 may have an orientation parallel to the orientation line 1000, which is different between the respective objects 114.

[0121] For example, the first object 114 (eg Fig.10EAt least a portion of the first object 114 (e.g., shown in FIG. 1 ) may be irradiated according to a first hatch vector 500 having a first orientation (e.g., a first direction component and / or a magnitude component). The first hatch vector 500 passing through at least a portion of the first object 114 may be parallel to the first orientation line 1000. The second object 114 (e.g., Fig.10F At least a portion of the first object 114 (shown in FIG. 1 ) can be irradiated according to a second hatch vector 500 having a second orientation (e.g., a second direction component and / or a magnitude component). The second hatch vector 500 passing through at least a portion of the second object 114 can be parallel to the second orientation line 1000. The orientation of the first hatch vector 500 passing through at least a portion of the first object 114 can be different from the orientation of the second hatch vector 500 passing through at least a portion of the second object 114. For example, the first hatch vector 500 and / or the second hatch vector 500 can differ in direction component, magnitude component, and / or slope.

[0122] refer to Fig.10E and 10F In some embodiments, the scan vectors 400 that respectively define the hatch vector 500 may be oriented in a common direction. For example, the scan vector 400 may be oriented away from the normal point 206, e.g., have at least one directional component oriented away from the normal point 206. Additionally or alternatively, the scan vectors 400 that respectively define the hatch vector 500 may be oriented counter-current to the airflow direction 800, e.g., have at least one directional component oriented counter-current to the airflow direction 800. The hatch vector 500 defined by the scan vector 400 may additionally or alternatively be oriented away from the normal point 206, e.g., have at least one directional component oriented away from the normal point 206. In some embodiments, the scan vectors 400 that respectively define the hatch vector 500 and the hatch vector 500 defined by such scan vector 400 may both be oriented away from the normal point 206, e.g., have at least one respective directional component oriented away from the normal point 206.

[0123] refer to Figure 10G and 10H, in some embodiments, the scan vectors 400 that respectively define the hatch vectors 500 may be oriented in alternating directions. With respect to the orientation of the scan vectors 400 in alternating directions, in some embodiments, the scan vectors 400 oriented in one or both of the alternating directions may be oriented away from the normal point 206, e.g., have at least one directional component oriented away from the normal point 206. Additionally or alternatively, with respect to the orientation of the scan vectors 400 in alternating directions, in some embodiments, the scan vectors 400 oriented in one or both of the alternating directions may be oriented counter-flow to the airflow direction 800, e.g., have at least one directional component oriented counter-flow to the airflow direction 800. Additionally or alternatively, the hatch vectors 500 defined by the respective scan vectors 400 may be oriented away from the normal point 206, e.g., have at least one directional component oriented away from the normal point 206. In some embodiments, with respect to scan vectors 400 being oriented in alternating directions, scan vectors 400 that respectively define shadow vectors 500 and shadow vectors 500 defined by such scan vectors 400 may both be oriented away from the normal point 206 , e.g., have at least one respective directional component oriented away from the normal point 206 .

[0124] Reference now Fig.11 In some embodiments, the size and / or ellipticity of the beam spot 300 may increase as the distance from the normal point 206 increases. In some embodiments, the plurality of scan vectors 400 may be radially oriented relative to a point (e.g., the normal point 206). The plurality of scan vectors 400 may define a hatch vector 500 that is oriented substantially annularly or semi-annularly relative to the point (e.g., the normal point 206). The plurality of beam paths 402 may be irradiated according to the scan vectors 400. The orientation of the scan vectors 400 and the corresponding position of the beam path 402 may be determined at least in part based on the size and / or ellipticity of the beam spot 300 at one or more positions along the beam path 402 (e.g., the size and / or ellipticity of the beam spot 300 at a radially inward position along the beam path 402, the size and / or ellipticity of the beam spot 300 at a radially outward position along the beam path 402), and / or the difference between the size and / or ellipticity of the beam spot 300 at a radially inward position and a radially outward position along the beam path 402. For example, the direction components and / or amplitude components of the plurality of scan vectors 400 may be determined at least in part based on such size and / or ellipticity of the beam spot 300 , and / or such difference in the size and / or ellipticity of the beam spot 300 .

[0125] In some embodiments, the shadow vector 500 defined by the plurality of radially oriented scan vectors 400 may have an orientation determined at least in part based on a size and / or ellipticity of the beam spot 300 corresponding to one or more of the plurality of scan vectors 400 at one or more locations along the corresponding beam path 402 (e.g., a size and / or ellipticity of the beam spot 300 at a radially inward location along the beam path 402, a size and / or ellipticity of the beam spot 300 at a radially outward location along the beam path 402), and / or a difference between the size and / or ellipticity of the beam spot 300 at a radially inward location and a radially outward location along the beam path 402. For example, the shadow vector 500 may have at least one direction component and / or at least one magnitude component determined at least in part based on such a size and / or ellipticity of the beam spot 300, and / or such a difference in the size and / or ellipticity of the beam spot 300. Additionally or alternatively, the hatch vector 500 may have a radius of curvature determined at least in part based on such size and / or ellipticity of the beam spot 300 , and / or such difference in size and / or ellipticity of the beam spot 300 .

[0126] Still reference Figure 6-11 In some embodiments, one or more irradiation parameters may be determined at least in part based on the scan segment 600 and / or the irradiation vector corresponding to such a scan segment. For example, one or more irradiation parameters may be determined at least in part based on the position, configuration, and / or orientation of the scan segment 600. Additionally or alternatively, one or more irradiation parameters may be determined at least in part based on the orientation of the irradiation vector (e.g., the scan vector 400, the hatch vector 500, and / or the profile vector 550). For example, one or more irradiation parameters may be determined at least in part based on the direction component and / or the magnitude component of the irradiation vector (e.g., the scan vector 400, the hatch vector 500, and / or the profile vector 550). Further additionally or alternatively, one or more scan segments 600 and / or one or more irradiation vectors (e.g., the scan vector 400, the hatch vector 500, and / or the profile vector 550) may be determined at least in part based on one or more irradiation parameters. For example, one or more scan segments 600 may be determined at least in part based on one or more beam parameters and / or one or more scan parameters. Additionally or alternatively, one or more irradiation vectors may be determined based at least in part on one or more beam parameters and / or one or more scan parameters.One or more irradiation parameters, scan segments, and / or irradiation vectors may be determined using the control system 104 .

[0127] Now turn to Fig.12, an exemplary control system 104 will be described. In some embodiments, the control system 104 can be configured to output one or more control commands associated with the additive manufacturing machine 102. The control commands may include irradiation control commands. The irradiation control commands may be configured to control one or more irradiation parameters, including one or more beam parameters and / or one or more scanning parameters. For example, one or more irradiation parameters may be controlled based at least in part on one or more model inputs. The irradiation control commands may be configured to impart a desired melting and / or sintering behavior. In some embodiments, the irradiation control commands may be based at least in part on the location of the object 114 or a portion of the object 114 on the build plane 130, the angle of incidence θ of the energy beam 200, and the orientation of the irradiation parameters. i and / or the ellipse angle θ of the beam spot 300 e , and / or based at least in part on the melting and / or sintering behavior and the position on the building plane 130, the incident angle θ of the energy beam 200 i and / or the ellipse angle θ of the beam spot 300 e The relationship between.

[0128] like Fig.12 As shown, the exemplary control system 104 includes an irradiation controller 1200, which is configured to control one or more irradiation parameters associated with the additive manufacturing machine 102. The irradiation controller 1200 can be communicatively coupled to the additive manufacturing machine 102. In some embodiments, the irradiation controller 1200 can be communicatively coupled to one or more components of the additive manufacturing machine 102 (e.g., the energy beam system 134 and / or the monitoring system 162). The irradiation controller 1200 can also be communicatively coupled to the management system 106 and / or the user interface 108.

[0129] The irradiation controller 1200 may include one or more computing devices 1202, which may be located locally or remotely relative to the additive manufacturing machine 102 and / or the calibration system 250. The one or more computing devices 1202 may include one or more processors 1204 and one or more memory devices 1206. The one or more processors 1204 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 1206 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 1206.

[0130] As used herein, the terms "processor" and "computer" and related terms, such as "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 are used interchangeably herein. The memory device 1206 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.

[0131] As used herein, the term "non-transitory computer-readable medium" is intended to represent any tangible computer-based device implemented in any method or technology for short-term and long-term information storage, such as 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 storage devices and / or memory devices. Such instructions, when executed by a processor, 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, CD-ROMs, DVDs, and any other digital resources, such as networks or the Internet, and digital means yet to be developed, with the sole exception of transient, propagating signals.

[0132] One or more memory devices 1206 may store information accessible by one or more processors 1204, including machine executable instructions 1208 executable by one or more processors 1204. Instructions 1208 may include any set of instructions that, when executed by one or more processors 1204, cause one or more processors 1204 to perform operations, including additive manufacturing operations, such as controlling and / or monitoring a build operation. In some embodiments, instructions 1208 may be configured to cause one or more processors 1204 to perform operations for which irradiation controller 1200 and / or one or more computing devices 1202 are configured, such as controlling and / or monitoring an additive manufacturing operation.

[0133] The memory device 1206 may store data 1210 accessible by the one or more processors 1204. The data 1210 may include current or real-time data 1210, past data 1210, or a combination thereof. The data 1210 may be stored in a database 1212. As an example, the data 1210 may include data 1210 associated with or generated by the additive manufacturing system 100 and / or the additive manufacturing machine 102, including data 1210 associated with or generated by the irradiation controller 1200, the additive manufacturing machine 102, the energy beam system 134, the monitoring system 162, the management system 106, the user interface 108, and / or the computing device 1202. Such data 1210 may include operational data 1214 and / or object data 1216. Such operational data 1214 may include data 1210 associated with operating the additive manufacturing machine 102, such as control commands for operating the additive manufacturing machine 102, including model inputs and / or irradiation control commands for the energy beam system 134, etc. Such object data 1216 may include data 1210 associated with one or more objects 114 to be additively manufactured, such as build files, object slice data, etc. Data 1210 may also include other data sets, parameters, outputs, information associated with the additive manufacturing system 100 and / or the additive manufacturing machine 102.

[0134] The one or more computing devices 1202 may also include a communication interface 1218 that can be used to communicate with a communication network 1220 via a wired or wireless communication line 1222. The communication interface 1218 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 1218 may allow the computing device 1202 to communicate with various nodes on the communication network 1220 (e.g., nodes associated with the additive manufacturing machine 102, the energy beam system 134, the monitoring system 162, the management system 106, and / or the user interface 108). The communication network 1220 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 1220 for transmitting messages to and / or transmitting messages from the irradiation controller 1200 across the communication line 1222. The communication links 1222 of the communication network 1220 may include a data bus or a combination of wired and / or wireless communication links.

[0135] The communication interface 1218 may allow the computing device 1202 to communicate with various components of the additive manufacturing system 100 and / or the additive manufacturing machine 102, including the energy beam system 134 and / or the monitoring system 162, which are communicatively coupled to the communication interface 1218 and / or to each other. The communication interface 1218 may additionally or alternatively allow the computing device 1202 to communicate with the management system 106 and / or the user interface 108. The management system 106 may include a server 1224 and / or a data warehouse 1226. As an example, at least a portion of the data 1210 may be stored in the data warehouse 1226, and the server 1224 may be configured to transmit the data 1210 from the data warehouse 1226 to the computing device 1202, and / or receive the data 1210 from the computing device 1202 and store the received data 1210 in the data warehouse 1226 for further purposes. The server 1224 and / or the data repository 1226 may be implemented as part of the control system 104 and / or as part of the management system 106 .

[0136] The irradiation controller 1200 may include one or more control modules 1228, which may utilize data 1210 including a database 1212 and / or other data sets, parameters, outputs, information associated with the additive manufacturing system 100, such as those associated with the additive manufacturing machine 102, the user interface 108, and / or the management system 106. One or more control modules 1228 may additionally or alternatively utilize data 210 from a data warehouse 1226, which may be transmitted from a server 1224 to the irradiation controller 1200. The control system 104 may be configured to perform operations such as additive manufacturing calibration and / or control operations. For example, the control system 104 may include one or more control modules 1228 to perform control operations such as those currently disclosed herein. In some embodiments, the irradiation controller 1200 may include one or more irradiation parameter control modules. Such an irradiation parameter control module may be configured to determine one or more irradiation control commands, for example, based at least in part on one or more model inputs.

[0137] Reference now Fig.13A and 13B, an exemplary control module 1228 will be described. The exemplary control module 1228 may include one or more irradiation control models 1300. The one or more irradiation control models 1300 may be configured to control one or more beam parameters, for example, based at least in part on one or more model inputs 1302 and / or one or more irradiation control commands 1304. The one or more irradiation control commands 1304 may include commands configured to change one or more operating parameters of the additive manufacturing machine 102. As shown, the exemplary irradiation parameter control module 1300 may be configured to receive one or more model inputs 1302. As shown in FIG. Fig.13A As shown, exemplary model inputs 1302 include operational data 1214 and / or object data 1216. One or more irradiation control commands 1304 may be determined based at least in part on the irradiation control model 1300. One or more irradiation control commands 1304 determined by the irradiation control model 1300 may be based at least in part on the one or more model inputs 1302. Exemplary irradiation control commands 1304 may include control commands related to irradiation parameters 1305 (including beam parameters 1306 and / or scan parameters 1308, scan segment parameters 1310, and / or irradiation vector parameters 1312).

[0138] Exemplary beam parameters 1306 include beam power or intensity, spot size, focal point, beam distribution (e.g., intensity distribution 202, power density distribution 404), etc. Beam power parameters may include one or more parameters related to a beam generating device of the energy beam system 134, including one or more parameters configured to impart a desired beam power, beam intensity, etc. Spot size parameters may include one or more parameters related to one or more optical devices of the energy beam system 134, including one or more parameters configured to impart a desired spot shape, spot cross-section, etc. Scanning speed parameters may include one or more parameters related to a scanner device of the energy beam system 134, including one or more parameters related to position, orientation, and / or movement speed, the one or more parameters configured to impart a desired beam velocity, shadow velocity, profile velocity, etc. Focus parameters may include one or more parameters related to a beam focusing device of the energy beam system 134, including one or more parameters configured to impart a desired focus, focus offset, etc. The beam distribution parameters may include one or more parameters related to the beam generating device and / or the optical device of the energy beam system 134, including one or more parameters configured to impart a desired energy density distribution 302 and / or power density distribution 404, etc.

[0139] Exemplary scanning parameters 1308 include beam offset, beam path, scanning speed, etc. The beam offset parameters may include one or more parameters related to the scanner device of the energy beam system 134, including one or more parameters related to the position, orientation, and / or movement speed, which are configured to impart a desired shadow line offset or overlap distance, contour offset or overlap distance, etc. The beam path parameters may include one or more parameters related to the scanner device of the energy beam system 134, including one or more parameters related to the position and / or orientation, which are configured to impart one or more desired irradiation vectors (e.g., scan vector 400, shadow line vector 500, and / or contour vector 550), and / or a desired scan length of such scan vector 400, a shadow line length of such shadow line vector 500, and / or a contour length of such contour vector 550, etc. The scanning speed parameters may include one or more parameters related to the scanner device of the energy beam system 134, including one or more parameters related to the movement of the scanner device, which one or more parameters are constructed to impart a desired scanning speed, including desired amplitude components of one or more irradiation vectors, such as amplitude components of one or more scan vectors 400, one or more shadow vectors 500 and / or one or more contour vectors 550.

[0140] Exemplary scan segment parameters 1310 may include parameters related to determining the configuration, orientation, size, shape, and / or position of one or more scan segments 600 (e.g., the configuration, orientation, size, shape, and / or position of one or more radial segments 602, annular segments 604, and / or semi-annular segments 606). Scan segment parameters 1310 may include one or more parameters related to determining the configuration, orientation, size, shape, and / or position of one or more scan segments 600, for example, based at least in part on object data 1216 (e.g., a CAD file of an object 114 to be additively manufactured), and / or a build file or object properties corresponding to and / or determined using object data 1216. Scan segment parameters 1310 may include parameters related to dividing build plane 130 into a plurality of scan segments 600 and / or dividing one or more objects 114 from object layer 900 into a plurality of scan segments 600. In some embodiments, one or more scan segment parameters 1310 may be used to determine one or more beam parameters 1306 and / or one or more scan parameters 1308. For example, one or more scan segment parameters 1310 can be configured to provide desired melting and / or sintering behavior produced by scanning the energy beam 200 across the powder bed 136 based on one or more scan segments 600 and / or corresponding beam parameters 1306 and / or scan parameters 1308 determined at least in part based on the one or more scan segment parameters 1310.

[0141] Exemplary irradiation vector parameters 1312 may include parameters related to determining an orientation of one or more irradiation vectors (e.g., an orientation of scan vector 400, hatch vector 500, and / or contour vector 550). Irradiation vector parameters 1312 may include parameters related to determining a directional component and / or a magnitude component of one or more irradiation vectors. For example, one or more irradiation vector parameters 1312 may be based at least in part on object data 1216 (e.g., a CAD file of object 114 to be additively manufactured), and / or a build file or object properties corresponding to object data 1216 and / or determined using object data 1216. Irradiation vector parameters 1312 may include parameters related to determining one or more irradiation vectors (e.g., one or more scan vectors 400, hatch vectors 500, and / or contour vectors 550) corresponding to one or more locations on build plane 130. Additionally or alternatively, the irradiation vector parameters 1312 may include parameters related to determining one or more irradiation vectors corresponding to one or more object layers 900, one or more objects 114 from the object layer 900, and / or one or more scan segments 600 corresponding to such objects 114. In some embodiments, the one or more irradiation vector parameters 1312 may be used to determine one or more beam parameters 1306 and / or one or more scan parameters 1308. For example, the one or more irradiation vector parameters 1312 may be configured to provide a desired melting and / or sintering behavior resulting from scanning the energy beam 200 across the powder bed 136 based on one or more irradiation vectors (e.g., one or more scan vectors 400, hatch vectors 500, and / or contour vectors 550) determined at least in part based on the one or more irradiation vector parameters 1312 and / or the beam parameters 1306 and / or scan parameters 1308 corresponding thereto.

[0142] The irradiation control model 1300 may use any number of model inputs 1302, including current or real-time data 1210, past data 1210, or a combination thereof. One or more model inputs 1302 may include data 1210 associated with or generated by the additive manufacturing system 100, including data 1210 associated with or generated by the additive manufacturing machine 102. Such data 1210 associated with the additive manufacturing system 100 may additionally or alternatively include data 1210 associated with or generated by the control system 104, the computing device 1202, and / or the irradiation control model 1300. The model inputs 1302 may include data 1210 associated with, including, or generated by the control system 104, data 1210 associated with, including, or generated by the computing device 1202, and / or data 1210 associated with, including, or generated by the irradiation control model 1300. As Fig.13AAs shown, exemplary model inputs 1302 may include scanner position, build plane height, and / or beam exposure signals (e.g., whether the energy beam generating device is currently emitting an energy beam). Fig. 13B As shown, exemplary model inputs 1302 may additionally or alternatively include user inputs; object specifications (e.g., mass specifications, material specifications, composition specifications, etc.); operational data 1214 including, for example, operating parameters (e.g., additive manufacturing machine parameters, etc.) and / or operating conditions (e.g., temperature, gas flow parameters, etc.); object data 1216 (e.g., data related to a data file or build file of an object 114 that has been additively manufactured or partially additively manufactured); and / or quality data (e.g., measured and / or calculated military properties of the object 114, melt pool monitoring parameters, etc.). Model inputs 1302 themselves may be considered data 1210, which may be stored in database 1212 and / or data warehouse 1226 and may be included in subsequent model inputs 1302. Model inputs 1302 may additionally include other data sets, parameters, outputs, information, etc. shown and / or described herein.

[0143] The irradiation control commands 1304 can be configured to adjust the irradiation parameters 1305 according to one or more irradiation settings 1314. The determined irradiation settings 1314 can include one or more values, including current or real-time values, averages, maximum values, minimum values, and / or ranges. The determined irradiation settings 1314 can additionally include one or more statistical parameters, such as distribution values ​​(e.g., variance, standard deviation) and / or regression coefficient values. The values ​​and / or schedule of one or more irradiation settings 1314 can be derived or determined from one or more model inputs 1302 and / or the irradiation control model 1300.

[0144] The irradiation control model 1300 may be configured to determine whether the irradiation parameters 1305 (e.g., beam parameters 1306, scan parameters 1308, scan segment parameters 1310, and / or irradiation vector parameters 1312) differ from one or more irradiation settings 1314 by, for example, at least a threshold level. When the irradiation parameters 1305 differ from the irradiation settings 1314 by, for example, at least a threshold level, the irradiation control model 1300 may determine an irradiation control command 1304 configured to adjust the irradiation parameters 1305 toward the irradiation settings 1314. In some embodiments, the irradiation control model 1300 may perform a comparison operation. The comparison operation may include one or more operations configured to compare the determined irradiation parameters 1305 (e.g., beam parameters 1306, scan parameters 1308, scan segment parameters 1310, and / or irradiation vector parameters 1312) to one or more irradiation settings 1314. The comparison operation may include a PID controller or any other suitable controller. The comparison operation may utilize linear or nonlinear control algorithms, as well as any analysis techniques, including frequency domain and / or time domain state space representation techniques. Additionally or alternatively, when the irradiation parameters 1305 differ from the irradiation settings 1314 by, for example, at least a threshold level, the irradiation control model 1300 may determine an irradiation control command 1304 configured to adjust one or more scan segment parameters 1310 and / or one or more irradiation vector parameters 1312. Such adjustments to the one or more scan segment parameters 1310 and / or one or more irradiation vector parameters 1312 may be configured to impart a change to one or more irradiation parameters 1305 (e.g., one or more beam parameters 1306, one or more scan parameters 1308, one or more scan segment parameters 1310, and / or one or more irradiation vector parameters 1312), for example, to reduce the difference between such one or more irradiation parameters and the corresponding one or more irradiation settings 1314.

[0145] In some embodiments, one or more irradiation control commands 1304 may be determined prior to irradiating a layer of the powder bed 136. For example, the beam parameters 1306 may be determined prior to starting additive manufacturing of the object 114 and / or prior to irradiating a particular layer of the object 114. Additionally or alternatively, one or more irradiation control commands 1304 may be determined in real time (e.g., while the energy beam 200 irradiates the corresponding layer of the object). Such real-time determined irradiation control commands 1304 may be based at least in part on one or more model inputs 1302 determined during the time the energy beam irradiates the corresponding layer of the object. Additionally or alternatively, such irradiation control commands 1304 may be executed, for example, by the energy beam system 134, during the time the energy beam irradiates the corresponding layer of the object. For example, the irradiation control commands 1304 may be determined at least in part based on one or more model inputs 1302 determined during the time the energy beam irradiates the corresponding layer of the object, and the irradiation control commands 1304 may be executed during the time the energy beam irradiates the corresponding layer of the object.

[0146] Exemplary irradiation control commands 1304 that may be determined prior to irradiating a layer of the powder bed 136 and / or prior to initiating additive manufacturing of the object 114 include irradiation control commands 1304 related to scan parameters 1308, such as beam offset parameters, beam path parameters, or scan speed parameters, and combinations of these parameters. Additionally or alternatively, exemplary irradiation control commands 1304 that may be determined prior to irradiating a layer of the powder bed 136 and / or prior to initiating additive manufacturing of the object 114 include scan segment parameters 1310 and / or irradiation vector parameters 1312. However, in some embodiments, the irradiation control commands 1304 for any one or more of the scan parameters 1308, scan segment parameters 1310, and / or irradiation vector parameters 1312 may be determined in real time, such as additionally or alternatively predetermining such scan parameters 1308, scan segment parameters 1310, and / or irradiation vector parameters 1312.

[0147] Exemplary irradiation control commands 1304 that may be determined in real time include irradiation control commands 1304 related to beam parameters 1306, such as irradiation control commands 1304 related to beam power parameters, spot size parameters, focus parameters, beam distribution parameters, and combinations of these parameters. However, in some embodiments, the irradiation control commands 1304 for any one or more of the beam parameters 1306 may be determined prior to irradiating a layer of the powder bed 136 and / or prior to initiating additive manufacturing of the object 114, such as in addition to or in lieu of determining such scan parameters 1308 in real time.

[0148] In some embodiments, the irradiation control model 1300 can utilize one or more processing conditions 1316. Exemplary processing conditions 1316 can include data 1210 associated with or including one or more operating modes of the additive manufacturing machine 102, as well as sensed, measured, calculated, or predicted conditions inside or outside the additive manufacturing machine 102 that can affect its operation. Such internal conditions include temperature, pressure, heat transfer rate, gas flow rate, vibration level, powder type, etc. Such external conditions include ambient temperature, pressure, humidity, etc. The irradiation control model 1300 can additionally or alternatively include one or more irradiation settings 1314, which can include setting values ​​and / or setting schedules for one or more irradiation parameters 1305 (e.g., beam parameters 1306, scan parameters 1308, scan segment parameters 1310, and / or irradiation vector parameters 1312).

[0149] refer to Fig.13A In some embodiments, the exemplary control module 1228 may include an irradiation control model 1300, which includes one or more power density factors 1318, one or more irradiation vector factors 1320, and / or one or more scan segment factors 1322. The irradiation control model 1300 may be based at least in part on such one or more power density factors 1318, irradiation vector factors 1320, and / or scan segment factors 1322. The irradiation control model 1300 may be configured to determine one or more irradiation control commands 1304 based at least in part on the one or more power density factors 1318, irradiation vector factors 1320, and / or scan segment factors 1322. Such power density factors 1318 may include an incident angle θi of the energy beam 200 and / or an elliptical angle θ of the beam spot 300. e. Irradiation control model 1300 can be configured to determine one or more power density factors 1318 based at least in part on one or more model inputs 1302. One or more model inputs 1302 can include operational data 1214, such as scanner position, build plane height, and / or beam exposure signal (e.g., a signal indicating that the beam generating device is emitting an energy beam). One or more model inputs 1302 can additionally or alternatively include object data 1216, such as data associated with a build file and / or object properties (e.g., material composition and / or desired physical properties). In some embodiments, irradiation control model 1300 can be configured to output one or more irradiation control commands 1304 based at least in part on one or more model inputs 1302 related to operational data 1214 (e.g., scanner position, build plane height, and beam exposure signal). One or more irradiation control commands 1304 can include one or more beam parameters 1306, such as one or more parameters related to beam power, spot size, scanning speed, and / or focus. The one or more irradiation control commands 1304 may additionally or alternatively include one or more scan parameters 1308, such as a beam offset, a beam path, and / or a scan speed. Additionally or alternatively, the one or more irradiation control commands 1304 may include one or more scan segment parameters 1310, such as one or more scan segments 600 corresponding to one or more objects 114 in one or more object layers 900. The one or more irradiation control commands 1304 may additionally or alternatively include one or more irradiation vector parameters 1312, such as an orientation of one or more scan vectors 400, hatch vectors 500, and / or profile vectors 550, such as a directional component and / or a magnitude component thereof.

[0150] The irradiation control model 1300 may be configured to determine one or more irradiation control commands 1304 configured to adjust the energy density and / or power density of the energy beam 200 based at least in part on one or more power density factors 1318. For example, the irradiation control model 1300 may determine irradiation control commands 1304 related to beam power parameters, spot size parameters, scanning speed parameters, and / or focus parameters. Such irradiation control commands 1304 may be output to the energy beam system 134, for example, via one or more energy beam system control commands 1324. The irradiation control commands 1304 and / or the energy beam system control commands 1324 may implement adjustments to the energy density and / or power density of the energy beam 200.

[0151] In some embodiments, the irradiation control model 1300 can additionally or alternatively be configured to determine one or more irradiation control commands 1304 based at least in part on one or more irradiation vector factors 1320. Such irradiation vector factors 1320 may include one or more factors related to an irradiation vector (e.g., scan vector 400, hatch vector 500, and / or profile vector 550). The irradiation control model 1300 can be configured to determine one or more irradiation vector factors 1320 based at least in part on one or more model inputs 1302 (e.g., orientation and / or magnitude of an irradiation vector (e.g., scan vector 400, hatch vector 500, and / or profile vector 550)), and / or whether one or more model inputs 1302 and / or one or more irradiation control commands 1304 correspond to an irradiation vector (e.g., scan vector 400, hatch vector 500, and / or profile vector 550). In some embodiments, the irradiation control model 1300 can be configured to output one or more irradiation control commands 1304 based at least in part on one or more model inputs 1302 related to an irradiation vector (e.g., scan vector 400, hatch vector 500, and / or profile vector 550). Additionally or alternatively, the irradiation control model 1300 can be configured to determine the irradiation control command 1304 based at least in part on whether the one or more model inputs 1302 correspond to an irradiation vector (e.g., scan vector 400, hatch vector 500, and / or profile vector 550). The one or more irradiation control commands 1304 can include one or more scan parameters 1308, such as one or more parameters related to beam power, spot size, scan speed, and / or focus.

[0152] In some embodiments, the irradiation control model 1300 may additionally or alternatively be configured to determine one or more irradiation control commands 1304 based at least in part on one or more scan segment factors 1322. Such scan segment factors 1322 may include one or more factors related to the configuration, orientation, and / or position of one or more objects 114 in the object layer 900, for example, relative to the normal point 206 and / or relative to the gas flow direction 800. The irradiation control model 1300 may be configured to determine one or more scan segment factors 1322 based at least in part on one or more model inputs 1302 (e.g., the operation data 1214 and / or the object data 1216). For example, the one or more scan segment factors 1322 may be determined at least in part based on a CAD file of the object 114 to be additively manufactured, and / or a build file or object properties corresponding to the object data 1216 and / or determined using the object data 1216. In some embodiments, the irradiation control model 1300 may be configured to output one or more irradiation control commands 1304 based at least in part on one or more scan segment factors 1322.

[0153] In some embodiments, the irradiation control model 1300 can be additionally or alternatively configured to determine one or more irradiation control commands 1304 that are related to one or more scan segment parameters 1310 and / or one or more irradiation vector parameters 1312. Exemplary scan segment parameters 1310 may include one or more parameters related to dividing the build plane 130 and / or one or more object layers 900 into a plurality of scan segments 600 (e.g., one or more radial segments 602, one or more annular segments 604, and / or one or more semi-annular segments 606). Such scan segment parameters 1310 may include parameters such as the configuration, arrangement, orientation, size, shape, etc. of the one or more scan segments 600. The irradiation control commands 1304 related to the scan segment parameters 1310 may be configured to determine and / or change the scan segment parameters 1310, such as the configuration, arrangement, orientation, size, shape, etc. of the one or more scan segments 600. In some embodiments, construction plane 130 and / or one or more object layers 900 can be divided into multiple scan segments 600 based at least in part on one or more scan segment parameters 1310. One or more beam parameters 1306 and / or one or more scan parameters 1308 can be determined based at least in part on one or more scan segment parameters 1310. Additionally or alternatively, one or more control commands related to beam parameters 1306 and / or scan parameters 1308 can be determined based at least in part on scan segment parameters 1310 and / or control commands related to scan segment parameters 1310.

[0154] Exemplary irradiation vector parameters 1312 may include one or more parameters related to one or more irradiation vectors (e.g., one or more scan vectors 400, one or more hatch vectors 500, and / or one or more contour vectors 550). For example, the irradiation control commands 1304 may be configured to control the orientation, e.g., direction component and / or magnitude component, of an irradiation vector (such as a scan vector 400, hatch vector 500, and / or contour vector 550). The one or more irradiation vector parameters 1312 may include one or more parameters related to assigning one or more irradiation vectors (e.g., scan vector 400, hatch vector 500, and / or contour vector 550) to one or more scan segments 600. Such irradiation vector parameters 1312 may include direction component and / or magnitude component of one or more irradiation vectors (e.g., scan vector 400, hatch vector 500, and / or contour vector 550). In some embodiments, one or more irradiation vectors (e.g., one or more scan vectors 400, one or more hatch vectors 500, and / or one or more contour vectors 550) may be assigned to a corresponding one of the plurality of scan segments 600 based at least in part on the one or more irradiation vector parameters 1312. One or more beam parameters 1306 and / or one or more scan parameters 1308 may be determined based at least in part on the one or more irradiation vector parameters 1312. Additionally or alternatively, one or more control commands related to the beam parameters 1306 and / or the scan parameters 1308 may be determined based at least in part on the irradiation vector parameters 1312 and / or control commands related to the irradiation vector parameters 1312.

[0155] In some embodiments, the orientation (such as a direction component and / or a magnitude component) of an irradiation vector (e.g., scan vector 400, hatch vector 500, and / or profile vector 550) can be determined based at least in part on one or more beam parameters 1306 and / or one or more scan parameters 1308. The orientation of the irradiation vector (e.g., scan vector 400, hatch vector 500, and / or profile vector 550) can be implemented by one or more irradiation control commands 1304 corresponding to one or more beam parameters 1306 and / or one or more scan parameters 1308. The irradiation control commands 1304 can be configured to be implemented specifically and / or exclusively during one or more periods corresponding to the scan vector 400, hatch vector 500, and / or profile vector 550. For example, the irradiation control commands 1304 can be based at least in part on whether the energy beam 200 is propagating along a scan vector 400 corresponding to the hatch vector 500 and / or a scan vector 400 corresponding to the profile vector 550. In some embodiments, one or more irradiation control commands 1304 relating to one or more beam parameters 1306 and / or one or more scan parameters 1308 may be based at least in part on whether the energy beam 200 is propagating along a scan vector 400 corresponding to a shadow vector 500 and / or a scan vector 400 corresponding to a contour vector 550.

[0156] The control module 1228 may be configured to output one or more irradiation control commands 1304 to the energy beam system 134. For example, the control module 1228 may output energy beam system control commands 1324 based at least in part on the irradiation control commands 1304. The energy beam system control commands 1324 may additionally or alternatively be based at least in part on the object data 1216 (e.g., a CAD file of the object 114 to be additively manufactured), and / or a build file or object properties corresponding to the object data 1216 and / or determined using the object data 1216. In some embodiments, the energy beam system control commands 1324 may be based on the irradiation control commands 1304 and build data from a build file. Additionally or alternatively, some of the energy beam system control commands 1324 may be based on build data from a build file, and some of the energy beam system control commands 1324 may be based on the irradiation control commands 1304.

[0157] Reference now Fig. 13B , further aspects of the exemplary control module 1228 will be described. Fig. 13BAs shown, in some embodiments, the irradiation control model 1300 may include a model trainer 1350. The model trainer 1350 may use any one or more of a variety of training or learning techniques, such as back propagation of errors, which may include performing truncated back propagation through time. In some embodiments, supervised training techniques may be used on a set of labeled training data. The model trainer 1350 may perform a variety of generalization techniques (e.g., weight decay, dropout, etc.) to improve the generalization ability of the trained irradiation control model 1300.

[0158] The exemplary model trainer 1350 may include a machine learning model 1352. The model trainer 1350 may utilize one or more model inputs 1302 as inputs, including, for example, as inputs to the machine learning model 1352. The model trainer 1350 may output one or more adjusted irradiation settings 1354. The adjusted irradiation settings 1354 may include updates or adjustments to settings, values, and / or schedules already included in the irradiation settings 1314. Additionally or alternatively, the adjusted irradiation settings 1354 may include new settings, values, and / or schedules to include or replace those already included in the irradiation settings 1314. In some embodiments, the machine learning model 1352 may include and / or may be based at least in part on one or more power density factors 1318, one or more irradiation vector factors 1320, and / or one or more scan segment factors 1322. The machine learning model 1352 can be constructed to determine one or more irradiance control commands 1304 based at least in part on one or more power density factors 1318 , irradiance vector factors 1320 , and / or scan segment factors 1322 .

[0159] The machine learning model 1352 may use any suitable machine learning technique, operating mechanism, or algorithm. The machine learning model 1352 may be constructed to use pattern recognition, computational learning, artificial intelligence, etc. to derive an algorithm that allows the machine learning model 1352 to determine one or more irradiation settings 1314. The machine learning model 1352 may include an unsupervised or supervised learning mechanism, including a semi-supervised learning mechanism, an active learning mechanism, a reinforcement learning mechanism, and / or a representation learning mechanism. The machine learning model 1352 may utilize a neural network, a decision tree, an association rule, an inductive logic algorithm, a cluster analysis algorithm, etc. In some embodiments, the model input 1302 may include data 1210 associated with or generated by the machine learning model 1352.

[0160] For example, Fig. 13BThe machine learning model 1352 shown in includes a neural network. However, the exemplary machine learning model 1352 may include any other suitable model, including a linear discriminant analysis model, a partial least squares discriminant analysis model, a support vector machine model, a random tree model, a logistic regression model, a naive Bayes model, a K-nearest neighbor model, a quadratic discriminant analysis model, an anomaly detection model, an improved bagged decision tree model, an artificial neural network model, a C4.5 model, a k-means model, and combinations thereof. Even more additional suitable types of machine or statistical learning models are also contemplated. It will also be understood that the machine learning model 1352 may use certain mathematical methods alone or in combination with one or more machine or statistical learning models.

[0161] In addition to outputting the adjusted irradiation setting 1354, in some embodiments, the irradiation control model 1300 (e.g., the machine learning model 1352) can output a confidence score 1356 that can provide an indication of a confidence level attributed to one or more outputs of the machine learning model 1352. The confidence score 1356 can be used, for example, to set an error tolerance to be used by the irradiation control model 1300 in determining the adjusted irradiation setting 1354. For example, in the case of a low confidence score 1356, the irradiation control model 1300 can consider a more conservative or wider error tolerance in determining the adjusted irradiation setting 1354, while in the case of a high confidence score 1356, the irradiation control model 1300 can allow for a more aggressive or narrower error tolerance in determining the adjusted irradiation setting 1354. In some embodiments, the model input 1302 can include data 1210 associated with or including the confidence score 1356.

[0162] Reference now Fig.14, an exemplary training computing device 1400 will be described. In some embodiments, the training computing device 1400 can be used to train the irradiation control model 1300, such as training the machine learning model 1352. The training computing device 1400 can be communicatively coupled to the irradiation controller 1200 via the communication network 1220. Alternatively, the training computing device 1400 can be included as part of the irradiation controller 1200. For example, the training computing device 1400 can be part of the computing device 1202, included as part of the irradiation controller 1200. The training computing device 1400 can include one or more processors 1204 and one or more memory devices 1206. The one or more memory devices 1206 can store information accessible by the one or more processors 1204, including computer readable instructions 1208 executable by the one or more processors 1204. The memory device 1206 can additionally or alternatively store data 1210 accessible by the one or more processors 1204. The training computing device 1400 can also include a communication interface 1418 configured to communicate with resources on the communication network 1220. The hardware, implementation, and functionality of the components of the training computing device 1400 may operate, function, and include the same or similar components as those described with respect to the one or more computing devices 1202 of the irradiation controller 1200 .

[0163] The training computing device 1400 may include a model trainer 1350 configured to train one or more irradiation control models 1300, such as a machine learning model 1352. In some embodiments, the model trainer 1350 may train one or more irradiation control models 1300 based on a set of training data 1402. The training data 1402 may include past operation data 1214 and / or object data 1216 of previously additively manufactured objects. In some embodiments, the training data 1402 may include at least a portion of the database 1212. Alternatively, the database 1212 may include the training data 1402 or at least a portion thereof.

[0164] The model trainer 1350 can utilize the past operating data 1214 to train one or more irradiation control models 1300 about how the additive manufacturing machine 102 has actually and / or uniquely operated in the past in terms of object specifications and / or operating parameters (e.g., under specific operating conditions and / or, for example, in relation to the additively manufactured objects 114 and / or the quality data produced). Additionally or alternatively, the model trainer 1350 can utilize the past operating data 1214 to validate or test the irradiation control model 1300, including the machine learning model 1352.

[0165] Now turn to Fig.15, an exemplary method for additively manufacturing a three-dimensional object 114 will be described, including a method for determining an irradiation control command 1304, and / or a method for controlling irradiation parameters 1305 (e.g., beam parameters 1306, scan parameters 1308, scan segment parameters 1310, and / or irradiation vector parameters 1312). Fig.15 As shown, the exemplary method 1500 may include, at block 1502, determining a plurality of scan segments 600 of the build plane 130 and / or one or more object layers 900 corresponding to one or more regions of the powder bed 136 that define the build plane 130, respectively. The plurality of scan segments 600 may be determined based at least in part on the irradiation control model 1300. The irradiation control model 1300 may be configured to determine the plurality of scan segments 600 based at least in part on one or more model inputs 1302. The one or more model inputs may include object data 1216 and / or operational data 1214. Additionally or alternatively, the irradiation control model 1300 may be configured to determine the plurality of scan segments 600 based at least in part on a power density factor, an irradiation vector factor, and / or a scan segment factor.

[0166] At block 1504, the exemplary method 1500 may additionally or alternatively include determining at least one irradiation vector for irradiating each of the plurality of scan segments 600 with the energy beam 200. The at least one irradiation vector determined for each of the plurality of scan segments 600 may include a hatch vector 500 and / or a plurality of scan vectors 400 defining the hatch vector 500. The hatch vector 500 and / or the plurality of scan vectors 400 defining the hatch vector 500 may be oriented away from a normal point 206 corresponding to the energy beam 200 on the construction plane 130. The irradiation control model 1300 may be configured to determine at least one irradiation vector based at least in part on one or more model inputs 1302. The one or more model inputs may include the object data 1216 and / or the operational data 1214. Additionally or alternatively, the irradiation control model 1300 may be configured to determine at least one irradiation vector based at least in part on the power density factor 1318, the irradiation vector factor 1320, and / or the scan segment factor 1322. Power density factor 1318, irradiation vector factor 1320 and / or scan segment factor 1322 can be based at least in part on the position of the corresponding scan segment 600 relative to the normal point 206 on the construction plane 130, and / or at least in part on the position of beam spot 300 from energy beam 200 relative to the normal point 206 on the construction plane 130.

[0167] In some embodiments, the exemplary method 1500 may include, at block 1506, outputting irradiation control commands 1304 to the energy beam system 134 based at least in part on the plurality of scan segments 600 and / or at least one irradiation vector for irradiating individual scan segments of the plurality of scan segments 600. The irradiation control commands 1304 may be configured to vary one or more irradiation parameters 1305 between at least some of the plurality of scan segments 600 and / or between at least some of the irradiation vectors for irradiating individual scan segments of at least some of the plurality of scan segments 600. The exemplary method 1500 may additionally or alternatively include, at block 1508, irradiating individual scan segments of the plurality of scan segments 600 according to the determined at least one irradiation vector that respectively corresponds to the individual scan segments of the plurality of scan segments 600. In some embodiments, at box 1508, example method 1500 may include directing energy beam 200 onto construction plane 130 according to an irradiation vector (e.g., scan vector 400, hatch vector 500 and / or contour vector 550) based at least in part on irradiation control commands 1304.

[0168] In some embodiments, the exemplary method 1500 may include, at block 1510, determining an irradiation setting 1314 for each of the plurality of scan segments 600 using the irradiation control model 1300. The irradiation control model 1300 may be configured to determine the irradiation setting 1314 for each of the plurality of scan segments 600 based at least in part on the power density factor 1318, the irradiation vector factor 1320, and / or the scan segment factor 1322. The exemplary method 1500 may additionally or alternatively include, at block 1512, outputting an irradiation control command 1304 to the energy beam system 134 based at least in part on the irradiation setting 1314. The irradiation control command 1304 may be configured to change one or more irradiation parameters 1305 corresponding to each of the plurality of scan segments 600.

[0169] Further aspects of the invention are provided by the subject matter of the following clauses:

[0170] 1. A method for additive manufacturing of a three-dimensional object, the method comprising: determining a construction plane and / or a plurality of scanning segments of one or more object layers corresponding to one or more regions of a powder bed defining the construction plane; determining at least one irradiation vector for irradiating each of the plurality of scanning segments using an energy beam, wherein the at least one irradiation vector determined for each of the plurality of scanning segments comprises a shadow vector and / or a plurality of scanning vectors defining the shadow vector, wherein the shadow vector and / or the plurality of scanning vectors defining the shadow vector are oriented away from a normal point on the construction plane corresponding to the energy beam; and outputting an irradiation control command to an energy beam system based at least in part on the plurality of scanning segments and / or the at least one irradiation vector for irradiating each of the plurality of scanning segments.

[0171] 2. The method according to any of the preceding clauses, comprising: determining the multiple scanning segments and / or the at least one irradiation vector for irradiating each of the multiple scanning segments using an irradiation control model, wherein the irradiation control model is constructed to determine the multiple scanning segments and / or the at least one irradiation vector for irradiating each of the multiple scanning segments based at least in part on one or more model inputs, and the one or more model inputs include object data and / or operation data.

[0172] 3. The method according to any of the preceding clauses, comprising: determining the multiple scanning segments and / or the at least one irradiation vector for irradiating each of the multiple scanning segments using an irradiation control model, wherein the irradiation control model is constructed to determine the multiple scanning segments and / or the at least one irradiation vector for irradiating each of the multiple scanning segments based at least in part on a power density factor, an irradiation vector factor and / or a scanning segment factor.

[0173] 4. A method according to any of the preceding clauses, wherein the irradiation control command is constructed to change one or more irradiation parameters in a scan segment between at least some of the multiple scan segments and / or between at least some of the irradiation vectors of individual scan segments used to irradiate at least some of the multiple scan segments.

[0174] 5. A method according to any preceding clause, comprising irradiating each of the plurality of scan segments according to the determined at least one irradiation vector corresponding to each of the plurality of scan segments.

[0175] 6. A method according to any preceding clause, wherein the plurality of scanning segments comprises one or more radial segments, one or more annular segments and / or one or more semi-annular segments.

[0176] 7. A method according to any preceding clause, wherein the number of scan segments per unit area of ​​the construction plane and / or per unit area of ​​the one or more object layers depends at least in part on the distance from the normal point and / or the angle of incidence of the energy beam.

[0177] 8. A method according to any preceding clause, wherein the area of ​​each scanning segment decreases with increasing distance from the normal point and / or with increasing angle of incidence of the energy beam.

[0178] 9. A method according to any of the preceding clauses, wherein one or more segment boundaries corresponding to each of the multiple scanning segments are determined at least in part based on an incident angle of the energy beam when it impinges on the corresponding scanning segment and / or at least in part based on one or more beam parameters that depend at least in part on the incident angle of the energy beam.

[0179] 10. A method according to any preceding clause, wherein the plurality of scan segments comprises a plurality of radial segments, and wherein the at least one determined irradiance vector corresponding to the plurality of radial segments comprises a shadow vector oriented away from the normal point.

[0180] 11. A method according to any preceding clause, wherein the plurality of scan segments comprises a plurality of radial segments, and wherein the at least one determined irradiation vector corresponding to the plurality of radial segments comprises a plurality of scan vectors oriented away from the normal point.

[0181] 12. A method according to any preceding clause, wherein the plurality of scanning segments intersect with each of the plurality of objects in the one or more object layers at different locations depending on the location of each of the plurality of objects on the construction plane and / or on the one or more object layers.

[0182] 13. A method according to any of the preceding clauses, wherein the multiple scan segments respectively include one or more segment boundaries, and wherein the construction and / or arrangement of the corresponding one or more segment boundaries are determined for one or more objects in the one or more object layers at least in part based on the position of the corresponding object in the corresponding object layer.

[0183] 14. A method according to any preceding clause, wherein the at least one irradiance vector determined for each of the plurality of scan segments comprises a shadow vector oriented substantially radially relative to the normal point.

[0184] 15. A method according to any preceding clause, wherein the at least one irradiance vector determined for each of the plurality of scan segments comprises a hatch vector oriented substantially circularly or semi-circularly relative to the normal point.

[0185] 16. A method according to any preceding clause, wherein the at least one irradiation vector determined for each of the plurality of scan segments comprises a plurality of shadow line vectors, and wherein the plurality of shadow line vectors correspond to a respective one of the plurality of scan segments oriented substantially parallel to each other.

[0186] 17. The method according to any of the preceding clauses, comprising: using an irradiation control model to determine the irradiation settings of each of the multiple scanning segments, wherein the irradiation control model is constructed to determine the irradiation settings of each of the multiple scanning segments based at least in part on a power density factor, an irradiation vector factor and / or a scanning segment factor.

[0187] 18. A method according to any of the preceding clauses, comprising: outputting an irradiation control command to an energy beam system based at least in part on the irradiation setting, wherein the irradiation control command is constructed to change one or more irradiation parameters corresponding to each of the multiple scanning segments.

[0188] 19. An additive manufacturing system, comprising: an energy beam system; and a control system, the control system comprising an irradiation controller; wherein the irradiation controller comprises a control module, the control module being constructed to perform a method, the method comprising: determining a plurality of scanning segments for constructing a plane and / or for one or more object layers corresponding to one or more regions of a powder bed respectively defining the constructing plane; determining at least one irradiation vector for irradiating each of the plurality of scanning segments using an energy beam, wherein the at least one irradiation vector determined for each of the plurality of scanning segments comprises a shadow vector and / or a plurality of scanning vectors defining the shadow vector, wherein the shadow vector and / or the plurality of scanning vectors defining the shadow vector are oriented away from a normal point on the constructing plane corresponding to the energy beam; and outputting an irradiation control command to the energy beam system based at least in part on the plurality of scanning segments and / or the at least one irradiation vector for irradiating each of the plurality of scanning segments.

[0189] 20. An additive manufacturing system according to any preceding clause, wherein the additive manufacturing system is configured to perform the method of any preceding clause

[0190] 21. A computer-readable medium comprising computer-executable instructions, which, when executed by a processor, cause the processor to perform a method, the method comprising: determining a plurality of scanning segments for constructing a plane and / or one or more object layers corresponding to one or more regions of a powder bed that define the construction plane; determining at least one irradiation vector for irradiating each of the plurality of scanning segments using an energy beam, wherein the at least one irradiation vector determined for each of the plurality of scanning segments comprises a shadow vector and / or a plurality of scanning vectors defining the shadow vector, wherein the shadow vector and / or the plurality of scanning vectors defining the shadow vector are oriented away from a normal point on the construction plane corresponding to the energy beam; and outputting an irradiation control command to an energy beam system based at least in part on the plurality of scanning segments and / or the at least one irradiation vector for irradiating each of the plurality of scanning segments.

[0191] 22. A computer-readable medium according to any preceding clause, wherein the computer-readable medium comprises computer-executable instructions which, when executed by a processor, cause the processor to perform the method of any preceding clause.

[0192] This written description uses exemplary embodiments to describe the presently disclosed subject matter, including the best mode, and also to enable any person skilled in the art to practice such subject matter, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the presently disclosed subject matter 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 non-transitory computer-readable medium comprising computer-executable instructions, characterized in that: When executed by a processor, the computer executable instructions cause the processor to perform a method of additively manufacturing a three-dimensional object, the method comprising: determining a plurality of scan segments for a build plane and / or for one or more object layers respectively corresponding to one or more regions of a powder bed defining said build plane; determining at least one irradiation vector for irradiating each of the plurality of scan segments with an energy beam, wherein the at least one irradiation vector determined for the each of the plurality of scan segments comprises a hatch vector and / or a plurality of scan vectors defining the hatch vector, wherein the hatch vector and / or the plurality of scan vectors defining the hatch vector are oriented away from a normal point on the construction plane corresponding to the energy beam; and outputting an irradiation control command to an energy beam system based at least in part on the plurality of scan segments, wherein one or more segment boundaries corresponding to each of the plurality of scan segments are determined at least in part based on an elliptical angle of the energy beam when incident on the corresponding scan segment and / or at least in part based on one or more beam parameters that at least in part depend on the elliptical angle of the energy beam, The number of scanning segments per unit area of ​​the construction plane and / or per unit area of ​​the one or more object layers depends at least in part on the distance from the normal point and / or the ellipse angle of the energy beam.

2. The non-transitory computer-readable medium of claim 1, wherein: Wherein the computer executable instructions, when executed by a processor, cause the processor to further perform the method of additively manufacturing a three-dimensional object, the method further comprising: The multiple scan segments and / or the at least one irradiation vector for irradiating each of the multiple scan segments are determined using an irradiation control model, wherein the irradiation control model is constructed to determine the multiple scan segments and / or the at least one irradiation vector for irradiating each of the multiple scan segments based at least in part on one or more model inputs, and the one or more model inputs include object data and / or operation data.

3. The non-transitory computer-readable medium of claim 1, wherein: Wherein the computer executable instructions, when executed by a processor, cause the processor to further perform the method of additively manufacturing a three-dimensional object, the method further comprising: The multiple scanning segments and / or the at least one irradiation vector for irradiating each of the multiple scanning segments are determined using an irradiation control model, wherein the irradiation control model is constructed to determine the multiple scanning segments and / or the at least one irradiation vector for irradiating each of the multiple scanning segments based at least in part on a power density factor, an irradiation vector factor and / or a scanning segment factor.

4. The non-transitory computer-readable medium of claim 1, wherein: The irradiation control commands are configured to change one or more irradiation parameters between at least some of the plurality of scan segments and / or between at least some of the irradiation vectors used to irradiate respective scan segments of the at least some of the plurality of scan segments.

5. The non-transitory computer-readable medium of claim 1, wherein: Wherein the computer executable instructions, when executed by a processor, cause the processor to further perform the method of additively manufacturing a three-dimensional object, the method further comprising: The respective ones of the plurality of scan segments are irradiated according to the determined at least one irradiation vector respectively corresponding to the respective ones of the plurality of scan segments.

6. The non-transitory computer-readable medium of claim 1, wherein: The plurality of scanning segments include one or more radial segments, one or more annular segments and / or one or more semi-annular segments.

7. The non-transitory computer-readable medium of claim 1, wherein: The area of ​​each scanning segment decreases as the distance from the normal point increases and / or as the incident angle of the energy beam increases.

8. The non-transitory computer-readable medium of claim 1, wherein: Wherein the plurality of scan segments comprises a plurality of radial segments, and wherein the at least one determined irradiance vector corresponding to the plurality of radial segments comprises a shadow vector oriented away from the normal point.

9. The non-transitory computer-readable medium of claim 1, wherein: Wherein the plurality of scan segments comprises a plurality of radial segments, and wherein the at least one determined irradiation vector corresponding to the plurality of radial segments comprises a plurality of scan vectors oriented away from the normal point.

10. The non-transitory computer readable medium of claim 1, wherein: The plurality of scan segments intersect the respective objects in the plurality of objects in the one or more object layers at different positions depending on the position of the respective objects in the plurality of objects on the construction plane and / or on the one or more object layers.

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