A method of making a workpiece in an additive manufacturing process includes determining a preferred angular orientation of the grid array about a build axis extending perpendicular to a layer to be built for a first layer of a workpiece. The preferred angular orientation is selected to align an edge of one or more pixels with an edge of the layer of the workpiece being built. The method further includes orienting a patterned image of radiant energy to the preferred angular orientation by rotating a projector before solidifying a portion of a resin that forms the first layer of the workpiece.

An additive manufacturing system configured to additively build an article can include an energy applicator, a build platform, and a powder nozzle configured to eject powder toward the build platform to be acted on by the energy applicator. The system can include a control module configured to control the energy applicator to create an amorphous structure forming at least a portion of the article.

An additive manufacturing system configured to additively build an article can include an energy applicator, a build platform, and a powder nozzle configured to eject powder toward the build platform to be acted on by the energy applicator. The system can include a control module configured to control the energy applicator to create an amorphous structure forming at least a portion of the article.

Methods, systems, and apparatus, for hybrid additive manufacturing of parts. In one aspect, a method includes providing a workpiece and manufacturing multiple additive layers on a surface of the workpiece. Manufacturing each of the multiple additive layers includes forming one or more formed layers on a surface of the workpiece by depositing a quantity of powder material on a growth surface, the growth surface inclusive of at least one of a first surface of the workpiece and a second surface of a previously formed layer, and applying a first amount of energy to the quantity of powder material to fuse the particles of the powder material into a formed layer fused to the growth surface, where the formed layer includes a formed surface, and further applying a secondary process to a particular area of the formed surface of the one or more formed layers on the workpiece.

The invention relates to an additive manufacturing method in which a component (10, 42, 43, 44, 45) is produced in layers using an energy beam (8, 41, 58) which solidifies a starting material (4) and is irradiated by energy beam irradiating means (9, 22, 31, 38, 39, 55, 59, 61) while the starting material (4) is held by a base surface (3, 15, 30, 36, 52) arranged on a base element (2, 16, 29, 35, 51). While the starting material (4) is being irradiated with the energy beam (8, 41, 58), the base element (2, 16, 29, 35, 51) is moved by a rotational component which has a base element rotational axis, wherein the starting material (4) is held on the base surface (3, 15, 30, 36, 52) by a centrifugal acceleration generated by the rotational component. The invention is characterized in that a rotational movement is produced for at least some of the energy beam irradiating means (9, 22, 31, 38, 39, 55, 59, 61). Analogously, at least one energy beam rotational axis (46) is proposed for rotating at least some of the energy beam irradiating means (9, 22, 31, 38, 39, 55, 59, 61) in an additive manufacturing device in which the starting material (4) is held on a base surface (3, 15, 30, 36, 52) by a centrifugal acceleration.

The invention relates to an additive manufacturing method in which a component (10, 42, 43, 44, 45) is produced in layers using an energy beam (8, 41, 58) which solidifies a starting material (4) and is irradiated by energy beam irradiating means (9, 22, 31, 38, 39, 55, 59, 61) while the starting material (4) is held by a base surface (3, 15, 30, 36, 52) arranged on a base element (2, 16, 29, 35, 51). While the starting material (4) is being irradiated with the energy beam (8, 41, 58), the base element (2, 16, 29, 35, 51) is moved by a rotational component which has a base element rotational axis, wherein the starting material (4) is held on the base surface (3, 15, 30, 36, 52) by a centrifugal acceleration generated by the rotational component. The invention is characterized in that a rotational movement is produced for at least some of the energy beam irradiating means (9, 22, 31, 38, 39, 55, 59, 61). Analogously, at least one energy beam rotational axis (46) is proposed for rotating at least some of the energy beam irradiating means (9, 22, 31, 38, 39, 55, 59, 61) in an additive manufacturing device in which the starting material (4) is held on a base surface (3, 15, 30, 36, 52) by a centrifugal acceleration.

An additive manufacturing apparatus comprises a laser beam source emitting a laser beam, a build platform, a powder source depositing a layer of powder onto the build platform, and a scanning assembly disposed along an optical path between the laser beam source and the build platform. The scanning assembly comprises at least one solid state optical deflector that modifies at least one of a size or an impingement location of the laser beam on the layer of powder at a scanning position of the laser beam. The at least one solid state optical deflector may be used to heat treat the layer of powder either before or after the powder is melted.

An additive manufacturing apparatus comprises a laser beam source emitting a laser beam, a build platform, a powder source depositing a layer of powder onto the build platform, and a scanning assembly disposed along an optical path between the laser beam source and the build platform. The scanning assembly comprises at least one solid state optical deflector that modifies at least one of a size or an impingement location of the laser beam on the layer of powder at a scanning position of the laser beam. The at least one solid state optical deflector may be used to heat treat the layer of powder either before or after the powder is melted.

A method of additive manufacture is disclosed. The method may include providing a powder bed and directing a shaped laser beam pulse train consisting of one or more pulses and having a flux greater than 20 kW/cm.sup.2 at a defined two dimensional region of the powder bed. This minimizes adverse laser plasma effects during the process of melting and fusing powder within the defined two dimensional region.

A method for manufacturing a three-dimensional object by solidifying selected areas of consecutive powder layers is provided. At least one electron beam successively irradiates predetermined sections of each powder layer by moving an interaction region in which the electron beam interacts with the powder layer. Electromagnetic radiation from a radiation source is directed onto the powder layer to reduce local electrostatic charging in the interaction region. In this way, levitation and scattering of charged powder will be avoided.