A method of additively manufacturing a three-dimensional object may be performed using an irradiation sequence that is based at least in part on a predicted location of one or more fume plumes emitted from the powder material when irradiated by a plurality of energy beams. An exemplary method may include determining, with a computing device, an irradiation sequence for selectively consolidating powder material using an energy beam system of an additive manufacturing machine, and providing control commands, from the computing device to the energy beam system, configured to cause the energy beam system to emit a plurality of energy beams to selectively consolidate the powder material.

The invention provides a cross-flow separation element comprising a single-piece rigid porous support (2) having within its volume at least one channel (4.sub.1) for passing a flow of the fluid medium for treatment, which channel presents a flexuous flow volume (V1) defined by sweeping a generator section along a curvilinear path around a reference axis, and in that the reference axis does not intersect said generator section and is contained within the volume of the porous support.

The invention provides a cross-flow separation element comprising a single-piece rigid porous support (2) having within its volume at least one channel (4.sub.1) for passing a flow of the fluid medium for treatment, which channel presents a flexuous flow volume (V1) defined by sweeping a generator section along a curvilinear path around a reference axis, and in that the reference axis does not intersect said generator section and is contained within the volume of the porous support.

A 3-dimensional shaping apparatus manufactures a 3-dimensional shaped object. The 3-dimensional shaping apparatus includes a beam irradiation unit, a spatial light modulator, a splitting optical system, and a scanning unit. The beam irradiation unit emits a light beam. The spatial light modulator spatially modulates the light beam emitted by the beam irradiation unit at least on the first axis. The splitting optical system includes at least one lens array having a plurality of lenses arranged along the first axis and splits the light beam modulated by the spatial light modulator into a plurality of light beams by the lens array. The scanning unit scans the shaping material with the plurality of light beams from the splitting optical system.

An additive manufacturing system (100) includes a build tool (110) configured to deposit a feedstock material and/or deliver consolidation energy promoting consolidation of the feedstock material within an accessible range defining a build space. The system also includes a controller (120) configured to determine a build trajectory through the build space, where the build trajectory includes build points at which the feedstock material and/or the consolidation energy is applied (202), determine respective consolidation times of the feedstock material for one or more of the plurality of the build points (204), determine a deposition rate at which the feedstock material is deposited and/or consolidation energy is delivered to the feedstock material based at least in part on the determined consolidation times of the feedstock material (204), and cause the build tool to build an object in accordance with the determined build trajectory and the determined deposition rate (208).

An additive manufacturing system (100) includes a build tool (110) configured to deposit a feedstock material and/or deliver consolidation energy promoting consolidation of the feedstock material within an accessible range defining a build space. The system also includes a controller (120) configured to determine a build trajectory through the build space, where the build trajectory includes build points at which the feedstock material and/or the consolidation energy is applied (202), determine respective consolidation times of the feedstock material for one or more of the plurality of the build points (204), determine a deposition rate at which the feedstock material is deposited and/or consolidation energy is delivered to the feedstock material based at least in part on the determined consolidation times of the feedstock material (204), and cause the build tool to build an object in accordance with the determined build trajectory and the determined deposition rate (208).

An additive manufacturing system (100) includes a build tool (110) configured to deposit a feedstock material and/or deliver consolidation energy promoting consolidation of the feedstock material within an accessible range defining a build space. The system also includes a controller (120) configured to determine a build trajectory through the build space, where the build trajectory includes build points at which the feedstock material and/or the consolidation energy is applied (202), determine respective consolidation times of the feedstock material for one or more of the plurality of the build points (204), determine a deposition rate at which the feedstock material is deposited and/or consolidation energy is delivered to the feedstock material based at least in part on the determined consolidation times of the feedstock material (204), and cause the build tool to build an object in accordance with the determined build trajectory and the determined deposition rate (208).

A method of calibrating a laser of an additive manufacturing system involves processing a test pattern with the laser while varying one or more of laser power and/or scan speed. Thermal energy emitted from the resulting meltpool is measured while processing the test pattern. The power of the laser is calculated using a relationship between volumetric energy density and the thermal emissions, and the laser power is adjusted based on the calculated laser power. An additive manufacturing system for performing such a method may include a laser, a thermal sensor configured to measure meltpool thermal emissions, a processor configured to calculate a laser power based on the measured meltpool thermal emissions of the test pattern, and a controller configured to adjust the laser power based on the calculated laser power.

A method of calibrating a laser of an additive manufacturing system involves processing a test pattern with the laser while varying one or more of laser power and/or scan speed. Thermal energy emitted from the resulting meltpool is measured while processing the test pattern. The power of the laser is calculated using a relationship between volumetric energy density and the thermal emissions, and the laser power is adjusted based on the calculated laser power. An additive manufacturing system for performing such a method may include a laser, a thermal sensor configured to measure meltpool thermal emissions, a processor configured to calculate a laser power based on the measured meltpool thermal emissions of the test pattern, and a controller configured to adjust the laser power based on the calculated laser power.

In the context of additive manufacturing processes wherein an object is built by layered accumulations of discrete instantaneous deposits of feedstock material at specific locations according to a three-dimensional digital data model, systems and methods are taught for operating multiple independently-moving depositing devices in a shared build space to build the object. In some embodiments, depositing components perform discrete material depositing actions according to sequential lists of deposit location instructions which are dynamically sortable, enabling a control methodology to alleviate collision risks among depositing components and to improve thermal conditions of a workpiece during construction. Further embodiments provide for dynamic apportionment of discrete deposition actions among the available depositing devices for load balancing and fault tolerance.