Optical system

Abstract

An additive manufacturing system has a build surface that supports a precursor material to be melted by incident light energy. The system includes an optical assembly to direct incident light energy along a beam path in a first direction toward a build surface, and an energy management system. The energy management system includes a beam block arranged along a beam path. The beam block has an aperture that allows incident light to pass through the beam block in a first direction. The beam block also has a surface for absorbing light energy traveling in a second direction different from the first direction or deflecting light energy traveling in the second direction different from the first direction away from the beam path. The energy management system also includes a heat sink to receive thermal energy from at least a portion of the light energy traveling in the second direction.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 63 / 429,210, filed on December 1, 2022, the entire contents of which are incorporated by reference for all purposes. Technical Field

[0003] The disclosed embodiments relate to optical systems and related methods of use, such as for use in additive manufacturing systems. Background Art

[0004] In the selective laser melting process used for additive manufacturing, one or more laser spots are scanned over or otherwise applied to a thin layer of powder. The powder, exposed to the light energy, is melted and fused into a solid structure. Once a layer is completed, a new layer of powder can be laid down, and the process can be repeated. The new layer can be selectively exposed to light energy, where at least some portions of the powder material melt and fuse to the solid material from the previous layer. This process can be repeated multiple times to build nearly any three-dimensional shape. Summary of the Invention

[0005] An optical system for use with an additive manufacturing system may include an optical assembly comprising a plurality of optical components configured to direct laser energy along a beam path toward a build surface to melt a portion of a precursor material on the build surface. The system may also include an optical support structure comprising a plurality of support posts and a plurality of support plates. Each support plate may span between two or more support posts at respective locations along the length of the support posts and may be configured to support at least one optical component of the optical assembly on the support posts.

[0006] In some embodiments, the optical system can be coupled to a gantry system and can be movable in at least one direction by the gantry system. Furthermore, the optical system can be configured to have a maximum displacement of approximately 40 microns in a direction away from the axis of the optical system when the optical system vibrates at the system's resonant frequency. In some embodiments, the optical assembly and the optical support structure can be configured to have a resonant frequency between approximately 400 hertz (Hz) and approximately 450 Hz. Additionally or alternatively, at least one support plate can have a thickness between approximately 15 millimeters (mm) and approximately 25 mm. In some embodiments, at least one support column can comprise a tube formed from a composite material. In some embodiments, the plurality of support plates can be configured to maintain alignment of the components during thermal expansion of the support plates. In some embodiments, each support plate can be axisymmetric. Additionally or alternatively, each support plate can have an optical support aperture sized and shaped to supportively receive at least one optical component. In some embodiments, the optical support aperture can be located at or near the center of the support plate. Additionally or alternatively, each support plate can comprise at least two support coupling apertures. Each support coupling hole may be sized and shaped to engage with a corresponding one of the at least two support posts, and each support coupling hole may be disposed at or near a periphery of the support plate.

[0007] In some embodiments, at least one support plate can be coupled to at least one support post by a clamping portion comprising a jaw extending from the support plate and cooperating with the support plate to form a throat. The throat can be sized and shaped to receive the support post, and a distal end portion of the jaw can include a through hole aligned with a bore in the support plate. The through hole and the bore can be configured to receive a fastener to adjust the size of the throat to secure the support post within the throat. In some embodiments, each support plate can be configured to receive a heat transfer conduit that carries a working fluid to receive thermal energy from the support plate. Additionally, each support plate can include a thermal coupling hole sized and shaped to receive the heat transfer conduit and to be in thermal contact with the heat transfer conduit. Additionally or alternatively, the working fluid can circulate through a return conduit disposed within the support post.

[0008] In some embodiments, the optical system may further include a plurality of heat transfer conduits and a plurality of heat transfer plates. Each of the heat transfer plates may span between two or more heat transfer conduits and may include a heat transfer component that at least partially surrounds the beam path between two optical components of the system. Each heat transfer plate may further be configured to absorb and / or deflect light energy and / or thermal energy. Each of the heat transfer conduits may be in thermal contact with each of the heat transfer plates and may carry a working fluid to receive thermal energy from the heat transfer plates. Furthermore, at least one of the heat transfer components may include a beam block configured to deflect light energy away from the beam path. Additionally or alternatively, at least one of the heat transfer components may include a heat sink configured to absorb thermal energy. In some embodiments, each of the heat transfer conduits may contain a flow of coolant that is configured to absorb thermal energy from the heat transfer plates and / or support plates.

[0009] In some embodiments, at least one optical component can be supported by two or more support plates. Some optical systems can also include two or more support posts extending between the two or more support plates. At least one optical component can be supported by at least one platform spanning between and supported by the two or more support posts. Additionally or alternatively, one or more support plates can include channels sized and shaped to receive coils thermally and fluidically coupled to the heat transfer conduits. In some embodiments, an additive manufacturing system can include any of the optical systems described herein and a build surface, and at least one source of optical energy configured to provide laser energy to the optical assembly.

[0010] In some embodiments, an additive manufacturing system may include a build surface for supporting a precursor material to be melted by incident light energy. The system may include an optical assembly configured to direct the incident light energy in a first direction along a beam path toward the build surface, and an energy management system. The energy management system may include a beam block disposed along the beam path and having an aperture sized and shaped to allow the incident light energy to pass through the beam block in the first direction. The beam block may also include a surface configured to absorb or deflect light energy traveling in a second direction different from the first direction away from the beam path. The energy management system may also include a heat sink configured to receive thermal energy from at least a portion of the light energy traveling in the second direction.

[0011] In some embodiments, a heat sink can be in thermal contact with the beam block to receive heat energy from the beam block. Additionally or alternatively, a heat sink can at least partially surround the beam block to absorb light energy deflected away from the beam path by the beam block. In some embodiments, the aperture of the beam block can have a major axis and a minor axis and can measure between approximately 80 millimeters (mm) and approximately 95 mm along the major axis and between approximately 5 mm and approximately 15 mm along the minor axis. In some systems, the surface of the beam block can taper inward, such that the beam block can be formed roughly as a cone, with the aperture extending through the cone along its height. Additionally or alternatively, the surface can be configured to reflect light energy traveling in a second direction away from the beam path. In some embodiments, the surface can be configured to deflect light energy traveling in the second direction toward the heat sink. In some systems, the surface can be configured to deflect at least a portion of the light energy traveling in the second direction in a direction perpendicular to the beam path and toward the heat sink. Additionally or alternatively, the surface can be configured to absorb light energy traveling in the second direction.

[0012] In some embodiments, the system may further include a heat transfer conduit configured to transport a working fluid thermally coupled to the radiator and / or beam block to receive thermal energy from the radiator and / or beam block. In addition, the heat transfer conduit may include a heat conductive pipe in contact with the radiator. Optionally, the beam block and / or radiator may be attached to the heat transfer conduit and / or supported by the heat transfer conduit. In some embodiments, the system may further include a turbulence inducing component within the conduit, the turbulence inducing component configured to induce turbulence and / or eddies within the flow of the working fluid. Some systems may further include a coil in thermal contact with the radiator and / or beam block and in fluid communication with the heat transfer conduit to transport the working fluid through the coil to receive thermal energy from the radiator and / or beam block. In some such embodiments, the coil may be arranged in a channel formed in the surface of the radiator and / or beam block. In some systems, the radiator and beam block may be a single component.

[0013] In some embodiments, a method of additive manufacturing may include directing incident optical energy in a first direction along a beam path toward a build surface supporting a precursor material to be melted by the incident optical energy. The method may also include deflecting optical energy traveling in a second direction different from the first direction away from the beam path, and absorbing thermal energy from at least a portion of the deflected optical energy in a heat sink.

[0014] In some embodiments, directing incident light energy along a beam path may include directing the incident light energy through an opening in a beam block, and deflecting light energy traveling in a second direction may include deflecting light energy traveling in the second direction from a surface of the beam block and away from the beam path. Furthermore, absorbing thermal energy from at least a portion of the deflected light energy in a heat sink may optionally include conducting the thermal energy from the beam block into the heat sink. Additionally or alternatively, absorbing thermal energy from at least a portion of the deflected light energy in a heat sink may include absorbing thermal energy in a heat sink that at least partially surrounds the beam block. Some methods may further include receiving thermal energy from the heat sink and / or the beam block in a heat transfer conduit thermally coupled to the heat sink and / or the beam block. In some embodiments, the method may further include flowing a working fluid through a heat conducting conduit of the heat transfer conduit. Additionally or alternatively, receiving thermal energy in the heat transfer conduit may optionally include receiving thermal energy in the working fluid. Some such methods may also include inducing turbulence and / or eddies in the flow of the coolant and / or flowing the working fluid through a coil in thermal contact with a radiator.

[0015] In some embodiments, deflecting light energy traveling in the second direction may include deflecting light energy traveling in the second direction from a surface of the heat sink and away from the light beam path. Additionally or alternatively, deflecting light energy traveling in the second direction may include reflecting light energy traveling in the second direction away from the light beam path. Furthermore, deflecting light energy traveling in the second direction may optionally include deflecting light energy traveling in the second direction away from the light beam path and toward the heat sink. Additionally or alternatively, deflecting light energy traveling in the second direction may include deflecting light energy traveling in the second direction in a direction perpendicular to the light beam path and toward the heat sink.

[0016] It should be understood that the aforementioned concepts and the additional concepts discussed below may be arranged in any suitable combination, as the present disclosure is not limited in this respect. In addition, other advantages and novel features of the present disclosure will become apparent from the following detailed description of various non-limiting embodiments when considered in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In the drawings, each identical or nearly identical component illustrated in various figures may be represented by a like reference numeral. For clarity, not every component may be labeled in every figure. In the drawings:

[0018] Figure 1 shows a schematic diagram of an additive manufacturing system according to one embodiment;

[0019] Figure 2A A schematic diagram illustrating one embodiment of an optical system in a stationary state;

[0020] Figure 2B Shows that when the optical system is in motion Figure 2A A schematic diagram of an embodiment of the invention;

[0021] Figure 3 shows a perspective view of an optical system according to one embodiment;

[0022] Figure 4 shows a top view of one embodiment of a support plate;

[0023] Figure 5 shows a cross-sectional view of one embodiment of an optical system;

[0024] Figure 6 shows a top view of a portion of an energy management system for an optical system according to one embodiment;

[0025] Figure 7 shows a cross-section of one embodiment of a portion of an energy management system;

[0026] Figure 8A shows a top view of one embodiment of a beam block;

[0027] Figure 8B A top view showing another embodiment of a beam block; and

[0028] Figure 8C A top view of another embodiment of a beam block is shown. DETAILED DESCRIPTION

[0029] In some laser additive manufacturing applications, the accuracy and predictability of the positioning of the laser throughout the build process may affect the quality, efficiency, or other characteristics of the build process or the product built during the build process. However, some additive manufacturing processes may include movement of an optical system through which the laser or light energy is transmitted. Some additive manufacturing systems or their optical systems may include an optical assembly that includes one or more optical components, including various optical fibers, lenses, windows, apertures, mirrors, filters, or other components. These components can direct or guide light energy from the light energy source along a beam path, through the optical assembly, and toward the build surface to melt portions of the precursor material on the build surface. In some embodiments, the system can scan the light energy across the build surface by moving the optical assembly relative to the build surface.

[0030] In some applications, such movement of optical components can result in inaccuracies or errors in the positioning of the laser spot on the build surface or precursor material. For example, the movement can induce vibrations through or within the optical assembly, which can cause one or more optical components to shift relative to a nominal or intended position within the optical assembly or relative to the optical assembly. Shifting of optical components and / or optical assemblies can result in shifting of the laser spot relative to the nominal or intended positioning of the laser spot on the build surface, ultimately leading to dimensional errors and / or build quality issues in the final built part. It will be appreciated that the magnitude of these shifts and positioning errors can be increased when the movement induces vibrations at the resonant frequency of the optical head, as the shifts can reach a maximum or near maximum at the resonant frequency, where the amplitude of the vibrations can reach a maximum or near maximum.

[0031] In view of the foregoing, the inventors have recognized and appreciated the benefits of optical systems that resist vibrations and resulting displacements in optical components or optical assemblies. Some optical systems may include an optical support structure to support the optical assembly and increase the stiffness of the optical system so that the optical system can resist vibrations and / or displacements at least at resonance or other selected frequency or frequencies. In some embodiments, the optical support structure may include one or more support plates spanning between two or more support posts. Each support plate may be configured to support at least one optical component of the optical assembly. Some optical systems, optical assemblies and / or optical support structures can resist vibrations and / or displacements by maintaining the maximum amplitude of vibrations within a specific frequency range. For example, an optical system can be designed to have a resonant frequency that is higher than the frequency at which the system may vibrate during movement or other operation. This can reduce the risk of the optical system vibrating at its resonant frequency, thereby maintaining the maximum vibration amplitude and / or maximum displacement of the optical component below a desired value.

[0032] For example, in some embodiments, the optical system can be configured to have a resonant frequency greater than or equal to 300 Hertz (Hz), 350 Hz, 400 Hz, 450 Hz, and / or any other suitable frequency. Additionally, the optical system can be configured to have a resonant frequency less than or equal to 500 Hz, 450 Hz, 400 Hz, 350 Hz, and / or any other suitable frequency. Combinations of the foregoing are contemplated, including, for example, greater than or equal to 300 Hz and less than or equal to 500 Hz, greater than or equal to 300 Hz and less than or equal to 350 Hz, greater than or equal to 400 Hz and less than or equal to 450 Hz, and / or any other suitable combination of the foregoing. Of course, while specific ranges of resonant frequencies are provided, it should be understood that other ranges greater than and less than the aforementioned ranges are also contemplated, as the present disclosure is not limited in this respect.

[0033] Additionally or alternatively, the optical system can be designed to have a maximum shift at resonance that is equal to or less than a desired value. For example, in some embodiments, the optical system can be configured to have a maximum shift at resonance that is greater than or equal to 20 micrometers (μm), 25 μm, 30 μm, 35 μm, or any other suitable shift value. Additionally, the optical system can be configured to have a maximum shift at resonance that is less than or equal to 100 μm, 50 μm, 45 μm, 40 μm, or any other suitable shift. Combinations of the foregoing are contemplated, including, for example, greater than or equal to 20 μm and less than or equal to 100 μm, greater than or equal to 35 μm and less than or equal to 45 μm, and / or any other suitable combination of the foregoing. Of course, while specific ranges of maximum shift at resonance are provided, it should be understood that other ranges greater than and less than the aforementioned ranges are also contemplated, as the present disclosure is not limited in this respect.

[0034] It will be appreciated that the stiffness, resonant frequency, and / or maximum displacement at resonance of an optical system may be affected by various material and dimensional parameters of various components of the optical system. Accordingly, the inventors have recognized and appreciated that the stiffness, resonant frequency, and / or maximum displacement at resonance may be affected by at least the physical properties of the support plate and / or support posts. For example, in embodiments where the support posts may be hollow, the stiffness, resonant frequency, and / or maximum displacement may also be affected by the wall thickness of the support posts, but it will be appreciated that in some embodiments, the support posts may be solid and / or have varying thicknesses.

[0035] In addition to the above, some laser additive manufacturing systems may include high energy lasers that have the ability to transfer large amounts of light energy into the precursor material. For example, some additive manufacturing systems may include a laser system that has an emitted light energy output greater than or equal to 10 kilowatts (kW), 50 kW, 75 kW, 100 kW, or any other suitable laser power. In some applications, a portion of the emitted light energy may be reflected or otherwise directed in an undesirable manner. For example, in an application where incident light energy is directed toward a build surface in a first direction along a beam path, some light energy may be reflected back along the beam path or an adjacent beam path in a second direction that is opposite to or different from the first direction. This light energy may damage various components of the additive manufacturing system, including various optical components, or may cause the components to malfunction.

[0036] In light of the foregoing, the inventors have recognized and appreciated the benefits of a system configured to manage unwanted light energy in an optical system. In some embodiments, an optical system can include an energy management system that can include one or more heat transfer components, such as a beam block, a heat sink, a heat transfer plate, and / or a heat transfer conduit. For example, a beam block can be positioned along a beam path of the optical system, and the beam block can include an aperture to allow incident light energy to pass through the beam block in a first direction along the beam path. The beam block can also include a surface configured to absorb or deflect light energy traveling in a second direction different from the first direction. In various embodiments, the surface can include a surface material, surface treatment, or surface finish configured to absorb and / or deflect light energy. For example, in some embodiments, the surface can include a black anodized surface finish, a black optical coating or foil, and / or any other suitable surface configuration for absorbing light. Additionally or alternatively, in some embodiments, the surface can include an anodized surface finish, a reflective coating or foil (e.g., copper, gold, steel, or other reflective material), and / or any other suitable surface configuration for reflecting or deflecting light. In some embodiments, the beam block can be formed from any suitable coated or uncoated material for partially or completely absorbing, reflecting and / or deflecting light energy, including copper, gold, steel, aluminum and / or any other suitable material or combination of materials, including materials having an absorptive coating, such as an optical black coating (e.g., Acktar black coating produced by Acktar Ltd. of Kiryat Gat, Israel) and / or materials having a reflective coating (e.g., a gold coating).

[0037] The size and shape of the openings in the beam block can correspond to the size and shape of the laser beam that carries incident light energy at a point along the beam path intended to locate the beam block. In some embodiments, the laser beam can be formed from a plurality of individual laser pixels. The pixels can be formed in any suitable shape or arrangement. For example, the pixels can be formed in an elongated arrangement, or can be formed into an elliptical pattern, such that the laser beam has a major axis and a minor axis. Some beam blocks can correspondingly include openings having a major axis and a minor axis. In various embodiments, the major axis and the minor axis can have any suitable length, such as 60 mm to 110 mm or any intermediate value (e.g., 80 mm to 95 mm) for the major axis, 2 mm to 20 mm or any intermediate value (e.g., 5 mm to 15 mm) for the minor axis, and any combination of lengths for the major axis and the minor axis. Of course, while specific ranges for the major axis and the minor axis are provided, it should be understood that other ranges greater than and less than the aforementioned ranges are also contemplated, as the present disclosure is not limited in this respect.

[0038] Additionally or alternatively, some optical systems or their energy management systems may include a heat transfer component comprising a heat sink. The heat sink may be configured to receive heat energy from at least a portion of the light energy traveling in the second direction. In some embodiments, the heat sink may at least partially surround the light beam path, and some heat sinks may at least partially surround a surface of the light beam block such that light energy deflected by the surface can be absorbed by the heat sink. In some embodiments, the heat sink may include at least one surface having a surface material, surface treatment, or surface finish configured to absorb light energy. For example, in some embodiments, the surface may include a black anodized surface finish, a black optical coating or foil, and / or any other suitable surface configuration for absorbing light. In some embodiments, the heat sink may be formed from any suitable coated or uncoated material for partially or completely absorbing, reflecting, and / or deflecting light energy, including copper, gold, steel, aluminum, and / or any other suitable material or combination of materials, including materials having an absorptive coating, such as an optical black coating (e.g., Acktar black coating), and / or materials having a reflective coating (e.g., gold coating). In some implementations, the beam block and the heat sink may be a single component such that a surface of the beam block is configured to receive thermal energy from at least a portion of the optical energy traveling in the second direction.

[0039] Additionally, in some embodiments, the optical system or its energy management system may include a heat transfer component, comprising a heat transfer conduit, in thermal contact with and / or configured to receive thermal energy from the beam block, heat sink, support plate, or other components of the optical system. In some embodiments, the heat transfer conduit may be configured to carry a working fluid, such as water or a coolant, to receive a portion of the thermal energy from the optical system and carry the thermal energy away from the optical system. In some embodiments, the heat transfer conduit may comprise a pipe, tube, coil, or channel in thermal contact with one or more components of the optical system. In various embodiments, the heat transfer conduit may be made of any suitable material, including any suitable metal, alloy, composite material, or any other suitable type of material. In some embodiments, the heat transfer conduit may comprise a metal with high thermal conductivity, such as copper, silver, aluminum, or other metals. Furthermore, the working fluid may be any fluid suitable for receiving heat from the support plate, including any suitable gas or liquid. In some embodiments, the working fluid may comprise a coolant or refrigerant, while in other embodiments, the working fluid may comprise water.

[0040] In some applications, the portion of optical energy that may be received by various components can cause one or more components to experience thermal expansion. In some applications, thermal expansion can affect or change the position of various components, which can affect the operation of the optical system. For example, thermal expansion of an optical component or a component supporting the optical component can change the position of the optical component along the optical beam path. This can cause the optical component to be misaligned relative to the optical beam path, which can result in a portion of the incident optical energy being misdirected along the optical beam path. Consequently, deviations in optical alignment caused by thermal expansion can lead to dimensional errors and / or build quality issues in the final built component.

[0041] In view of the foregoing, the inventors have recognized and appreciated the benefits of an optical system including a support component configured to maintain the position of one or more optical components during thermal expansion. In some embodiments, such a support component can be symmetrical or axisymmetric such that a center point, axis, or other feature of the component remains at a desired position within the optical system during thermal expansion or contraction. In some embodiments, a support plate configured to support an optical component can be formed with a symmetrical or axisymmetric geometry to maintain alignment of the optical component during thermal expansion cycles. For example, the support plate can be formed with a generally triangular axisymmetric geometry such that the position of the axis of the support can be maintained during thermal expansion cycles.

[0042] In addition to the above, some laser additive manufacturing systems can also be configured to move the optical system or its optical components at high rates and / or at high accelerations. Some systems can move the optical system or optical components at an acceleration that is several times the acceleration due to gravity. For example, some systems can move the optical system at an acceleration of up to 2g (i.e., twice the acceleration due to gravity), 3g, 4g, 5g, or any other suitable value. Additionally or alternatively, some systems can move the optical system at a speed of up to 1 meter per second (m / s), 2m / s, or any other suitable speed. In some embodiments, the optical system can be coupled to a gantry system that is configured to move the optical system at a desired speed and / or acceleration. It will be understood that the mass or weight of the optical system may affect the power required to move the optical system at a desired speed or acceleration, as well as the force generated to move the optical system at a desired acceleration. For example, a heavier optical system may require more power to move at a given speed or acceleration than a lighter optical system, and at a given acceleration, a heavier optical system may generate more force than a lighter system.

[0043] In view of the foregoing, the inventors have recognized and understood the benefits of optical systems designed to be lightweight. Accordingly, some optical systems may include optical support structures, optical components, and / or energy management systems that are designed to be lightweight and / or formed at least in part from various lightweight materials. In some embodiments, the lightweight configuration can reduce the power required to move the optical system at a desired speed or acceleration. Additionally or alternatively, in addition to the stiffness and / or thermal benefits discussed above, certain configurations can also provide the benefits of lightweight manufacturing. For example, in some embodiments, support posts can be formed from a composite material of suitable shape and size to be sufficiently lightweight to reduce the power requirements associated with motion, and sufficiently rigid to increase the resonant frequency of the structure or reduce the maximum displacement experienced by the structure in response to certain accelerations. Additionally or alternatively, in some embodiments, support posts, support plates, and / or heat transfer components can be sized, shaped, and / or formed from suitable materials to reduce the power requirements associated with motion, increase or otherwise tune the resonant frequency, or reduce the maximum displacement experienced by the structure in response to high accelerations. In some cases, the material used to form the component can have suitable thermal properties (eg, thermal conductivity, thermal resistivity, coefficient of thermal expansion, etc.) for managing the energy received by the optical system from the optical energy.

[0044] In various embodiments, the optical system or optical support structure can have any suitable mass or weight to provide the desired characteristics, such as resonant frequency and / or displacement. For example, in some embodiments, the optical support structure, including any support plates and / or support posts, can have a mass between 5 kilograms (kg) and 50 kg, or any intermediate value. Of course, while specific ranges for the mass of the optical support structure are provided, it should be understood that other ranges greater and less than the aforementioned ranges are also contemplated, as the present disclosure is not limited in this respect.

[0045] It will be understood that any embodiment of the systems, components, methods, and / or programs disclosed herein, or any portion thereof, can be used to form any component suitable for production using additive manufacturing. For example, in addition to any other method steps disclosed herein, a method for additively manufacturing one or more components can also include the step of selectively melting one or more portions of multiple layers of precursor material deposited onto a build surface to form the one or more components. This can be done in a sequential manner, where each layer of precursor material is deposited onto the build surface and selected portions of the uppermost layer of precursor material are melted to form individual layers of the one or more components. This process can continue until the one or more components are fully formed.

[0046] Turning to the drawings, specific non-limiting embodiments are described in further detail. It should be understood that the various systems, components, features, and methods described with respect to these embodiments may be used alone and / or in any desired combination, as the present disclosure is not limited to only the specific embodiments described herein.

[0047] Figure 1 A schematic diagram of an additive manufacturing system 100 is shown, according to one embodiment. Additive manufacturing system 100 can include a build volume 102 containing an optical system 104 suspended above a build surface 106 that supports a precursor material 108. Precursor material 108 can be any suitable material for additive manufacturing, including any suitable plastic, metal, polymer, composite, or other powdered or non-powdered material. Optical system 104 can include an optical assembly comprising one or more optical components 110 that can be configured to direct incident light energy 112 along a beam path through optical system 104 toward build surface 106. Optical assembly or components 110 can be supported by an optical support structure that can include one or more support plates 120 and two or more support posts 122. Optical system 104 can also include an energy management system that can include various heat transfer components, including a beam block 142 and one or more heat sinks 146.

[0048] At the point where light energy 112 is incident on precursor material 108, incident light energy 112 can generate a molten pool 114 by melting a portion of the precursor material. Optical system 104 can be movable relative to the build surface via stage system 116 to scan incident light energy 112 over various portions of precursor material 108. After exposure to light energy, the melted portions of the precursor material can cool, solidify, and / or fuse together. When adjacent portions of the precursor material have previously melted, fused, and / or solidified, the melted portions can fuse together with the adjacent portions to form build part 118. This process can be repeated, with new layers of precursor material deposited on top of build part 118, until the build part is complete.

[0049] Figures 2A to 2B A schematic diagram depicting motion along direction 124 of one embodiment of optical system 104 is shown. Figures 2A to 2B In the embodiment of FIG, the energy management system has been removed for clarity of illustration. Figure 2A In the embodiment, the optical system 104 can be in a stationary state. Figure 2B, optical system 104 can be subjected to acceleration by applying a force to cause system 104 to move in direction 124. In this example, the force is applied only to the uppermost portion of optical system 104, rather than being applied equally to every component of the system. As shown in the figure, the optical system can have an intended beam path 126, for example, toward a build surface. In some embodiments, intended beam path 126 can be linear and can coincide with the optical axis of optical system 104, but it will be understood that the intended beam path and / or optical axis can be any suitable linear or nonlinear path through or between any number of optical components. When optical system 104 is stationary, as shown Figure 2A As shown in FIG, the optical component 110 can be properly aligned to direct the incident light energy 112 along the desired beam path 126. However, as will be seen with reference to FIG. Figure 2B As will be appreciated, when subjected to acceleration or deceleration, optical component 110 may become misaligned relative to intended beam path 126. For example, a force causing acceleration along direction 124 may cause optical component 110 to shift 128 from the intended aligned position of the optical component. Displacement 128 of the optical component may cause incident light energy 112 to deviate from intended beam path 126, which may cause the incident light energy to melt or fuse a portion of the precursor material that was not intended to be melted or fuse. This may produce dimensional errors or distortions in the build part. As will be appreciated, the forces and displacements caused by acceleration and deceleration of the optical system may produce vibrations within the optical system that may propagate and / or decay over a period of time. During the decay period, the displacement may oscillate between successive vibration peaks, thereby causing further dimensional distortions in the build part.

[0050] Figure 3 One embodiment of an optical system 104 is depicted that includes an optical assembly 130 that can be configured to direct light energy along a beam path toward a build surface. The optical assembly 130 can include various optical components 110. The optical components can include any suitable element of an optical system, including any suitable optical fiber, lens, window, aperture, mirror, filter, beam block, or any combination thereof. In some embodiments, the optical system can also include an optical support structure 132. The optical support structure can include a plurality of support posts 122A and a plurality of support plates 120A. In some embodiments, each support plate 120A can span between two or more support posts 122A at respective locations along the length of the support posts 122A. Additionally, each support plate can be configured to support at least one optical component 110 of the optical assembly 130. In some embodiments, the support posts and / or support plates can be configured to reduce displacement of the optical components as discussed above, for example, by increasing stiffness and / or tuning the resonant frequency of the optical system in a desired manner.

[0051] In some embodiments, the optical component can be supported by two or more support plates. For example, the optical support structure can include a nested arrangement of support columns and support plates, so that the auxiliary support structure can be supported by the main support structure. In some embodiments, one or more main support plates 120A can span between two or more main support columns 122A. Two or more auxiliary support columns 122B can span between two or more main support plates 120A and be supported by two or more main support plates 120A. One or more auxiliary support plates 120B can span between the auxiliary support columns 122B and be supported by the auxiliary support columns 122B. Each of the auxiliary support plates 120B can support the optical component 110. Because the auxiliary support plates can be supported by the auxiliary support columns spanning between two or more main support plates, each optical component can ultimately be supported by the main support plate 120A. In some embodiments, the auxiliary support columns can be smaller than the main support columns. Additionally or alternatively, the auxiliary support plates can be smaller than the main support plates, for example, to fit within the space between the main support columns. Additionally, while the illustrated embodiment includes only two primary support plates spanning between three primary support posts and three auxiliary support plates spanning between three auxiliary support posts, it will be understood that the optical support structure may include any suitable number of support plates and support posts, as the present disclosure is not limited in this respect. Similarly, while the illustrated embodiment includes only primary and auxiliary support structures, it will be understood that the optical support structure may include any suitable number of support structures, including any suitable number of nested support structures, including only a single (i.e., non-nested) support structure.

[0052] In addition to the above, an optical system according to the present disclosure may include an energy management system that may include at least one heat transfer conduit in thermal contact with at least one support plate. The heat transfer conduit may be configured to receive heat from the at least one support plate to provide a cooling or other heat transfer effect to the support plate. For example, each primary support plate 120A may be in thermal contact with a heat transfer conduit 134. In some embodiments, the heat transfer conduit 134 may be disposed within a through-hole 136 of the support plate, which may be sized and shaped to receive and thermally contact the heat transfer conduit. In other embodiments, the heat transfer conduit may be disposed along the surface of the support plate, such as within a groove formed in the surface of the support plate. While through-holes, surface contact, and grooves are discussed herein, it will be understood that the support plate may be configured to physically and / or thermally contact the heat transfer conduit in any suitable arrangement, as the present disclosure is not limited in this respect. Each heat transfer conduit may be configured to carry a working fluid, which may receive thermal energy from the support plate via the heat transfer conduit. For example, in some embodiments, the heat transfer conduit may be a pipe configured to carry the working fluid therethrough.

[0053] Figure 4An embodiment of a single support plate 120 spanning between three support posts 122 is depicted. In some embodiments, the support plate 120 can include an optical support aperture 168 sized and shaped to supportively receive an optical component. While the figure depicts a circular optical support aperture 168, it will be understood that the optical component can be supported by any suitable arrangement, including apertures having a rectilinear geometry or any other regular or irregular geometry. Additionally, the support plate 120 can be in thermal contact with one or more heat transfer conduits 134, which can be received in through-holes of the support plate. Furthermore, in some embodiments, the heat transfer conduits 134 can be optionally fluidly coupled to coils or other conduits 170 in thermal contact with the support plate. For example, in some embodiments, the coils 170 can be arranged within grooves formed in a surface of the support plate. Coil 170 can be configured to transport the working fluid to and / or from the heat transfer conduit 134 to transfer heat between the support plate and the working fluid. In some embodiments, the heat transfer conduit 134 can optionally be fluidically coupled to a channel 186 configured to transport the working fluid to and / or from the heat transfer conduit 134. Channel 186 can be used to transport the working fluid to and / or from a heat exchanger or other component to transfer heat to and / or from the working fluid. For example, channel 186 can be coupled to a heat exchange circuit that is operable to regulate the temperature of the working fluid. For example, the heat exchange circuit can include a pump, a heat exchanger, a chiller, and / or any other suitable component. In various embodiments, the channel can be comprised of any material suitable for transporting the working fluid, including any suitable plastic, such as polyvinyl chloride (PVC), cross-linked polyethylene (PEX), perfluoroalkoxyalkane (PFA), tetrafluoroethylene (TFE), or any other suitable material. In some embodiments and as shown, channels 186 may alternatively be disposed within the support column 122 or its interior volume. In some embodiments, the heat transfer conduit 134 may be eliminated, and one or more channels 186 may be fluidly coupled to the conduit 170 to supply and / or receive a working fluid for heat exchange relative to the support plate.

[0054] from Figure 4As will be appreciated from the top view of the support plate, the support plate can be formed with a symmetrical geometry relative to the support plate's axis 172. In some embodiments, the support plate can be configured to support an optical component that can be centered about or otherwise oriented about an axis that can coincide with the beam path of incident light energy passing through the optical component. For example, the optical support aperture 168 can be centered about axis 172, such that the optical component can direct incident light energy along axis 172. It will be appreciated that during operation of an optical system in some applications, absorbed light or thermal energy may cause thermal expansion of some components of the optical system. For example, as the system heats and cools during operation, the support plate 120 may expand or contract in a radial direction relative to line 174. As will be appreciated, any asymmetry in the expansion or contraction of the support plate may cause the optical component to become misaligned with axis 172, which may cause the optical component to direct incident light energy in a direction that is misaligned with the axis. Therefore, the support plate can be formed with a symmetrical or axisymmetric geometry to maintain alignment of the optical component during thermal expansion / contraction. For example, the support plate 120 can be formed into a generally triangular axisymmetric geometry as shown so that the axis 172 can remain at or near the center of the optical support opening 168 during thermal expansion and contraction of the optical support opening 168 in radial directions 174.

[0055] Figure 4Also shown in the figures is a coupling mechanism between the support plate and the support posts according to some embodiments. It will be understood that the support plate can be coupled to the support posts in any suitable configuration, any suitable configuration including inserting the support posts into support coupling holes, which can include through holes formed in the support plate. However, in some applications, it may be desirable to control or adjust the tightness of the fit between the support posts and the support plate, for example to limit rattling, shaking, or play between the support posts and the support plate during movement of the optical system. Accordingly, in some embodiments, the clamping portion 176 can include a jaw 178 extending from the support plate 120. The jaw 178 can include a proximal end portion 180 extending from the support plate and a distal end portion 182 spaced apart from the support plate. The jaw 178 can cooperate with the support plate 120 to form a throat 180 that can be sized and shaped to receive the support post 122. The distal end portion 182 can be adjustably or controllably coupled to the support plate 120 such that the coupling can be adjusted or controlled to selectively tighten or loosen the throat 180 around the support post 122. For example, in some embodiments, the distal end portion 182 can include a through-hole through which a threaded fastener 184 can be inserted. The through-hole can be aligned with a threaded bore in the support plate such that the threaded fastener 184 can engage the bore when the threaded fastener is inserted into the through-hole of the distal end portion. As will be appreciated, by selectively rotating the threaded fastener in one direction or the other, the throat can be selectively tightened or loosened around the support post.

[0056] Figure 5 A cross-sectional view of one embodiment of the optical system 104 or a portion of the optical system 104 is depicted. Figure 5Embodiments may include an optical assembly having one or more optical components 110. Optical component 110 may include a single lens or dual lens arrangement, or any other suitable optical component configured to direct incident optical energy 112 from an optical energy source 138 toward a build surface to form a molten pool 114 from a precursor material disposed on the build surface. Optical system 104 may also include an optical support structure including support plate 120 and support posts 122 as described above. Additionally, optical system 104 may include an energy management system configured to receive optical energy 144 traveling in a second direction and / or transfer the optical energy as thermal energy during operation of the laser system. In some embodiments, optical energy 144 may be generated from incident optical energy reflected or scattered from molten pool 114 in the second direction. Additionally or alternatively, optical energy 144 may be emitted from the fiber cladding of various optical fiber components, or optical energy 144 may be deflected, reflected, scattered, diffracted, or refracted at an interface with an optical component or aperture. Thus, while the second direction is illustrated as being opposite or nearly opposite to the first direction of incident light energy 112, it will be understood that the second direction can be any suitable direction, as light energy can travel in a variety of directions, including directions that are opposite, nearly or partially opposite, and / or different from the first direction.

[0057] In some embodiments, the energy management system can include a plurality of heat transfer components, which can include heat transfer conduits 134, heat transfer plates 140, beam blocks, and / or heat sinks. In some embodiments, the heat transfer conduits 134 can extend through each of the support plates 120 and through the plurality of heat transfer plates 140. Each of the heat transfer plates can at least partially surround a beam path along which incident light energy 112 can be directed by the optical assembly. Each of the heat transfer conduits 134 can be in thermal contact with at least one of the heat transfer plates 140 to receive thermal energy from the heat transfer plates. In addition to being in thermal contact with one or more heat transfer conduits, each heat transfer plate can include or be coupled to a heat sink and / or beam block, each of which can be configured to receive and / or transfer energy (e.g., light energy and / or thermal energy).

[0058] In some embodiments, beam block 142 can be arranged along the beam path as shown and can include an aperture sized and shaped to allow incident light energy 112 to pass through the beam block in a first direction (e.g., toward the build surface). Beam block 142 can also include a surface configured to absorb or deflect light energy 144 traveling in a second direction different from the first direction away from the beam path. Additionally or alternatively, in some embodiments, heat transfer plate 140 can include or be coupled to a heat sink 146 configured to receive thermal energy from at least a portion of the light energy 144 traveling in the second direction. In some embodiments, heat sink 146 can at least partially surround beam block 142 to absorb light energy 144 deflected away from the beam path by the beam block. In some embodiments, the beam block can be configured to receive thermal energy from at least a portion of the light energy traveling in the second direction, such that the beam block can additionally function at least partially as a heat sink. The beam block can be thermally coupled to the heat transfer plate 140 so that heat energy can be transferred from the beam block to the heat transfer plate 140, and optionally from the heat transfer plate 140 to the heat transfer conduit 134 or other components. The portion of the heat transfer plate 140 that receives more heat and / or light energy can be made to have a relatively larger mass than the portion that receives less heat and / or light energy. For example, as can be seen in FIG. Figure 5 As seen in FIG, the portion of the heat transfer plate 140 that receives reflected energy from the beam block 142 can be made with a greater radial thickness and / or without radially extending fins on the outer surface. Conversely, the portion that does not receive reflected energy from the beam block or receives less reflected energy from the beam block can be made radially thinner and / or have radially extending fins on the outer surface.

[0059] Figure 6 Depicts, for example, Figure 5FIG2 is a cross-section of one embodiment of an energy management system for an optical system according to the present disclosure, taken along line AA. In the cross-section, it can be seen that a heat sink 146 can surround the beam block 142 to receive light energy deflected from the surface of the beam block. Additionally, the beam block 142 can include an aperture 148 of any suitable size or shape to allow incident light energy to pass through the beam block at a given point along the beam path. It will be appreciated that the incident light energy can include a laser beam that, in some applications, can vary in size or shape along the beam path, and the size and shape of the aperture of the beam block can be selected to correspond to the beam geometry at the point where the beam block will be deployed. In some embodiments (e.g., in applications where multiple laser pixels are aggregated into a single laser beam), the laser beam can have an oblong or elliptical shape at certain points along the beam path. Accordingly, in some embodiments, the aperture 148 can have a corresponding oblong or elliptical shape, such that the aperture has a major axis 150 and a minor axis 152.

[0060] Figure 6 As further shown in the figure, the heat sink can optionally be formed in multiple pieces that can be assembled together within the optical system. In some applications, this arrangement can simplify the manufacture or assembly of the optical system. In some embodiments, the heat sink 146 can include a first portion 154A, a second portion 154B, and a third portion 154C, wherein each portion forms a portion of the inner surface 156. In some embodiments, the inner surface 156 can optionally include a geometry that is configured to increase the rate of heat transfer at the inner surface. For example, in some embodiments, the inner surface 156 can optionally include a plurality of fins 158 to facilitate heat transfer to the heat sink. Although the figure depicts the inner surface 156 having a plurality of fins, it will be understood that other embodiments can include an inner surface having any suitable features or geometries, including a flat surface (e.g., to simplify the manufacture of the heat sink). In some embodiments, each of the first portion 154A, the second portion 154B, and the third portion 154C can be coupled to, supported by, and / or in thermal contact with a separate heat transfer conduit 134. Each heat transfer conduit can be configured to receive thermal energy from a corresponding portion of the heat sink. In some embodiments, the heat transfer conduit 134 can optionally include a component configured to alter the flow of the working fluid through the heat transfer conduit to increase the rate of heat transfer from the heat sink to the working fluid. For example, the heat transfer conduit can optionally include a turbulence-inducing component 160, which can be configured to generate turbulence and / or eddies in the working fluid.

[0061] Figure 7 Depicts, for example, Figure 6A cross section of a portion of the energy management system of the optical system is taken along line BB. Figure 7 , it can be seen that incident light energy 112 can pass through aperture 148 of beam block 142 in a first direction (e.g., toward the build surface) along a beam path. Figure 5 As discussed, the light energy may travel in a second direction different from the first direction after being deflected, reflected, refracted, diffracted, scattered, or otherwise deviated from the beam path. The light energy traveling in the second direction may be absorbed or deflected by various energy management components of the optical system. In various embodiments, the surfaces of the beam block and / or heat sink may be configured to absorb and / or deflect a portion of the light energy traveling in the second direction. For example, in some embodiments, the surface 162 of the beam block 142 may be configured to absorb a portion of the light energy, such as by including a light absorbing coating or surface finish. In other embodiments, the surface 162 may be configured to deflect or reflect a portion of the light energy, such as by including a reflective coating or surface finish. In some embodiments, the surface 162 may be configured to absorb and reflect a portion of the light energy, such as by including a reflective and absorptive coating or surface finish.

[0062] For example, in some embodiments, a first portion 144A of the optical energy can be deflected from a surface 162 of the beam block 142. The first portion 144A can be absorbed by the heat sink 146 as a first portion 164A of thermal energy. In embodiments including a heat transfer conduit 134, the first portion 164A of the thermal energy (or a portion thereof) can be transferred from the heat sink to the heat transfer conduit 134. Additionally, in embodiments in which the heat transfer conduit carries a flow 166 of the working fluid, the first portion 164A of the thermal energy, or a portion thereof, can be transferred to the working fluid to be carried away from the optical system. As described above, in some embodiments, the heat transfer conduit can include a turbulence-inducing component configured to induce turbulence and / or eddies in the flow 166 of the working fluid. For example, the turbulence-inducing component 160 can include a rod inserted into the heat transfer conduit 134. The rod can include a helix or thread around the circumference and along the length of the rod to cause the working fluid to flow in a spiral manner around the rod, thereby improving the cooling effect of the working fluid. Additionally or alternatively, a second portion 144B of the light energy can be absorbed by the light beam block 142 at the surface 162. In some embodiments, the light beam block can be, for example, Figure 5 The heat transfer plate 140 is shown in thermal contact with the heat transfer conduit 134 (it will be understood that the heat transfer plate can be Figure 7 is cut away in the partial cross-sectional view, but may be connected to the heat sink 146 in the same manner as described above. Figure 7146). Although the heat transfer conduit 134 is depicted as being inserted into the through-holes of the heat sink 146, it will be understood that the heat transfer conduit may be coupled to or in thermal contact with the heat transfer plate, heat sink, or beam block in any suitable manner, including using the methods described above with reference to FIG. Figure 4 The adjustable jaw arrangement described.

[0063] Figures 8A to 8C Various embodiments of beam blocks 142 are depicted having apertures 148 of various sizes and shapes. For example, Figure 8A A beam block 142 is depicted having an annular or circular opening 148, and Figure 8B The beam block comprises a cross-shaped opening in which two elliptical shapes intersect so that their major axes extend in multiple directions. Figure 8C , beam block 142 may include more than one aperture, such as multiple apertures 148. From the foregoing, it will be appreciated that the apertures of the beam block may be formed in any suitable shape or configuration, including in suitable regular or irregular geometries, as the present disclosure is not limited in this respect.

[0064] Although the present teachings have been described in conjunction with various embodiments and examples, it is not intended that the present teachings be limited to such embodiments or examples. On the contrary, as will be appreciated by those skilled in the art, the present teachings encompass various alternatives, modifications, and equivalents. Therefore, the foregoing description and accompanying drawings are intended to be illustrative only.

Claims

1. An optical system for use with an additive manufacturing system, the optical system comprising: an optical assembly comprising a plurality of optical components configured to direct laser energy along a beam path toward a build surface to melt a portion of a precursor material on the build surface; as well as An optical support structure comprising a plurality of support posts and a plurality of support plates, each support plate spanning between two or more support posts at a corresponding position along the length of the support posts, and each support plate being configured to support at least one optical component of the optical assembly on the support posts.

2. The optical system according to claim 1, wherein The optical system is coupled to a gantry system and is movable in at least one direction by the gantry system.

3. The optical system according to claim 2, wherein: The optical system is configured to have a maximum displacement of approximately 40 micrometers in a direction away from an axis of the optical system when the optical system is vibrated at a resonant frequency of the system.

4. The optical system according to claim 1, wherein: The optical assembly and the optical support structure are configured to have a resonant frequency between about 400 Hertz (Hz) and about 450 Hz.

5. The optical system according to claim 1, wherein The thickness of the at least one support plate is between about 15 millimeters (mm) and about 25 mm.

6. The optical system according to claim 1, wherein: At least one support column includes a tube formed from a composite material.

7. The optical system according to claim 1, wherein: The plurality of support plates are configured to maintain alignment of the optical components during thermal expansion of the support plates.

8. The optical system according to claim 7, wherein: Each support plate is axisymmetric.

9. The optical system according to claim 1, wherein: Each support plate has an optical support aperture sized and shaped to supportively receive the at least one optical component, the optical support aperture being disposed at or near a center of the support plate.

10. The optical system according to claim 1, wherein: Each support plate has at least two support coupling holes, each support coupling hole is sized and shaped to engage with a corresponding support column of the at least two support columns, each support coupling hole is arranged at or near the periphery of the support plate.

11. The optical system according to claim 1, wherein: At least one support plate is coupled to at least one support post via a clamping portion comprising a jaw extending from and cooperating with the support plate to form a throat sized and shaped to receive the support post, a distal end portion of the jaw comprising a through hole aligned with a bore in the support plate, the through hole and the bore being configured to receive a fastener to adjust the size of the throat to secure the support post within the throat.

12. The optical system according to claim 1, wherein: Each support plate is configured to receive a heat transfer conduit carrying a working fluid to receive thermal energy from the support plate.

13. The optical system according to claim 12, wherein: Each support plate includes a thermal coupling aperture sized and shaped to receive and make thermal contact with the heat transfer conduit.

14. The optical system according to claim 12, wherein: The working fluid circulates through a return conduit disposed within the support column.

15. The optical system of claim 1 , further comprising a plurality of heat transfer tubes and a plurality of heat transfer plates, each of the heat transfer plates spanning between two or more heat transfer tubes and comprising a heat transfer component at least partially surrounding the light beam path between two optical components of the system, and each of the heat transfer plates being configured to absorb and / or deflect optical energy and / or thermal energy, each of the heat transfer tubes being in thermal contact with each of the heat transfer plates and carrying a working fluid to receive thermal energy from the heat transfer plates.

16. The optical system according to claim 15, wherein: At least one of the heat transfer components includes a beam block configured to deflect optical energy away from the beam path.

17. The optical system according to claim 15, wherein: At least one of the heat transfer components includes a heat sink configured to absorb thermal energy.

18. The optical system according to claim 15, wherein: Each of the heat transfer conduits contains a flow of coolant configured to absorb thermal energy from the heat transfer plate and / or the support plate.

19. The optical system according to claim 1, wherein: At least one optical component is supported by two or more support plates.

20. The optical system of claim 19, further comprising two or more support columns extending between the two or more support plates, the at least one optical component being supported by at least one platform spanning between and supported by the two or more support columns.

21. The optical system according to claim 19, wherein: Each support plate includes a channel sized and shaped to receive a coil of tubing thermally and fluidly coupled to the heat transfer conduit.

22. An additive manufacturing system comprising the optical system of claim 1, the build surface, and at least one optical energy source configured to provide the laser energy to the optical assembly.

23. A method for additive manufacturing, the method comprising: directing laser energy along a beam path toward a build surface; melting a portion of the precursor material on the build surface; providing an optical support structure having a plurality of support posts and a plurality of support plates, the support plates spanning between two or more of the support posts at respective locations along the lengths of the support posts; as well as At least one optical component of the optical assembly is supported on the support post.

24. The method of claim 23, further comprising moving the optical system in at least one direction using a stage system.

25. The method according to claim 24, wherein Moving the optical system in at least one direction includes displacing the optical system by up to about 40 micrometers in a direction away from an axis of the optical system while the optical system is vibrating at a resonant frequency of the system.

26. The method according to claim 23, wherein The resonant frequency of the optical assembly and the optical support structure is between about 400 Hertz (Hz) and about 450 Hz.

27. The method according to claim 23, wherein The thickness of the at least one support plate is between about 15 millimeters (mm) and about 25 mm.

28. The method according to claim 23, wherein At least one support column includes a tube formed from a composite material.

29. The method of claim 23, further comprising: The plurality of support plates are used to maintain alignment of the optical components during thermal expansion of the support plates.

30. The method according to claim 29, wherein Each support plate is axisymmetric.

31. The method of claim 23, further comprising: An optical support opening is provided for each support plate at or near the center of the support plate, and the at least one optical component is received in the optical support opening.

32. The method of claim 23, further comprising: At least two support coupling holes are provided for each support plate at or near the periphery of the support plate, and each of the support coupling holes is engaged with a corresponding support column of the at least two support columns.

33. The method of claim 23, further comprising: At least one support plate is coupled to at least one support column using a clamping portion having a jaw extending from and cooperating with the support plate to form a throat, and the throat is utilized to receive the support column, a through hole is provided that aligns with the bore of the support plate, and a fastener is received using the through hole and the bore to adjust the size of the throat to secure the support column within the throat.

34. The method of claim 23, further comprising: Each support plate is utilized to receive a heat transfer conduit carrying a working fluid to receive thermal energy from the support plate.

35. The method of claim 34, further comprising: Thermal contact is made between the thermal coupling holes on each of the support plates and the heat transfer conduits.

36. The method of claim 34, further comprising: The working fluid is circulated through a return conduit within the support column.

37. The method of claim 23, further comprising: providing a plurality of heat transfer conduits and a plurality of heat transfer plates, each of the heat transfer plates spanning between two or more heat transfer conduits and comprising a heat transfer component that at least partially surrounds the light beam path between two optical components of the system; absorbing and / or deflecting optical energy and / or thermal energy using the heat transfer conduits and the heat transfer plates; and receiving thermal energy from the heat transfer plates using the heat transfer conduits.

38. The method of claim 37, further comprising deflecting optical energy away from the beam path using a beam block.

39. The method of claim 37, further comprising absorbing thermal energy using a heat sink.

40. The method of claim 37, further comprising flowing a coolant through the heat transfer conduit and using the coolant to absorb thermal energy from the heat transfer plate and / or the support plate.

41. The method of claim 23, wherein Supporting the at least one optical component includes supporting the at least one optical component using two or more support plates.

42. The method of claim 41, further comprising supporting the at least one optical component with at least one platform spanning between and supported by two or more support posts.

43. The method of claim 41 further comprising utilizing channels within each support plate to receive coils of tubing in thermal and fluid communication with the heat transfer conduits.

44. A component manufactured using the method according to any one of claims 23 to 43.

45. An additive manufacturing system comprising a build surface that supports a precursor material to be melted by incident light energy, the system comprising: an optical assembly configured to direct the incident light energy in a first direction along a beam path toward the build surface; as well as An energy management system, comprising: a beam block arranged along the beam path, the beam block having: an aperture sized and shaped to allow the incident light energy to pass through the beam block in the first direction; and a surface configured to absorb or deflect light energy traveling in a second direction different from the first direction away from the beam path, and A heat sink is configured to receive thermal energy from at least a portion of the optical energy traveling in the second direction.

46. The system of claim 45, wherein: The heat sink is in thermal contact with the beam block to receive heat energy from the beam block.

47. The system of claim 45, wherein: The heat sink at least partially surrounds the beam block to absorb light energy deflected by the beam block away from the beam path.

48. The system of claim 45, wherein: The opening has a major axis and a minor axis, the opening measuring between about 80 millimeters (mm) and about 95 mm along the major axis and between about 5 mm and about 15 mm along the minor axis.

49. The system of claim 45, wherein: The surfaces taper inwardly such that the beam block is generally formed as a cone, wherein the aperture extends through the cone along a height of the cone.

50. The system of claim 45, wherein: The surface is configured to reflect the light energy traveling in the second direction away from the beam path.

51. The system of claim 45, wherein: The surface is configured to deflect the light energy traveling in the second direction toward the heat sink.

52. The system of claim 45, wherein: The surface is configured to deflect at least a portion of the optical energy traveling in the second direction in a direction perpendicular to the beam path and toward the heat sink.

53. The system of claim 45, wherein: The surface is configured to absorb the light energy traveling along the second direction.

54. The system of claim 45, further comprising a heat transfer conduit configured to carry a working fluid thermally coupled to the heat sink and / or the beam block to receive thermal energy therefrom.

55. The system of claim 54, wherein: The heat transfer conduit includes a heat conductive pipe in contact with the heat sink.

56. The system of claim 55, wherein: The beam block and / or the heat sink are attached to and supported by the heat transfer conduit.

57. The system of claim 55, further comprising a turbulence inducing component within the conduit, the turbulence inducing component configured to induce turbulence and / or eddies within the flow of the working fluid.

58. The system of claim 55, further comprising a coil in thermal contact with the heat sink and / or the beam block and in fluid communication with the heat transfer conduit to carry the working fluid through the coil to receive thermal energy from the heat sink and / or the beam block.

59. The system of claim 58, wherein: The coils are arranged in channels formed in a surface of the heat sink and / or the beam block.

60. The system of claim 45, wherein: The heat sink and the beam block are a single component.

61. A method of additive manufacturing, comprising: directing incident optical energy in a first direction along a beam path toward a build surface supporting a precursor material to be melted by the incident optical energy; deflecting light energy traveling in a second direction different from the first direction away from the beam path; as well as Thermal energy is absorbed in a heat sink from at least a portion of the deflected optical energy.

62. The method of claim 61, wherein Directing the incident light energy along the beam path includes directing the incident light energy through an aperture of a beam block, and wherein deflecting the light energy traveling along the second direction includes deflecting the light energy traveling along the second direction from a surface of the beam block and away from the beam path.

63. The method of claim 62, wherein: Absorbing the thermal energy in the heat sink from at least the portion of the deflected optical energy includes conducting the thermal energy from the beam block into the heat sink.

64. The method of claim 62, wherein: Absorbing the thermal energy from at least the portion of the deflected optical energy in the heat sink includes absorbing the thermal energy in the heat sink that at least partially surrounds the beam block.

65. The method of claim 62, further comprising receiving thermal energy from the heat sink and / or the beam block in a heat transfer conduit thermally coupled to the heat sink and / or the beam block.

66. The method of claim 65, further comprising flowing a working fluid through a thermally conductive conduit of the heat transfer conduit, and wherein Receiving the thermal energy in the heat transfer conduit includes receiving the thermal energy in the working fluid.

67. The method of claim 66, further comprising inducing turbulence and / or eddies in the flow of the coolant.

68. The method of claim 66, further comprising flowing the working fluid through a coil in thermal contact with the heat sink.

69. The method of claim 61, wherein Deflecting the optical energy traveling in the second direction includes deflecting the optical energy traveling in the second direction from a surface of the heat sink and away from the beam path.

70. The method of claim 61, wherein Deflecting the optical energy traveling in the second direction includes reflecting the optical energy traveling in the second direction away from the beam path.

71. The method of claim 61, wherein Deflecting the optical energy traveling in the second direction includes deflecting the optical energy traveling in the second direction away from the beam path and toward the heat sink.

72. The method of claim 61, wherein Deflecting the light energy traveling along the second direction includes deflecting the light energy traveling along the second direction in a direction perpendicular to the beam path and toward the heat sink.

73. The method of any one of claims 61 to 72, further comprising melting the precursor material using one or more pixels of laser energy to form one or more features on the build surface.

74. A component manufactured using the method according to any one of claims 61 to 73.

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