WO2021003309A2

WO2021003309A2 - Selective sintering and powderbed containment for additive manufacturing

Info

Publication number: WO2021003309A2
Application number: PCT/US2020/040565
Authority: WO
Inventors: Alton Hugh Phillips; Yeon-Jun Choi; Lexian GUO; Daniel Gene Smith; Michael Birk BINNARD; Jacek Kazimierz TYMINSKI; Eric Peter Goodwin; Johnathan Agustin MARQUEZ; Brett William HERR; Matthew Parker-Mccormick Bjork; Patrick Shih CHANG; Motofusa Ishikawa; Paul Derek Coon
Original assignee: Nikon Corporation
Priority date: 2019-07-02
Filing date: 2020-07-01
Publication date: 2021-01-07
Also published as: WO2021003309A3

Abstract

A processing machine (10) for building an object (11) from powder (12) includes a build platform (32) that supports a powder layer (14), and an energy system (22). The energy system (22) selectively heats a portion of the powder (12) to generate a sintered portion (26) in the powder layer (14); and subsequently melts the powder (12) to generate a melted portion (28) in the sintered portion (26) of the powder layer (14) to form the object (11). The sintered portion (26) is smaller than the entire powder layer (14). Thus, only a selected, sintered portion (26) of the powder layer (14) is sintered, instead of the entire powder layer (14). A containment structure (611 B) can be concurrently formed to capture unsintered powder (29).

Description

SELECTIVE SINTERING AND POWDERBED CONTAINMENT

FOR ADDITIVE MANUFACTURING

RELATED APPLICATIONS

[0001] This application claims priority on U.S. Provisional Application No: 62/869,858 filed on July 2, 2019 and entitled “SELECTIVE SINTERING FOR ADDITIVE MANUFACTURING”. As far as permitted the contents of U.S. Provisional Application No: 62/869,858 are incorporated in their entirety herein by reference.

[0002] This application also claims priority on U.S. Provisional Application No: 62/943,010 filed on December 3, 2019 and entitled“POWDERBED CONTAINMENT FOR 3D BUILD PRINTING SYSTEM PARTS”. As far as permitted the contents of U.S. Provisional Application No: 62/943,010 are incorporated in their entirety herein by reference.

[0003] Additionally, as far as permitted the contents of PCT Application No: PCT/US18/67407 entiteld“ADDITIVE MANUFACTURING SYSTEM WITH ROTARY POWDER BED” filed on December 22, 2018, and the contents of PCT Application No: PCT/US18/67406 entiteld“ROTATING ENEGY BEAM FOR THREE-DIMENSIONAL

PRINTER” filed on December 22, 2018 are incorporated in their entirety herein by reference.

BACKGROUND

[0004] Three-dimensional printing systems are used to print three-dimensional objects. Existing three-dimensional printing systems are relatively slow, have a low throughput, are expensive to operate, and/or generate excessive waste.

[0005] One such system is an electron beam additive manufacturing (EBAM) system that uses an electron beam generator to generate an electron beam, and a powder bed in which layers of very small powder particles are sequentially deposited over time. For each powder layer, the electron beam is directed to melt certain particles to form the object. However, with an EBAM system, because the electron beam uses a stream of charged particles (electrons) to heat the powder particles, those particles can develop a charge and repulse each other. When the charge is large enough, the particles develop enough repulsive force to overcome gravity and fly apart. This phenomenon has many names including powder ‘smoking’ and powder ‘spreading’.

[0006] One method used to inhibit smoking includes completely sintering each powder layer to a large fraction of the melting temperature of the powder. This lightly melts (“sinters”) the powder of each layer together. For example, each powder layer can be sintered by rapidly scanning the electron beam over the entire powder bed using a defocused electron beam so that the charge buildup in the powder is given time to dissipate while the powder slowly heats. For each powder layer, once it is sintered together, the electron beam can be controlled to melt the desired regions of the powder layer to form a portion of the object.

[0007] Unfortunately, this sintering process has a number of disadvantages. For example, it is time consuming to sinter each powder layer. This slows production time.

[0008] Further, the sintered powder is lightly melted together and sticks together when the powder bed is returned to room temperature. Thus, the sintered powder needs to be forcibly removed.

[0009] A conventional technique for removal includes sand blasting the partially melted powder using un-melted powder. While this technique works for areas that can be hit by the sand blasting spray, it does not work for internal channels which cannot be so accessed. In general, one of the major advantages to additive manufacturing is the ability to construct complicated internal channels. This advantage is diminished when using an EBAM system and the sintering process described above.

[0010] Another cited advantage of additive manufacturing is that there is very little waste as the powder can be reused. However, the sintered powder does not return to the original powder size, even when broken apart because the small powder grains have begun to fuse together. For this reason, the sintered powder has limited reusability. Since all of the powder is partially melted in the above-mentioned sintering process, this reusability is limited.

SUMMARY

[0011] The present implementation is directed to a processing machine for building an object from powder. In various implementations, the processing machine includes a build platform and an energy system. The build platform supports a first powder layer. The energy system (i) heating the powder in a sintered portion of the first powder layer, the sintered portion being smaller than the first powder layer; and (ii) melting the powder in a melted portion of the sintered portion of the first powder layer to form a first section of the object. Stated in another fashion, the energy system (i) generates the sintered portion in the first powder layer, the sintered portion being smaller than the first powder layer; and (ii) generates the melted portion in the sintered portion, the melted portion of the first powder layer comprising a first section of the object.

[0012] In some embodiments, the melted portion is smaller than the sintered portion. Additionally, in one such embodiment, the melted portion is encircled by the sintered portion.

[0013] Additionally, in certain embodiments, the sintered portion has a sintered outer perimeter, and the melted portion is positioned within the sintered outer perimeter. In one such embodiment, the melted portion is spaced apart a separation distance from the sintered outer perimeter that is less than twenty millimeters and greater than 0.5 millimeters. In another such embodiment, the melted portion is spaced apart a separation distance from the sintered outer perimeter that is less than ten millimeters and greater than one millimeter. In still another such embodiment, the melted portion is spaced apart a separation distance from the sintered outer perimeter that is less than five millimeters and greater than one millimeter.

[0014] Further, in some embodiments, (i) the first powder layer has a layer surface area; (ii) the sintered portion has a sintered surface area; (iii) the melted portion has a melted surface area; (iv) the layer surface area is larger than the sintered surface area; and (v) the sintered surface area is larger than the melted surface area. In one such embodiment, the layer surface area is at least ten percent larger than the sintered surface area, and the sintered surface area is at least one percent larger than the melted surface area. In another such embodiment, the layer surface area is at least twenty-five percent larger than the sintered surface area, and the sintered surface area is at least two percent larger than the melted surface area.

[0015] In certain embodiments, the build platform supports a second powder layer positioned on top of the first powder layer. In such embodiments, the energy system (i) sinters a sintered portion of the second powder layer that is smaller than the second powder layer; and (ii) melts the powder in a melted portion of the sintered portion of the second powder layer to form a second section of the object. Stated in another fashion, the energy system (i) generates the sintered portion in the second powder layer, the sintered portion being smaller than the second powder layer; and (ii) generates the melted portion in the sintered portion, the melted portion of the second powder layer comprising a second section of the object. In one such embodiment, the sintered portion of the second powder layer at least partly overlaps the sintered portion of the first powder layer. Additionally, in another such embodiment, the melted portion of the second powder layer at least partly overlaps the melted portion of the first powder layer. Further, in some such embodiments, the melted portion of the second powder layer is fused with the melted portion of the first powder layer.

[0016] Additionally, in some embodiments, the energy system includes an electron beam generator that generates an electron beam that heats and sinters the sintered portion of the first powder layer, and subsequently heats and melts the melted portion of the first powder layer. [0017] Further, in some embodiments, the energy system includes a laser beam generator that generates a laser beam that heats and sinters the sintered portion of the first powder layer and subsequently melts the melted portion of the first powder layer.

[0018] Additionally, in certain embodiments, the energy system includes (i) a sinter system that sinters the powder in the sinter portion; and (ii) a melting system that melts the powder in the melted portion. In one such embodiment, the sinter system generates an electron beam, and the melting system generates an electron beam. In another such embodiment, the sinter system generates an electron beam, and the melting system generates a laser beam. In still another such embodiment, the sinter system generates a laser beam, and the melting system generates an electron beam. In yet another such embodiment, the sinter system generates an optical beam including infrared, visible and/or ultraviolet light, and the melting system generates an electron beam. In still another such embodiment, the sinter system includes an irradiation device that generates an irradiation beam. In yet another embodiment, the sinter system generates at least one of the following: a laser beam, a proton beam, a particle beam, an ion beam, an infrared beam, an ultraviolet beam, or a visible beam.

[0019] In some embodiments, the melted portion melted by the energy system comprises a section of a containment structure. In one embodiment, the containment structure retains at least some of the powder on the build platform. Additionally, in one embodiment, the containment structure retains the object. Further, in certain such embodiments, the processing machine further includes a robotic arm that selectively moves the containment structure with the object from build platform.

[0020] Additionally, in certain embodiments, the build platform is movable relative to the energy system.

[0021] Further, in some embodiments, the sinter system and the melting system are calibrated relative to each other.

[0022] Additionally, in another application, the present invention is further directed toward a method for building a three-dimensional object from powder, the method including the steps of supporting a first powder layer with a build platform; generating a sintered portion in the first powder layer with an energy system, the sintered portion being smaller than the first powder layer; and generating a melted portion in the sintered portion of the first powder layer with the energy system to form a first section of the object.

[0023] In another implementation, the processing machine includes (i) a build platform having a support surface that supports the powder; (ii) a measurement device that provides measurement feedback; (iii) an energy system that generates an energy beam that is adapted to melt at least a portion of the powder; and (iv) a control system that controls the energy system to direct the energy beam and the measurement feedback to calibrate the energy system. For example, the support surface can include a fiducial mark that is irradiated by the energy beam from the energy system to calibrate the energy system. The measurement device can monitor scattered light to generate the measurement feedback used to calibrate the energy system. Additionally, or alternatively, the measurement device can include an image sensor that monitors heat generated in the powder to generate the measurement feedback used to calibrate the energy system. Additionally, or alternatively, the energy system includes a sinter system that directs a sinter beam at the powder to sinter the powder, and a melting system that generates a melting beam at the powder to melt the powder, and the control system uses measurement feedback to calibrate the sinter system and the melting system. In yet another implementation, the processing machine includes a build platform including a support surface that supports a powder layer of powder, the support surface that includes a fiducial mark; and an energy system that generates an energy beam to irradiate the fiducial mark.

[0024] In another implementation, the processing machine includes (i) a mover that moves the build platform so a specific position on the build platform is moved along a moving direction; (ii) a powder supply device which supplies the powder to the moving build platform; (iii) an energy system irradiates at least a portion of the powder layer with an energy beam to form at least a portion of the object from the powder layer during a first period of time; and (iv) a measurement device which measures at least portion of the object during a second period of time; wherein at least part of the first period in which the energy system irradiates the powder with the energy beam and at least part of the second period in which the measurement device measures are overlapped.

[0025] In still another implementation, the processing machine includes: (i) a mover which moves the build platform so as to move a specific position on the build platform along a moving direction; (ii) a powder supply device which supplies a powder to the build platform which moves, and forms a powder layer; and (iii) an irradiation device that changes an irradiation position where the beam is irradiated to the powder layer along a direction crossing the moving direction.

[0026] In yet another implementation, the processing machine includes: (i) a mover which moves the build platform so as to move a specific position on the build platform along a moving direction; (ii) a powder supply device which supplies a powder to the build platform which moves, and forms a powder layer; and (iii) an irradiation device (also referred to as an energy system) including a plurality of irradiation systems which irradiate the layer with an energy beam to form a built part from the powder layer, wherein the irradiation systems arranged along a direction crossing the moving direction.

[0027] In still another implementation, the processing machine includes: (i) a build platform; (ii) a powder supply device that deposits the powder onto the build platform; and (iii) a mover that rotates at least one of the build platform and the powder supply device about a rotation axis while the powder supply device deposits the powder onto the build platform.

[0028] In another implementation, the processing machine includes: (i) a build platform including a support surface; (ii) a mover which moves the build platform so a specific position on the support surface is moved along a moving direction; (iii) a powder supply device which supplies a powder to the moving build platform to form a powder layer during a powder supply time; and (iv) an energy system device which irradiates at least a portion of the powder layer with an energy beam to form at least a portion of the object from the powder layer during an irradiation time; and wherein at least part of the powder supply time and the irradiation time are overlapped.

[0029] In still another implementation, the processing machine includes: (i) a support device (“build platform”) including a non-flat support surface; (ii) a powder supply device which supplies a powder to the support device and which forms a curved powder layer; and (iii) an irradiation device which irradiates the layer with an energy beam to form a built part from the powder layer.

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The novel features of this embodiment, as well as the embodiment itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:

[0031] Figure 1 is a schematic side illustration, in partial cut-away of an embodiment of a processing machine having features of the present embodiments that is usable for building an object from powder;

[0032] Figure 2A is a schematic top illustration of a material bed assembly retaining a second powder layer;

[0033] Figure 2B is a schematic top illustration of the material bed assembly and the second powder layer of Figure 2A after generating a sintered portion;

[0034] Figure 2C is a schematic top illustration of the material bed assembly and the second powder layer of Figure 2A after generating the sintered portion, and melting of a melted portion;

[0035] Figure 3A is a schematic top illustration of the material bed assembly and a third powder layer after sintering of the sintered portion;

[0036] Figure 3B is a schematic top illustration of the material bed assembly and the third powder layer of Figure 3A after generating the sintered portion, and melting of the melted portion;

[0037] Figure 4 is an image of a portion of a powder layer, a first sintered region, and a first melted region;

[0038] Figure 5 is an image that illustrates a first sintered region and a second sintered region;

[0039] Figure 6A is a schematic side illustration, in partial cut-away of the processing machine with a built containment structure and an object;

[0040] Figure 6B is a simplified top illustration of the material bed assembly, the containment structure, and the object of Figure 6A;

[0041] Figure 7 is a simplified top illustration of the material bed assembly, the object, and a different containment structure;

[0042] Figure 8 is a simplified top illustration of the material bed assembly, the object, and still another, different containment structure;

[0043] Figure 9 is a schematic side illustration, in partial cut-away of another embodiment of a processing machine for building an object from powder;

[0044] Figure 10A is a schematic side illustration, in partial cut-away of still another embodiment of a processing machine for building an object from powder;

[0045] Figure 10B is a simplified schematic top view illustration of a portion of the processing machine illustrated in Figure 10A, and the object;

[0046] Figure 1 1 is a schematic side illustration, in partial cut-away of yet another embodiment of a processing machine for building an object from powder;

[0047] Figure 12 is a top view of another material bed assembly;

[0048] Figure 13 is a simplified top view of a portion of still another embodiment of a processing machine;

[0049] Figure 14 is a simplified top view of a portion of still another embodiment of a processing machine for building an object from powder;

[0050] Figure 15 is a simplified side illustration of a portion of yet another embodiment of the processing machine;

[0051] Figure 16A is a simplified side illustration of a portion of yet another embodiment of the processing machine;

[0052] Figure 16B is a top view of a support bed in which curved support regions are shaped into linear rows;

[0053] Figure 16C is a top view of a support bed in which curved support regions are shaped into annular rows;

[0054] Figure 17 is a simplified side illustration of a portion of still another embodiment of the processing machine; and

[0055] Figure 18 is a simplified side perspective illustration of a portion of yet another embodiment of the processing machine for building an object from powder.

DESCRIPTION [0056] Figure 1 is a simplified schematic side illustration of a processing machine

10 that may be used to manufacture one or more three-dimensional objects 1 1. As provided herein, the processing machine 10 can be an additive manufacturing system, e.g. a three-dimensional printer, in which powder 12 (illustrated as small circles) is joined, melted, solidified, and/or fused together in a series of powder layers 14 (illustrated as dashed horizontal lines) to manufacture one or more three-dimensional object(s) 1 1 .

[0057] The type of three-dimensional object(s) 1 1 manufactured with the processing machine 10 may be almost any shape or geometry. As a non-exclusive example, the three-dimensional object 1 1 may be a metal part, or another type of part, for example, a resin (plastic) part or a ceramic part, etc. The three-dimensional object

1 1 may also be referred to as a“built part”.

[0058] The type of powder 12 joined and/or fused together may be varied to suit the desired properties of the object(s) 1 1 . As a non-exclusive example, the powder 12 may include metal powder grains (e.g., including one or more of titanium, aluminum, vanadium, chromium, copper, stainless steel, or other suitable metals) or alloys for metal three-dimensional printing. Alternatively, the powder 12 may be non-metal powder, a plastic, polymer, glass, ceramic powder, organic powder, an inorganic powder, or any other material known to people skilled in the art. The powder 12 may also be referred to as“material”.

[0059] A number of different designs of the processing machine 10 are provided herein. In certain implementations, the processing machine 10 includes (i) a material bed assembly 16; (ii) a powder supply device 18 (illustrated as a box); (iii) a measurement device 20 (illustrated as a box); (iv) an energy system 22 (illustrated as a box) that generates an energy beam 22A; and (v) a control system 24 (illustrated as a box) that cooperate to make each three-dimensional object 1 1 . The design of each of these components may be varied pursuant to the teachings provided herein. Further, the positions of the components of the processing machine 10 may be different than that illustrated in Figure 1 . Moreover, the processing machine 10 can include more components or fewer components than illustrated in Figure 1 . For example, the processing machine 10 can include a cooling device (not shown in Figure 1 ) that uses radiation, conduction, and/or convection to cool the powder 12.

[0060] As an overview, for each powder layer 14, the energy system 22 is controlled to (i) heat the powder 12 only in a sintered portion 26 (partly illustrated with triangles) that is smaller than the overall powder layer 14 to generate the sintered portion 26; and (ii) melt the powder 12 in a melted portion 28 (illustrated with small squares) to form each layer of the object 1 1 . For each powder layer 14, the powder 12 outside the sintered portion 26 is not sintered and is in an unsintered portion 29 of the respective powder layer 14.

[0061] In this implementation, the powder 12 in the sintered portion 26 of each powder layer 14 is sintered to barely melt and sinter the powder 12. The sintered portion 26 has not melted enough to be structurally strong, but it has melted enough to stick together. It is this slight melting that keeps the powder 12 from flying apart when the energy beam 22A subsequently melts the powder 12 in the melted portion 28.

[0062] For each powder layer 14, (i) the powder 12 in the sintered portion 26 is heated at a sufficient temperature and for a sufficient time so that this“sintered powder” becomes a somewhat coherent mass without fully melting, (the“sintered powder” can be also be referred to as“partially melted powder”); (ii) the powder 12 in the melted region 28 is fully melted and can be referred to as“fully melted powder”; and (iii) the powder 12 outside of the sintered portion 26 (in the unsintered portion 29) is not sintered (not partly melted) or drastically altered, and can be referred to as“unsintered powder”. It should be noted that during the melting process, some of the previously sintered powder in the sintered portion 26 is melted and becomes the fully melted (fused) powder of the melted portion 28.

[0063] With the implementations provided herein, because only the sintered portion 26 of each powder layer 14 is sintered, (i) the time required to sinter each powder layer 14 is reduced; (ii) the amount of partially melted powder is reduced, thereby reducing the processing time required to remove the partially melted powder; (iii) complicated internal channels can be formed without being fully blocked by partially melted powder; and/or (iv) there is less partially melted powder, and more unsintered powder in each powder layer, and this results in more powder 12 that can be reused in the manufacture of subsequent objects 1 1 .

[0064] Stated in another fashion, the problems created by sintering each entire powder layer 14 is solved by selectively sintering only an area (the sintered potion 26) that is slightly larger than the area (melted portion 28) that will be melted. This results in improved throughput, improved powder reusability and the possibility of interior or captive channels.

[0065] A number of Figures include an orientation system that illustrates an X axis, a Y axis that is orthogonal to the X axis, and a Z axis that is orthogonal to the X and Y axes. It should be noted that any of these axes can also be referred to as the first, second, and/or third axes. Further, as used herein, movement with six degrees of freedom shall mean along and about the X, Y, and Z axes.

[0066] In Figure 1 , a portion of the material bed assembly 16 is illustrated in cut away so that the powder 12, the powder layers 14 and the object 1 1 are visible. With the present design, one or more objects 1 1 can be simultaneously made with the processing machine 10. In Figure 1 , two spaced apart objects 1 1 are visible. In this design, these objects 1 1 can remain separate or they can be joined in subsequently added layers to form a larger object 1 1 .

[0067] It should be noted that any of the processing machines 10 described herein may be operated in a controlled environment, e.g. such as a vacuum, using a build chamber 30 (illustrated in Figure 1 as a box). For example, one or more of the components of the processing machine 10 can be positioned entirely or partly within the build chamber 30. Alternatively, at least a portion of one or more of the components of the processing machine 10 may be positioned outside the build chamber 30. Still alternatively, the processing machine 10 may be operated in a non-vacuum environment such as an inert gas (e.g., nitrogen gas or argon gas) environment.

[0068] The material bed assembly 16 supports the powder 12 and the object 1 1 while being formed. In the simplified implementation illustrated in Figure 1 , the material bed assembly 16 includes (i) a build platform 32 having a support surface 32A that supports the powder layers 14; (ii) a side wall assembly 34; and (iii) a platform mover 36 (e.g., one or more actuators, and illustrated as a box) that selectively moves the build platform 32 downward as each subsequent powder layer 14 is added. [0069] In one implementation, the build platform 32 is flat, rectangular-shaped, and the side wall assembly 34 is rectangular tube-shaped and extends upward around the build platform 32. In this embodiment, the build platform 32 can be moved somewhat similar to a piston relative to the side wall assembly 34 which acts like the piston’s cylinder wall. Alternatively, other shapes of the build platform 32 and/or side wall assembly 34 may be utilized. As non-exclusive examples, the build platform 32 can be flat circular disk-shaped, or polygonal-shaped, with the side wall assembly 34 having the corresponding tubular-shape.

[0070] The powder supply device 18 deposits the powder 12 onto the build platform 36 to sequentially form each powder layer 14. With the present design, the powder supply device 18 sequentially forms individual powder layers 14 on top of the build platform 32.

[0071] For simplicity, the example of Figure 1 illustrates only eight separate, stacked powder layers 14. Moving from bottom to top of Figure 1 , the individual powder layers 14 can be identified as a first powder layer 14A, a second powder layer 14B, a third powder layer 14C, a fourth powder layer 14D, a fifth powder layer 14E, a sixth powder layer 14F, a seventh powder layer 14G, and an eighth powder layer 14H. It should be noted that any of these powder layers 14A-14H can be referred to as a first, second, third, etc., powder layer.

[0072] Further, it should be noted that depending upon the design of the object 1 1 , the building process will require many more powder layers 14 than eight. Moreover, in some embodiments, the first powder layer 14A may not be melted as part of the object(s) 1 1 so that the object(s) 1 1 are not melted directly to the build platform 32. Alternatively, the powder 12 in the first powder layer 14A can be melted as part of the object(s) 1 1 .

[0073] After the powder supply device 18 deposits the second powder layer 14B, the energy system 22 sinters the desired sintered portion 26 of the second powder layer 14B, and subsequently melts the desired melted portion 28 of the second powder layer 14B. Next, the powder supply device 18 deposits the third powder layer 14C, and the energy system 22 sinters the desired sintered portion 26 of the third powder layer 14C, and subsequently melts the desired melted portion 28 of the third powder layer 14C. This process is repeated for each subsequent powder layer 14D-14H.

[0074] In the non-exclusive embodiment in Figure 1 , the powder supply device 18 is a single overhead powder supply that supplies the powder 12 onto the top of the build platform 32. In this design, the powder supply device 18 can include a rake (not shown) or other device that distributes/levels each sequential powder layer 14. Alternatively, the powder supply device 18 can be designed to include multiple powder supplies (at different locations) and/or other ways to distribute/level each sequential powder layer 14.

[0075] The powder supply device 18 can include one or more reservoirs (not shown) which retain the powder 12 and a powder mover (not shown) that moves the powder 12 from the reservoir(s) to the build platform 32. The number of the powder supply devices 18 may be one or plural.

[0076] Still alternatively, in each of the processing machines 10 disclosed herein, the powder supply device 18 can be a table-integrated powder supply (not shown) which delivers the powder 12 from the side or through the material bed assembly 16, or another type of powder supply device.

[0077] The measurement device 20 inspects and monitors the melted (fused) layers of the object 1 1 as they are being built, and/or the deposition of the powder layers 14. The number of the measurement devices 20 may be one or plural. The measurement device 20 may inspect the powder layer(s) 14 or the built part 1 1 optically, electrically, or physically.

[0078] As non-exclusive examples, the measurement device 20 may include one or more optical elements such as a uniform illumination device, fringe illumination device (structured illumination device), cameras that function at one or more wavelengths, lens, interferometer, or photodetector, or a non-optical measurement device such as an ultrasonic, eddy current, or capacitive sensor.

[0079] The energy system 22 is controlled to sinter the powder 12 in the sintered portion 26, and subsequently melt a melted portion 28 in the sintered portion 16 for each powder layer 14. In Figure 1 , the energy system 22 is illustrated as a single system that generates the energy beam 22A that is steered to sinter (by heating) the sintered portion 26, and subsequently steered to melt (by heating) the melted portion 28 for each powder layer 14. Alternatively, the energy system 22 can include multiple energy systems that are used to perform one or both of these functions. For example, the energy system 22 can include (i) one or more sinter systems (not shown in Figure 1 ) that heat the powder 12 in the sinter portion 26 of each powder layer 14; and (ii) one or more melting systems (not shown in Figure 1 ) that melt the powder 12 in the melted portion 28 of each powder layer 14.

[0080] In one embodiment, the energy system 22 is an electron beam generator and the energy beam 22A is a charged particle electron beam. In this design, for each powder layer 14, the electron beam generator 22 is controlled (based on a data regarding the object(s) 1 1 being built) to steer the electron beam 22A to sinter the sintered portion 26, and subsequently melt the melted portion 28 to form at least a portion of the object 1 1 . The data may be corresponding to a computer-aided design (CAD) model data.

[0081] It is appreciated that typically there is no (or very little) cooling time between sintering and melting as it is generally desired to have the sintered part at the same temperature at the start of melting.

[0082] In the electron beam generator 22, the electrons can be quickly and accurately manipulated by electric and magnetic fields to precisely steer the electron beam 22A. The electrons collide with the powder 12 to heat the powder 12. In certain embodiments, the electron beam generator 22 is slightly defocused when heating the sintered portion 26 in each powder layer 14 so that the charge buildup in the powder 12 is given time to dissipate while the powder 12 slowly heats.

[0083] The sinter temperature (and sinter time) required to partly melt and lightly bond the powder 12, and the melt temperature required to fully melt and fully fuse the powder 12 will vary according to the type of powder 12. It is understood that different powders 12 have different melting points and therefore different desired sintering points. The sinter temperature (and sinter time) is selected to partly melt the powder 12 enough to lightly stick together, while not melting it enough to be structurally strong. It is this slight melting that keeps the powder 12 from flying apart when the energy beam 22A from the energy system 22 hits the powder 12. It is further appreciated that the particle size of the powder 12 also plays a role in whether or not the powder 12 flies apart, as the bigger the particles the more charge is needed to overcome gravity. Thus, the particle size of the powder 12 may also be considered when determining the appropriate sinter temperature.

[0084] In alternative, non-exclusive examples, the sinter temperature is less than fifty, sixty, sixty-five, seventy, seventy-five, eighty, or ninety percent of the melt temperature. Further, depending upon the type of powder 12, the sinter temperature must be at least fifty, sixty, sixty-five, seventy, seventy-five, eighty, ninety percent of the melt temperature to achieve the slight melting.

[0085] As non-exclusive examples, the desired sinter temperature may be at least 300, 500, 700, 900, or 1000 degrees Celsius. Stated in a different fashion, in alternative, non-exclusive examples, the sinter temperature is at least 50, 100, 200, 300, 500, 700, or 1000 degrees Celsius less than the melt temperature.

[0086] As non-exclusive examples, the melt temperature may be at least 1000, 1400, 1700, 2000, or more degrees Celsius. In one specific example, the powder 12 is stainless steel. In this example, the melt temperature is at about 1450 degrees Celsius, and the sinter temperature can be about 900 degrees Celsius (the exact melt and sinter temperatures will depend on many things such as the alloy and chamber pressure, etc.).

[0087] The control system 24 controls the components of the processing machine 10 to build the three-dimensional object 1 1 from the computer-aided design (CAD) model by successively adding powder layer 14 by powder layer 14. For example, as provided herein, the control system 24 can control operation of the energy system 22 to selectively sinter the sintered portion 26 of each powder layer 14 to reduce smoking; and subsequently melt the melted portion 28 of each powder layer 14.

[0088] The control system 24 may include, for example, a CPU (Central Processing Unit) 24A, a GPU (Graphics Processing Unit) 24B, and an electronic memory 24C. The control system 24 functions as a device that controls the operation of the processing machine 10 by the CPU executing the computer program. This computer program is a computer program for causing the control system 24 (for example, a CPU) to perform an operation to be described later to be performed by the control system 24 (that is, to execute it). That is, this computer program is a computer program for making the control system 24 function so that the processing machine 10 will perform the operation to be described later. A computer program executed by the CPU may be recorded in a memory (that is, a recording medium) included in the control system 24, or an arbitrary storage medium built in the control system 24 or externally attachable to the control system 24, for example, a hard disk or a semiconductor memory. Alternatively, the CPU may download a computer program to be executed from a device external to the control system 24 via the network interface. Further, the control system 24 may not be disposed inside the processing machine 10, and may be arranged as a server or the like outside the processing machine 10, for example. In this case, the control system 24 and the processing machine 10 may be connected via a communication line such as a wired communications line (cable communications), a wireless communications line, or a network. In the case of physically connecting with a wired communications line, it is possible to use serial connection or parallel connection of IEEE1394, RS-232x, RS-422, RS-423, RS-485, USB, etc. or 10BASE-T, 100BASE TX, 1000BASE- T or the like via a network. Further, when connecting using radio, radio waves such as IEEE 802.1 x, OFDM, or the like, radio waves such as Bluetooth (registered trademark), infrared rays, optical communication, and the like may be used. In this case, the control system 24 and the processing machine 10 may be configured to be able to transmit and receive various types of information via a communication line or a network. Further, the control system 24 may be capable of transmitting information such as commands and control parameters to the processing machine 10 via the communication line and the network. The processing machine 10 may include a receiving device (receiver) that receives information such as commands and control parameters from the control system 24 via the communication line or the network. As a recording medium for recording the computer program executed by the CPU, a CD- ROM, a CD-R, a CD-RW, a flexible disk, an MO, a DVD-ROM, a DVD-RAM, a DVD- R, a DVD + R, a DVD-RW, a magnetic medium such as a magnetic disk and a magnetic tape such as DVD + RW and Blu-ray (registered trademark), a semiconductor memory such as an optical disk, a magneto-optical disk, a USB memory, or the like, and a medium capable of storing other programs. In addition to the program stored in the recording medium and distributed, the program includes a form distributed by downloading through a network line such as the Internet. Further, the recording medium includes a device capable of recording a program, for example, a general- purpose or dedicated device mounted in a state in which the program can be executed in the form of software, firmware or the like. Furthermore, each processing and function included in the program may be executed by program software that can be executed by a computer, or processing of each part may be executed by hardware such as a predetermined gate array (FPGA, ASIC) or program software, and a partial hardware module that realizes a part of hardware elements may be implemented in a mixed form.

[0089] In the simplified example of Figure 1 , the processing machine 10 additionally includes (i) an upper frame assembly 38 that retains the powder supply device 18, the measurement device 20, and the energy system 22; and (ii) a lower frame assembly 40 that retains the material bed assembly 16. It should be noted that the processing machine 10 can be designed to have one or more of the following features: (i) one or more of the powder supply device 18, the measurement device 20, and the energy system 22 can be selectively moved relative to the upper frame assembly 38 and/or the build platform 32 with one or more of the six degrees of freedom; (ii) the upper frame assembly 38 with one or more of the powder supply device 18, the measurement device 20, and the energy system 22 can be selectively moved relative to the build platform 32 with one or more of the six degrees of freedom; (iii) the powder bed assembly 16 can be selectively moved relative to the lower frame assembly 40 with one or more of the six degrees of freedom; and/or (iv) the lower frame assembly 40 with the powder bed assembly 16 can be selectively moved relative to the upper frame assembly 38 with one or more of the six degrees of freedom.

[0090] It should be noted that when a three-dimensional object 1 1 is formed through consecutive fusions of consecutively formed cross-sections of powder layers 14, successively laid down by the powder supply device 18, the partial layer sintering process may be performed on at least one of the powder layers 14A-14H. As provided herein, the partial layer sintering process may be performed on all the powder layers 14A-14H, or on some of the powder layers 14A-14H (e.g., on every other powder layer). For each powder layer 14A-14H, the sintered portion 26 and the melted portion 28 may be designed and determined with the control system 24 based on the design data (e.g., the computer-aided design (CAD) model) of the object(s) 1 1 .

[0091] Figure 2A is a simplified schematic top illustration of the material bed assembly 16 supporting the second powder layer 14B of Figure 1 . At this time, the powder 12 has been evenly distributed and is ready for processing. Further, the powder 12 is at a spread temperature which allows the powder 12 to be easily spread into the first powder layer 14A. Typically, the spread temperature is well below a melt temperature of powder 12 and below a sinter temperature of the powder 12. In some embodiments, the spread temperature is the ambient “room temperature.” In alternative embodiments, the spread temperature may be warmer than the ambient “room temperature”, but lower than the sinter temperature and the melt temperature. For example, in certain non-exclusive alternative embodiments, the spread temperature may be 100, 200, 300, or 500 degrees Celsius.

[0092] Figure 2B is a simplified schematic top illustration of the material bed assembly 16 and the second powder layer 14B of Figure 2A after sintering of the powder 12 in sintered portion 26 (highlighted with small triangles) to the sinter temperature with the energy system 22 (illustrated in Figure 1 ). In Figure 2B, the powder 12 of the second powder layer 14B is represented with just a few small circles. For each powder layer, the powder 12 outside the sintered portion 26 is not sintered and is in the unsintered portion 29.

[0093] Figure 2C is a simplified schematic top illustration of the material bed assembly 16 and the second powder layer 14B of Figure 2A after sintering the powder 12 in the sintered portion 26 (highlighted with small triangles), and subsequently melting the powder 12 in the melted portion 28 (highlighted with small squares) with the energy system 22 (illustrated in Figure 1 ). In this Figure, the powder 12 of the second powder layer 14B is again represented with just a few small circles at the upper left corner. It should be noted that the entire melted portion 28 was previously sintered, and the melted portion 28 overlaps the sintered portion 26. This is represented in Figure 2C with a few triangles intermixed with the squares of the melted portion 28. Further, it should be noted that each melted portion 28 forms a section of the one or more objects 1 1 being built. [0094] With reference to Figures 2B and 2C, for each powder layer 14B, the design of the sintered portion 26 and the melted portion 28 will correspond to the characteristics (size and shape) of the one or more objects 1 1 (illustrated in Figure 1 ) being built. In the simplified example in Figures 2B and 2C, for the second powder layer 14B, (i) the sintered portion 26 includes four spaced apart sintered regions 26A- 26D, and (ii) the melted portion 28 includes four spaced apart melted regions 28A-28D that correspond to the sintered regions 26A-26D. In this example, each of melted regions 28A-28D can remain separate and be part of a separate object 1 1 being built with subsequent layers. Alternatively, one or more of the melted regions 28A-28D can be joined together in subsequent (or previous) layers to be part of a larger object 1 1 . Alternatively, depending on the design of the object(s) 1 1 being built, the respective layer 14B can include fewer than four (e.g. 0, 1 , 2 or 3), or more than four spaced apart sintered regions 26A-26D, and corresponding melted regions 28A-28D.

[0095] It should be noted that (i) the shape(s) and number of sintered region(s) 26A- 26D can correspond to the shape(s) and number of melted regions(s) 28A-28D. Stated in another fashion, the size and shape of each sintered region(s) 26A-26D can mirror its corresponding melted region(s) 28A-28D. The goal is to have the sintered region(s) 26A-26D be as small as possible while still inhibiting smoking during melting of the melted region(s) 28A-28D.

[0096] In Figure 2B, the four spaced apart sintered region(s) 26A-26D can be labeled as (i) a first sintered region 26A; (ii) a second sintered region 26B; (iii) a third sintered region 26C; and (iv) a fourth sintered region 26D. In this non-exclusive example, (i) the first sintered region 26A is rectangular shaped; (ii) the second sintered region 26B is circular shaped; (iii) the third sintered region 26C is irregularly shaped; and (iv) the fourth sintered region 26D is offset tubular shaped.

[0097] Similarly, in Figure 2C, the four spaced apart melted region(s) 28A-28D can be labeled as (i) a first melted region 28A; (ii) a second melted region 28B; (iii) a third melted region 28C; and (iv) a fourth melted region 28D. In this example, (i) the first melted region 28A is rectangular shaped; (ii) the second melted region 28B is circular shaped; (iii) the third melted region 28C is irregularly shaped; and (iv) the fourth melted region 28D is offset tubular shaped. [0098] A single melted region 28A-28D and its corresponding sintered region 26A- 26D can be referred to as a“sintered/melted pair.”

[0099] With reference to Figures 2B, each sintered region 26A-26D is smaller than the second powder layer 14B, and the sintered portion 26 (combined sintered regions 26A-26D) is smaller than the second powder layer 14B. With this design, (i) the second powder layer 14B has a layer surface area; (ii) the sintered portion 26 has a sintered surface area for the second powder layer 14B; and (iii) the layer surface area is larger than the sintered surface area. As alternative, non-exclusive examples, for each powder layer 14B, the sintered surface area of the sintered portion 26 is approximately ninety-nine, ninety-five, ninety, eighty, seventy, sixty, fifty, forty, thirty, twenty, ten or five percent less than the layer surface area. Further, as alternative, non-exclusive examples, for each powder layer 14B, the sintered surface area of the sintered portion 26 is at least approximately one, two, five, ten, twenty, twenty-five, or thirty percent of the layer surface area.

[00100] Stated in another fashion, as alternative, non-exclusive examples, for each powder layer 14B, the area of the sintered portion 26 is approximately ninety-five, ninety, eighty, seventy, sixty, fifty, forty, thirty, twenty, ten or five percent less than the area of the unsintered portion 29.

[00101 ] With reference to Figure 2C, (i) the melted portion 28 is slightly smaller than the sintered portion 26; (ii) the melted portion 28 is encircled by the sintered portion 26; and (iii) the melted portion 28 overlaps the sintered portion 26. Stated in a different fashion, (i) each melted region 28A-28D is slightly smaller than its corresponding sintered region 26A-26D; (ii) each melted region 28A-28D is encircled by its corresponding sintered region 26A-26D; and (iii) each melted region 28A-28D overlaps its corresponding sintered region 26A-26D.

[00102] Stated in yet another different fashion, each sintered region 26A-26D has a sintered outer perimeter 26E, and its corresponding melted region 28A-28D is positioned within the sintered outer perimeter 26E. Thus, for each melted region 28A- 28D, a melted outer perimeter 28E is smaller than the sintered outer perimeter 26E of its corresponding sintered region 26A-26D. Further, for each sintered/melted pair, the sintered outer perimeter 26E is designed to mirror and be slightly larger than the melted outer perimeter 28E of its corresponding melted region 28A-28D.

[00103] With this design, for each melted region 28A-28D, the melted outer perimeter 28E is spaced apart an outer separation distance 42 from the sintered outer perimeter 26E of the corresponding sintered region 26A-26D. In one embodiment, the energy system 22 (illustrated in Figure 1 ) is controlled so that for one, some or all of the sintered/melted pairs, the outer separation distance 42 is less than twenty millimeters and greater than 0.5 millimeters. In another embodiment, the outer separation distance 38 is less than ten millimeters and greater than one millimeter. In still another embodiment, the outer separation distance 42 is less than ten millimeters and greater than one millimeter.

[00104] Moreover, the fourth melted region 28D defines a portion of an internal channel 43. In this embodiment, the fourth sintered region 26D has a sintered inner perimeter 26F, and the fourth melted region 28D has a melted inner perimeter 28F to allow for the internal channel 43. With this design, for the fourth melted region 28D, the melted inner perimeter 28F is spaced apart an inner separation distance 44 from the sintered inner perimeter 26F. In one embodiment, the energy system 22 (illustrated in Figure 1 ) is controlled so that the inner separation distance 44 is less than twenty millimeters and greater than 0.5 millimeters. In another embodiment, the inner separation distance 44 is less than ten millimeters and greater than one millimeter. In still another embodiment, the inner separation distance 44 is less than ten millimeters and greater than one millimeter.

[00105] Further, as alternative, non-exclusive examples, for each sintered/melted pair, the outer separation distance 42 and/or the inner separation distance 44 is less than thirty, twenty-five, twenty, fifteen, ten, five, four, three, two, or one millimeters, and/or is greater than 0.5, one, 1 .5, two, three, four, or five millimeters.

[00106] Moreover, as alternative, non-exclusive examples, for each powder layer 14B, the sintered surface area of the sintered portion 26 is at least approximately forty, twenty, ten, five, two, one, or 0.5 percent larger than the melted surface area of the melted portion 28. Further, as alternative, non-exclusive examples, for each powder layer 14B, the sintered surface area of the sintered portion 26 can be no more than 0.5, one, two, five, ten, or twenty percent larger than the melted surface area of the melted portion 28.

[00107] With this design, because only the sintered portion 26 of each powder layer 14 is sintered, (i) the time required to sinter each powder layer 14 is reduced; (ii) the amount of sintered powder is reduced, thereby reducing the processing time required to remove the sintered powder; (iii) complicated internal channels 43 can be formed without being fully blocked by sintered powder; and/or (iv) there is less powder that has been sintered, and this results in more powder that can be reused in the manufacture of subsequent objects 1 1 .

[00108] Subsequently, after the second powder layer 14B is processed, the third powder layer 14C is deposited as illustrated in Figure 3A. More specifically, Figure 3A is a schematic top illustration of the material bed assembly 16 and the third powder layer 14C after sintering of the powder 12 in sintered portion 326 (highlighted with small triangles) to the sinter temperature. In Figure 3A, the powder 12 of the third powder layer 14C is represented with just a few small circles.

[00109] Figure 3B is a simplified top illustration of the material bed assembly 16 and the third powder layer 14C of Figure 3A after sintering the powder 12 in the sintered portion 326 (highlighted with small triangles), and subsequently melting the powder 12 in the melted portion 328 (highlighted with small squares) with the energy system 22 (illustrated in Figure 1 ). In this Figure, the powder 12 of the third powder layer 14C is again represented with just a few small circles at the upper left corner. Further, the entire melted portion 328 was previously sintered. This is represented in Figure 3B with a few triangles intermixed with the squares of the melted portion 328. Moreover, each melted portion 328 forms a section of one or more objects 1 1 (illustrated in Figure 1 ) ·

[00110] With reference to Figures 3A and 3B, for the third powder layer 14C, (i) the sintered portion 326 again includes four spaced apart sintered regions 326A-326D, and (ii) the melted portion 328 again includes four spaced apart melted regions 328A- 328D that correspond to the sintered regions 326A-326D. In this embodiment, (i) the sintered regions 326A-326D are similar to the corresponding sintered regions 26A-26D described above and illustrated in Figures 2B and 2C; and (ii) the melted regions 328A- 328D are similar to the corresponding melted regions 28A-28D described above and illustrated in Figure 2C. Alternatively, these regions 326A-326D, 328A-328D can be different depending up the characteristics of the object(s) 1 1 (illustrated in Figure 1 ) being built.

[00111 ] With the present design, (i) the sintered portion 326 of the third powder layer 14C at least partly overlaps the sintered portion 26 of the second powder layer 14B;

(ii) the melted portion 328 of the third powder layer 14C at least partly overlaps the melted portion 28 of the second powder layer 14B; and (iii) the melted portion 328 of the third powder layer 14C can be melted (fused) into the melted portion 28 of the second powder layer 14B to form at least a portion of the object(s) 1 1 .

[00112] Figure 4 is an image of a portion of a powder layer 414, a sintered region 426A, and its corresponding melted region 428A. As seen in this image, the melted region 428A is part of the sintered region 426A; and the sintered region 426A encircles the melted region 428A. Further, (i) the powder 412 in the melted region 428A is fully melted (“fully melted powder”); (ii) the powder 412 in the portion of the sintered region 426A that encircles the melted region 428A is partly melted (“sintered powder”); and

(iii) the powder 412 in the powder layer 414 outside of the sintered region 426A is unsintered (“unsintered powder”) and is not drastically altered.

[00113] Figure 5 is an image of a portion of another powder layer 514, a first sintered region 526A on the left, and a second sintered region 526B on the right. As seen in this image, the first sintered region 526A and the second sintered region 526B are at different stages of sintering. More specifically, at this time (i) the powder 512 in the second sintered region 526B has just begun to partly melt together; and (ii) the powder 512 in the first sintered region 526A is now partly melted together. Thus, as shown in this image, local area sintering is possible, without sintering the rest of the powder 512 in the powder layer 514. Thus, the rest of the powder 512 outside of the sintered regions 526A, 526B remains loose and not significantly altered.

[00114] Figure 6A is a schematic side illustration, in partial cut-away of a processing machine 610 with a first built object 61 1 A and a second built object 61 1 B. In this implementation, the processing machine 610 includes (i) a material bed assembly 616; (ii) a powder supply device 618 (illustrated as a box); (iii) a measurement device 620 (illustrated as a box); (iv) an energy system 622 (illustrated as a box) that generates an energy beam 622A; (v) a control system 624 (illustrated as a box); and (vi) a build chamber 630 that similar to the corresponding components described above and illustrated in Figure 1 .

[00115] Again, in this embodiment, for each powder layer 614, the energy system 622 is controlled to (i) sinter the powder 612 only in a sintered portion 626 (partly illustrated with triangles) that is smaller than the overall powder layer 614; and (ii) melt the powder 612 in a melted portion 628 (illustrated with small squares) to form each layer (section) of each object 61 1 A, 61 1 B. In this implementation, the sintered portion 626 of each powder layer 614 is sintered to barely melt or sinter the powder 612. Further, for each powder layer 614, the powder 612 outside of the sintered portion 626 is not sintered and is in the unsintered portion 629.

[00116] In Figure 6A, the first object 61 1 A is the object desired to be built (“desired object”), and the second object 61 1 B is a containment structure that is used to capture, contain, and/or support the unsintered powder and/or the first object 61 1 A. In this embodiment, the processing machine 610 is controlled to form/print the containment structure 61 1 B somewhat concurrently with the forming/printing of the first object 61 1 A. As provided herein, the containment structure 61 1 B makes it easier to capture and recycle of the unsintered powder, while minimizing the dispersal and loss of unused, unsintered powder.

[00117] During the printing process, the temperature of the melted powder 612 can become quite high, and it can be desirable to allow the melted powder 612 to cool slowly so that the desired object 61 1 A is properly annealed. The annealing time may take place on the material bed assembly 616, but this reduces throughput because the processing machine 610 cannot make another part while the material bed assembly 616 is occupied.

[00118] Additionally, in some cases, the unsintered powder 612 has to be removed with the desired built object 61 1 A, which tends to scatter the powder 612 making a mess and making recycling of unused powder 612 difficult or impossible.

[00119] Accordingly, to address at least some of these concerns, the processing machine 610 can be controlled to build one or more containment structures 61 1 B concurrently with the desired built object 61 1 A. In certain implementations, the first object 61 1 A is formed within the containment structure 61 1 B. In the non-exclusive embodiment of Figure 6A, the containment structure 61 1 B is open box shaped with a bottom and four side walls. In another non-exclusive embodiment of Figure 6A, the containment structure 61 1 B can be tube shaped with four side walls (surrounding wall) and no bottom. Still alternatively, a cylindrical tube can be formed instead of the four side walls. The containment structure 61 1 B can approximate the size and shape of the material bed assembly 616 as near as possible to avoid losing powder 612. Flowever, other shapes and designs of the containment structure 61 1 B can be utilized. For example, a separate containment structures 61 1 B can be built for each desired built object 61 1 A, and/or the containment structure 61 1 B can be built to mirror and be only slightly bigger than the desired built object 61 1 A.

[00120] With this design, for example, after the desired object 61 1 A and the containment structure 61 1 B are built, a robotic arm 650 (illustrated as a box) can be used to remove the containment structure 61 1 B with the undisturbed desired built object 61 1 A and powder 612 from the material bed assembly 616, and move them to an annealing location (not shown) for slow or controlled cooling. This will free up the processing machine 610 to build subsequent objects. Subsequently, the robotic arm 650 can remove the desired built object 61 1 A, and the unsintered powder can be collected from the containment structure 61 1 B and reused.

[00121 ] The annealing location can be either inside or outside of the build chamber 630. If the annealing location is within the build chamber 630, the desired object 61 1 A can be cooled without breaking the vacuum and without much clean-up.

[00122] In this embodiment, if multiple desired object(s) 61 1A are built concurrently, they can all be retained in the same containment structure 61 1 B, or one or more of the desired object(s) 61 1 A can have a separate containment structure (not shown).

[00123] Figure 6B is a simplified schematic top illustration of the material bed assembly 616 and the eighth powder layer 614H after sintering the powder 612 in sintered portion 626 (highlighted with small triangles and dashed lines) to the sinter temperature, and subsequently melting the powder 612 in the melted portion 628 (highlighted with small squares and thick lines) with the energy system 622 (illustrated in Figure 6A). In this Figure, the powder 612 of the eighth powder layer 614H is again represented with just a few small circles. It should be noted that the entire melted portion 628 was previously sintered, and the melted portion 628 was part of the sintered portion 626. This is represented in Figure 6B with a few triangles intermixed with the squares of the melted portion 628.

[00124] As provided herein, for each powder layer 614H, the design of the sintered portion 626 and the melted portion 628 will correspond to the characteristics (size and shape) of the objects 61 1 A, 61 1 B being built. In the simplified example in Figure 6B, for the eighth powder layer 614H, (i) the sintered portion 626 includes two spaced apart sintered regions 626A, 626B, and (ii) the melted portion 628 includes two spaced apart melted regions 628A, 628B that correspond to the sintered regions 626A, 626B.

[00125] In this example, (i) the first melted region 628A forms the desired object 61 1 A and is rectangular shaped; and (ii) the second melted region 628B forms part of the side wall of the containment structure 61 1 B and is rectangular tube-shaped. In Figure 6B, the second melted region 628B is represented with a thick line instead of small squares. Further, in this embodiment, (i) the first sintered region 626A is rectangular-shaped and slightly larger than the first melted region 628A; and (ii) the second sintered region 626B is rectangular tube-shaped and is a thicker than the second melted region 628B. In Figure 6B, the second sintered region 626B is represented with dashed lines instead of triangles.

[00126] It should be noted that in Figures 6A and 6B, the wall thickness of the containment structure 61 1 B can be adjusted to suit the strength requirements of the containment structure 61 1 B. Further, a lid (not shown) could be printed on the containment structure 61 1 B to fully enclose the unsintered powder and the desired built object 61 1 A.

[00127] With reference to Figures 6A and 6B, during the building of the desired object

61 1 A, the material bed assembly 616 is filled with a large amount of powder 612. In the situation in which the material bed assembly 616 is large and the desired object 61 1 A is small, the amount of unused powder 612 will be large. If this unused powder

612 is not recycled, this will lead to lots of wasted powder, and increased operating cost. This problem is especially pronounced when attempting to print small parts in a large material bed assembly 616. [00128] The concurrently built containment structure 61 1 B has numerous advantages and benefits. These include but are not limited to: minimizing the dispersal or loss of unused powder 612, surrounding the desired object 61 1 A and the material bed assembly 616, reducing the waste of raw materials, facilitating ease of clean-up and recycling, improving productivity, and improving usability through the automatic generation and editing of the containment structure 61 1 B.

[00129] Figure 7 is a simplified top illustration of the material bed assembly 716, the object 71 1 A, and two, different containment structures 71 1 B, 71 1 C. In this embodiment, the object 71 1 A, a first containment structure 71 1 B, and a second containment structure 71 1 C are substantially concurrently built. In Figure 7, each containment structure 71 1 B, 71 1 C is shaped somewhat similar to a rectangular box with a rectangular-shaped indentation that allows the respective containment structure 71 1 B, 71 1 C to wrap around a portion of the object 71 1A; and the containment structures 71 1 B, 71 1 C are spaced apart.

[00130] Figure 7 illustrates the eighth powder layer 714H after sintering the powder 712 in sintered portion 726 (highlighted with small triangles and dashed lines) to the sinter temperature, and subsequently melting the powder 712 in the melted portion 728 (highlighted with small squares and thick lines) with the energy system 622 (illustrated in Figure 6A). In this Figure, the powder 712 of the eighth powder layer 714H is again represented with just a few small circles. It should be noted that the entire melted portion 728 was previously sintered, and the melted portion 728 was part of the sintered portion 726. This is represented in Figure 7 with a few triangles intermixed with the squares of the melted portion 728.

[00131 ] As provided herein, for each powder layer 714H, the design of the sintered portion 726 and the melted portion 728 will correspond to the characteristics (size and shape) of the objects 71 1 A, 71 1 B, 71 1 C being built. In the simplified example in Figure 7, for the eighth powder layer 714H, (i) the sintered portion 726 includes three spaced apart sintered regions 726A, 726B, 726C; and (ii) the melted portion 728 includes three spaced apart melted regions 728A, 728B, 728C that correspond to the sintered regions 726A, 726B, 726C.

[00132] In this example, (i) the first melted region 728A forms the desired object 71 1 A and is rectangular-shaped; (ii) the second melted region 728B forms part of the side wall of the first containment structure 71 1 B and is somewhat rectangular tube shaped; and (iii) the third melted region 728C forms part of the side wall of the second containment structure 71 1 C and is somewhat rectangular tube-shaped. In Figure 7, the second and third melted regions 728B, 728C are each represented with a thick line instead of small squares. Further, in this embodiment, (i) the first sintered region 726A is rectangular-shaped and slightly larger than the first melted region 728A; (ii) the second sintered region 726B is somewhat rectangular tube-shaped and is thicker than the second melted region 728B; and (iii) the third sintered region 726C is somewhat rectangular tube-shaped and is thicker than the third melted region 728C. In Figure 7, the second and third sintered regions 726B, 726C are each represented with dashed lines instead of triangles.

[00133] It should be noted that in Figure 7, the wall thickness can be adjusted to suit the strength requirements of the containment structures 71 1 B, 71 1 C.

[00134] In Figure 7, the containment of the powder 712 is provided or configured in the form of several containers 71 1 B, 71 1 C so that the powder 712 is well contained. In any of the embodiments provided herein, it may also be desirable to fully enclose the powder 712 within the containers 71 1 B, 71 1 C so that they can be removed and placed in a recycling bin for later processing. In Figure 7, the desired object 71 1 A is positioned between the containment structures 71 1 B, 71 1 C. With this design, a lid (not shown) can be printed for each of the containment structures 71 1 B, 71 1 C to enclose and/or seal each containment structures 71 1 B, 71 1 C, with the desired object 71 1 A positioned outside of the containment structures 71 1 B, 71 1 C.

[00135] As a result thereof, for example, (i) the desired object 71 1 A can be moved for individual processing, and (ii) the containment structures 71 1 B, 71 1 C (filled with the unsintered powder) can be sent for recycling. In some cases, the containment structures 71 1 B, 71 1 C are subsequently opened and the unused powder is reprocessed for later use and the walls of the containment structures 71 1 B, 71 1 C are sent to another recycling process that may or may not produce more powder.

[00136] Alternatively, a lid (not shown) can be printed for each containment structures 71 1 B, 71 1 C to enclose and/or seal each of the containment structures 71 1 B, 71 1 C, with the desired object 71 1 A positioned inside one of the containment structures 71 1 B, 71 1 C.

[00137] In some embodiments, it is desirable to minimize the thickness of the walls of the containment structures 71 1 B, 71 1 C, for example, so as to minimize energy, time, and materials spent in making the containment structures 71 1 B, 71 1 C. For this reason, it may be desirable to include tension struts or other supports. Prior to printing the containment structures 71 1 B, 71 1 C, the bottom of the containment structures 71 1 B, 71 1 C may be printed so that unsintered powder can be sealed when separating the containment structures 71 1 B, 71 1 C from the build plate (the material bed assembly 716).

[00138] Figure 8 is a simplified top illustration of the material bed assembly 816, the built, desired object 81 1 A, and two different, built containment structures 81 1 B, 81 1 C. In this embodiment, the object 81 1 A, the first containment structure 81 1 B, and the second containment structure 81 1 C are somewhat similar to the corresponding components described above and illustrated in Figure 7. Flowever, in the embodiment of Figure 8, each containment structure 81 1 B, 81 1 C includes one or more support structures 850 that are also built substantially concurrently with the desired object 81 1 A.

[00139] Figure 8 also illustrates the eighth powder layer 814H after sintering the powder 812 in sintered portion 826 (highlighted with small triangles and dashed lines), and subsequently melting the powder 812 in the melted portion 828 (highlighted with small squares and thick lines). In this Figure, the powder 812 of the eighth powder layer 814H is again represented with just a few small circles. Further, the entire melted portion 828 was previously sintered, and the melted portion 828 was part of the sintered portion 826. This is represented in Figure 8 with a few triangles intermixed with the squares of the melted portion 828.

[00140] As provided herein, for each powder layer 814H, the design of the sintered portion 826 and the melted portion 828 will correspond to the characteristics (size and shape) of the objects 81 1 A, 81 1 B, 81 1 C being built. In the simplified example in Figure 8, for the eighth powder layer 814H, (i) the sintered portion 826 includes three spaced apart sintered regions 826A, 826B, 826C; and (ii) the melted portion 828 includes three spaced apart melted regions 828A, 828B, 828C.

[00141 ] In this example, (i) the first melted region 828A forms the desired object 81 1 A and is rectangular-shaped; (ii) the second melted region 828B forms part of the side wall of the first containment structure 81 1 B and is somewhat rectangular tube shaped with three support structures 850; and (iii) the third melted region 828C forms part of the side wall of the second containment structure 81 1 C and is somewhat rectangular tube-shaped with three support structures 850. In Figure 8, the second and third melted regions 828B, 828C are each represented with a thick line instead of small squares. Further, in this embodiment, (i) the first sintered region 826A is slightly larger than the first melted region 828A; (ii) the second sintered region 826B is slightly larger than the second melted region 828B; and (iii) the third sintered region 826C is slightly larger than the third melted region 828C. In Figure 8, the second and third sintered regions 826B, 826C are each represented with dashed lines instead of triangles.

[00142] It should be noted that in Figure 8, the wall thickness, and the number and design of the support structures 850 can be adjusted to suit the strength requirements of the containment structures 81 1 B, 81 1 C.

[00143] With reference to Figures 6A-8, in some embodiments, the computer software of the control system 624 is configured to control the processing machine 610 to automatically print the containment structures 61 1 B, 71 1 B, 71 1 C, 81 1 B, 81 1 C as described herein. In some cases, the design of the containment structure(s) is displayed for human review and modification prior to building.

[00144] As provided herein, the containment structures 61 1 B, 71 1 B, 71 1 C, 81 1 B, 81 1 C disclosed herein can be used to extract a desired object 61 1 A, 71 1 A, 81 1 A within a defined variable powder deposition area so that it can be retrieved easily in a simple, efficient, and cost-effective manner.

[00145] In certain embodiments, one or more of the containment structures 61 1 B, 71 1 B, 71 1 C, 81 1 B, 81 1 C can be built to be perforated for ease in subsequently opening the containment structure 61 1 B, 71 1 B, 71 1 C, 81 1 B, 81 1 C. Moreover, the size and shape of the containment structure(s) 61 1 B, 71 1 B, 71 1 C, 81 1 B, 81 1 C can be varied as needed for the desired object 61 1 A, 71 1 A, 81 1 A being built. [00146] As provided herein, the problem of a transferring a printed desired object 61 1 A, 71 1 A, 81 1 A from a material bed assembly 616 while minimizing the dispersal or loss of unused powder 612, 712, 812 is solved by printing one or more containment structures 61 1 B, 71 1 B, 71 1 C, 81 1 B, 81 1 C, surrounding the desired object 61 1 A, 71 1 A, 81 1 A and/or surrounding some or almost all of the unsintered powder.

[00147] It should be noted that the concurrent building of the containment structures 61 1 B, 71 1 B, 71 1 C, 81 1 B, 81 1 C in Figures 6A-8 can be performed without the selective sintering described with respect to Figures 1 -5. For example, these containment structures 61 1 B, 71 1 B, 71 1 C, 81 1 B, 81 1 C can be built with another method of suppressing smoking.

[00148] Figure 9 is a schematic side illustration, in partial cut-away of a processing machine 910 with a built object 91 1 . In this implementation, the processing machine 910 includes (i) a material bed assembly 916; (ii) a powder supply device 918 (illustrated as a box); (iii) a measurement device 920 (illustrated as a box); (iv) an energy system 922; (v) a control system 924 (illustrated as a box); and (vi) a build chamber 930. In this embodiment, except for the energy system 922, the other components are similar to the corresponding components described above and illustrated in Figure 1 . Moreover, in this embodiment, the control system 924 uses measurement feedback from the measurement device 920 to calibrate the energy system 922. For example, the measurement device 920 can include an image sensor 920A (e.g. an infrared image sensor that senses infrared light to monitor heat generated in the powder); and/or a backscatter sensor 920B that senses scattered and backscattered light.

[00149] Again, in this embodiment, for each powder layer 914, the energy system 922 is controlled to (i) sinter the powder 912 only in a sintered portion 926 (partly illustrated with triangles); and (ii) melt the powder 912 in a melted portion 928 (illustrated with small squares). Thus, the processing machine 910 selectively sinters just a portion of some or all of the powder layers 914.

[00150] Flowever, in Figure 9, the energy system 922 includes (i) a sinter system 923A that generates a sinter beam 923B that selectively sinters the sinter portion 926 of each powder layer 914; and (ii) a melting system 923C that generates a melting beam 923D that melts the powder 912 in the melted portion 928 of each powder layer 914. Alternatively, the energy system 922 can be designed to include more than one sinter system 923A and/or more than one melting system 923C.

[00151 ] The design of the sinter system 923A and the melting system 923C can be varied. As non-exclusive examples, the sinter system 923A can be designed to include one or more of the following: (i) an electron beam generator that generates a charged particle electron beam; (ii) an irradiation system that generates an irradiation beam; (iii) an infrared laser that generates an infrared beam; (iv) a mercury lamp; (v) a thermal radiation system; (vi) a visual wavelength system; (vii) a microwave wavelength system; or (viii) an ion beam system. Similarly, as non-exclusive examples, the melting system 923C can be designed to include one or more of the following: (i) an electron beam generator that generates a charged particle electron beam; (ii) an irradiation system that generates an irradiation beam; (iii) an infrared laser that generates an infrared beam; (iv) a mercury lamp; (v) a thermal radiation system; (vi) a visual wavelength system; (vii) a microwave wavelength system; or (viii) an ion beam system.

[00152] Further, in the embodiment of Figure 9, the processing machine 910 is designed to have one or more of the following features: (i) one or more of the powder supply device 918, the measurement device 920, and the energy system 922 can be selectively and individually moved relative to the upper frame assembly 938 and/or the build platform 932 with one or more of the six degrees of freedom using one or more component movers 952 (illustrated as a box); (ii) the upper frame assembly 938 with one or more of the powder supply device 918, the measurement device 920, and the energy system 922 can be selectively moved with a upper frame mover 954 (illustrated with a box) relative to the build platform 932 with one or more of the six degrees of freedom; (iii) a portion of the powder bed assembly 916 can be selectively moved relative to the lower frame assembly 940 with one or more of the six degrees of freedom with the platform mover 936 (illustrated as a box); and/or (iv) the lower frame assembly 940 with the powder bed assembly 916 can be selectively moved with a lower frame mover 956 relative to the upper frame assembly 938 with one or more of the six degrees of freedom.

[00153] For example, each mover 936, 952, 954, 956 can include one or more linear actuators, rotary actuators, or other types of actuator. Further, each mover 936, 952, 954, 956 can be selectively and individually controlled by the control system 924.

[00154] In one implementation, the build platform 932 is moved linearly by the platform mover 936 along the Z axis during the printing of the object 91 1 . Additionally, or alternatively, the lower frame mover 956 can move the build platform 932 along the Y axis, and/or along the X axis. In a different implementation, the build platform 932 is stationary during the printing of the object 91 1 .

[00155] In some embodiments, the sinter system(s) 923A and the melting system(s) 923C are calibrated to ensure that the sinter system(s) 923A and the melting system(s) 923C have the same coordinate system with respect to the material bed assembly 916. For example, one or more first fiducial mark(s) 958 (illustrated as a box) can be generated (e.g. sintered) in the powder layer 914 using the sinter system(s) 923A; and one or more second fiducial mark(s) 960 (illustrated as a box) can be generated (e.g. melted) in the powder layer 914 using the melting system(s) 923C. Subsequently or concurrently, the measurement device 920 measures the locations of the first fiducial mark(s) 958 and the second fiducial mark(s) 960 and calibrates the relative positions of the first fiducial mark(s) 958 and the second fiducial mark(s) 960, calibrates the relative rotations of the first fiducial mark(s) 958 and the second fiducial mark(s) 960, and calibrates the spatial distortion of the first fiducial mark(s) 958 and the second fiducial mark(s) 960, etc. The first fiducial mark(s) 958 and the second fiducial mark(s) 960 can be generated (e.g. by sintering and/or melting) again in the powder layer during or after calibration and re-measured to see whether the corrections are correct. The process can be repeated until the sinter system(s) 923A and the melting system(s) 923C are each calibrated, and can write in the same coordinate system so that overlapping or adjacent marks can be made with high spatial accuracy and integrity. In some embodiments, the calibration is performed using many fiducial marks 958, 960 that are printed to cover the entire area in which the object 91 1 can be made within the material bed assembly 916 to ensure that the calibration of the sinter system(s) 923A, and the melting system(s) 923C is accurate. For example, (i) the generating of each first fiducial mark(s) 958 with the sinter system(s) 923A generates infrared blackbody radiation that can be detected by the image sensor 920A to generate measurement feedback to calibrate the sinter system(s) 923A; and (ii) the generating of each second fiducial mark(s) 960 with the melting system(s) 923C generates infrared heat that can be detected by the image sensor 920A to generate measurement feedback to calibrate the melting system(s) 923C. In a specific example, (i) the control system 924 can control the sinter system(s) 923A to steer the sinter beam 923B to attempt to print a plus“+” or parallel lines shaped first fiducial mark 958 at a first location; and (ii) the control system 924 can control the melting system(s) 923C to steer the melting beam 923D to attempt to print a plus“+”or parallel lines shaped second fiducial mark 960 at a second location. Subsequently, the measurement feedback from the measurement device 920 can be used to determine the relative positions of the fiducial mark(s) 958, 960; the relative rotations of the fiducial mark(s) 958, 960, and/or the spatial distortion of the fiducial mark(s) 958, 960. In alternative, non-exclusive embodiments, other shapes of the fiducial mark(s) 958, 960 are possible, such as“box in box” of nested rectangles, individual points, or a constellation of points.

[00156] In some embodiments, the fiducial marks 958, 960 are removed from the material bed assembly 916 prior to making the object 91 1 . In some embodiments, the fiducial marks 958, 960 are covered over with one or more powder layers 914 so that they are separated from any object 91 1 that is fabricated in the powder 912.

[00157] In another embodiment, the fiducial marks 958, 960 are not melted powder, but are just heated areas in the powder 914. The fiducial marks 958, 960 can also be referred to as residual heat marks. For example, (i) the control system 924 can control the sinter system(s) 923A to attempt to heat (without sintering or melting the powder) a plus“+” or parallel lines shaped first fiducial mark 958 at a first location; and/or (ii) the control system 924 can control the melting system(s) 923C to attempt to heat (without sintering or melting the powder) a plus“+” or parallel lines shaped second fiducial mark 960 at a second location. Subsequently, the measurement feedback from the measurement device 920 can be used to determine the relative positions of the fiducial mark(s) 958, 960; the relative rotations of the fiducial mark(s) 958, 960, and/or the spatial distortion of the fiducial mark(s) 958, 960. Stated in another fashion, the sinter system(s) 923A and/or the melting system(s) 923C deposit energy on the powder 912, and the measurement device 920 includes an infrared camera 920A that is used to register the residual heat marks 958, 960 to determine a calibration for position, rotation, and distortion between sinter system(s) 923A and/or the melting system(s) 923C. In some embodiments, the residual heat marks 958, 960 are marks that are not sintered powder, and in some embodiments, the residual heat marks 958, 960 are marks that are not melted powder.

[00158] Additionally, or alternatively, a support surface 932A of the build platform 932 can include one or more spaced apart surface fiducial mark(s) 962 (only one is shown with a box in Figure 9). As non-exclusive examples, the one or more surface fiducial mark(s) 962 can be a plus“+” or parallel lines shaped structure that has different reflecting, absorbing, and/or scattering properties than the rest of the support surface 932A. For example, the surface fiducial mark(s) 962 can be chrome on glass. With this design, the control system 924 controls the energy system 922 to direct the energy beam at support surface 932A (without the powder), and the backscatter sensor 920B of the measurement feedback 920 monitors the backscattered signal (e.g., backscattered electrons or light) to determine when the energy beam is directed at the surface fiducial mark(s) 962. In this example, the support surface 932A includes the surface fiducial mark(s) 962 that are irradiated by the energy beam, and the measurement device 920 monitors backscattered electrons light to generate the measurement feedback used to calibrate the energy system.

[00159] Further, for the design with both the sinter system 923A and the melting system 923C, the control system 924 can individually control the systems 923A, 923C (individually steer the respective beams 923B, 923D) to direct the respective beam 923B, 923D (at different times) at support surface 932A (without the powder), and the backscatter sensor 920B of the measurement feedback 920 monitors the backscattered electrons or light to calibrate the respective systems 923A, 923C.

[00160] It should be noted that the calibrations in Figure 9 are discussed as calibrating both the sinter system 923A and the melting system 923C. Flowever, the calibration methods described herein can be used to calibrate the energy system(s) 22 described above that use the same steerable energy beam to both sinter and melt.

[00161 ] Figure 10A is a schematic side illustration, in partial cut-away of another processing machine 1010 with built object(s) 101 1 . In this implementation, the processing machine 1010 includes (i) a material bed assembly 1016; (ii) a powder supply device 1018 (illustrated as a box); (iii) a measurement device 1020 (illustrated as a box); (iv) an energy system 1022; (v) a control system 1024 (illustrated as a box); and (vi) a build chamber 1030 that are somewhat similar to the corresponding components described above and illustrated in Figure 9.

[00162] Again, in this embodiment, for each powder layer 1014, the energy system 1022 is controlled to (i) sinter the powder 1012 only in a sintered portion 1026 (partly illustrated with triangles); and (ii) melt the powder 1012 in a melted portion 1028 (illustrated with small squares). Thus, the processing machine 1010 can selectively sinter just a portion of one, some or all of the powder layers 1014.

[00163] In Figure 10A, the energy system 1022 again includes (i) a sinter system 1023A that generates a sinter beam 1023B to selectively sinter the powder 1012; and (ii) a melting system 1023C that generates a melting beam 1023D to selectively melt the powder 1012. Alternatively, the energy system 1022 can be designed to include a single system that performs both tasks at different times as illustrated in Figure 1.

[00164] Figure 10B is a simplified schematic top view illustration of a portion of the material bed assembly 1016 of Figure 10A and the three-dimensional object(s) 101 1 . Figure 10B also illustrates (i) the pre-heat system 1023A (illustrated as box) and a pre heat zone 1023E (illustrated with dashed lines) which represents the area in which the powder 1012 is being pre-heated with the pre-heat system 1023A; (ii) the powder supply device 1018 (illustrated as a box) and a deposit zone 1018A (illustrated in phantom) which represents the area in which the powder 1012 (illustrated with a few circles) is being added to the material bed assembly 1016 by the powder supply device 1018; (iii) the measurement device 1020 (illustrated as a box) and a measurement zone 1020A (illustrated in phantom) which represents the area in which the powder 1012 and/or the object(s) 101 1 is being measured by the measurement device 1020; and (iv) the melting system 1023C (illustrated as a box) and a melting zone 1023F (illustrated in phantom) which represents the area in which the powder 1012 is selectively melted and fused together. It should be noted that these zones may be spaced apart differently from the non-exclusive example illustrated in Figure 10B. Additionally, or in the alternative, one or more of the zones may overlap one another. [00165] With reference to Figures 10A and 10B, in certain embodiments, the processing machine 1010 can be designed so that there is substantially constant relative motion along a moving direction 1062 (illustrated by an arrow in Figure 10B) between the object(s) 101 1 being formed and each of the sinter system 1023A, the powder supply device 1018, the measurement device 1020, and the melting system 1023C. In one embodiment, the build platform 1032 is moved (e.g., rotated) by the lower frame mover 1056 relative to the sinter system 1023A, the powder supply device 1018, the measurement device 1020, and the heating system 1023C. This allows nearly all of the rest of the components of the processing machine 1010 to be fixed while the build platform 1032 is moved. The moving direction 1062 may include a rotation direction about a support rotation axis 1064. With this design, the powder 1012 may be deposited and fused relatively quickly. This allows for the faster forming of the object(s) 101 1 , increased throughput of the processing machine 1010, and reduced cost for the objects 101 1 . Additionally, or in the alternative, the moving direction 1062 may include a lateral direction that is parallel to the support surface 1032A of the build platform 1032 of the material bed assembly 1016, i.e. the build platform 1032 may be moved linearly with a linear motion stage. Still alternatively, in other embodiments, the general concepts of the present invention can also be applicable in a processing machine 1010 utilizing a stationary build platform 1032, i.e. a stationary stage.

[00166] In one implementation, the lower frame mover 1056 can move (e.g. rotate) the material bed assembly 1016 at a substantially constant or variable angular velocity. As alternative, non-exclusive examples, the lower frame mover 1056 may move the material bed assembly 1016 at a substantially constant angular velocity of at least approximately 2, 5, 10, 20, 30, 60, or more revolutions per minute (RPM). As used herein, the term“substantially constant angular velocity” shall mean a velocity that varies less than 5% over time. In one embodiment, the term“substantially constant angular velocity” shall mean a velocity that varies less 0.1 % from the target velocity. The lower frame mover 1056 may also be referred to as a“drive device”.

[00167] Additionally, the platform mover 1036 may move the build platform 1032 linearly at a variable velocity or in a stepped or other fashion. [00168] In the non-exclusive example in Figure 10A, the sinter system 1023A, the powder supply device 1018, the measurement device 1020, and the melting system 1023C are be fixed together and retained by a common upper frame assembly 1038. Collectively these components may be referred to as the top assembly. For example, the top assembly can be moved with one or more degrees of freedom with an upper frame mover 1054.

[00169] In another embodiment, one or more of these components of the top assembly can be individually and selectively movable relative to upper frame assembly 1038.

[00170] With reference to Figures 10A and 10B, the build platform 1032 may be referenced as a clock face for ease of discussion. It is appreciated that the layout of the use of the components relative to the build platform 1032 as shown in Figures 10A and 10B is just one representative example, and the components can be positioned and/or applied in a different manner than is specifically shown. In this non-exclusive example, (i) at 12:00 on the clock face, the melting of the powder 1012 takes place using the melting system 1023C; (ii) at 1 :30 on the clock face, the measurement with the measurement device 1020 may take place; (iii) at about 3:15, the powder supply device 1018 deposits the powder 1012 onto the build platform 1032; and (iv) at about 5 o’clock, the sinter system 1023A selectively sinters the powder 1012. However, other layouts are possible.

[00171 ] It should also be noted that with the unique design provided in any of the embodiments disclosed herein, each of the components extend along a direction that is crossed by the moving build platform 1032, and multiple operations may be performed at the same time (simultaneously) to improve the throughput of the processing machine 1010. Stated in another fashion, one or more of the sinter time when the powder is sintered, the deposit time when the powder is deposited, the measurement time when the powder or object is measured, and the melting time when the powder is melted may be partly or fully overlapping in time for any given processing of a powder layer to improve the throughput. For example, two, three, or all of these times may be partly or fully overlapping.

[00172] Additionally, it should be noted that the processing machine 1010 illustrated in Figures 10A and 10B may be designed so that (i) the build platform 1032 is rotated about the Z axis and moved along the Z axis to maintain the desired height; or (ii) the build platform 1032 is rotated about the Z axis, and the upper frame assembly 1038 and the top assembly are moved along the Z axis only to maintain the desired height. In certain embodiments, it may make sense to assign Z movement to one component and rotation to the other.

[00173] Figure 1 1 is a schematic side illustration, in partial cut-away of another processing machine 1 1 10 with built object(s) 1 1 1 1 . In this implementation, the processing machine 1 1 10 includes (i) a material bed assembly 1 1 16; (ii) a powder supply device 1 1 18 (illustrated as a box); (iii) a measurement device 1 120 (illustrated as a box); (iv) an energy system 1 122; (v) a control system 1 124 (illustrated as a box); and (vi) a build chamber 1 130 that are somewhat similar to the corresponding components described above and illustrated in Figure 10A.

[00174] Again, in this embodiment, for each powder layer 1 1 14, the energy system 1 122 is controlled to (i) sinter the powder 1 1 12 only in a sintered portion 1 126 (partly illustrated with triangles); and (ii) melt the powder 1 1 12 in a melted portion 1 128 (illustrated with small squares). Thus, the processing machine 1 1 10 can selectively sinter just a portion of one, some or all of the powder layers 1 1 14.

[00175] In Figure 1 1 , the energy system 1 122 again includes (i) a sinter system 1 123A that generates a sinter beam 1 123B to selectively sinter the powder 1 1 12; and (ii) a melting system 1 123C that generates a melting beam 1 123D to selectively melt the powder 1 1 12. Alternatively, the energy system 1 122 can be designed to include a single system that performs both tasks at different times as illustrated in Figure 1.

[00176] Flowever, in Figure 1 1 , the upper frame mover 1 154 can rotate the sinter system 1 123A, the powder supply device 1 1 18, the measurement device 1 120, and the melting system 1 123C with the upper frame assembly 1 138 (collectively the“top assembly”) about the rotary axis 1 164 relative to the material bed assembly 1 1 16. The rotation can be at a constant or variable velocity. Additionally, the upper frame mover 1 154 can move the top assembly linearly along one or more axes.

[00177] With this design, the build platform 1 132 can be stationary, while the top assembly is moved. Still alternatively, the build platform 1 132 can be moved linearly, in a rastered fashion, and/or rotated with the platform mover 1 136 along one or more axes while the top assembly is moved.

[00178] It should be noted that the processing machine 1 1 10 may be designed so that (i) the top assembly is rotated about the Z axis and moved along the Z axis to maintain the desired height; or (ii) the top assembly is rotated about the Z axis, and the build platform 1 132 is moved along the Z axis only with the platform mover 1 136.

[00179] Figure 12 is a simplified top illustration of a material bed assembly 1216 that can be used in any of the processing machines 10, 610, 910, 1010, 1 1 10 disclosed above. In this embodiment, the material bed assembly 1216 can be used to make multiple objects 121 1 substantially simultaneously. The number of objects 121 1 that may be made concurrently can vary according the type of object 121 1 and the design of the processing machine 10, 610, 910, 1010, 1 1 10. In the non-exclusive embodiment illustrated in Figure 12, six objects 121 1 are made simultaneously. Alternatively, more than six or fewer than six objects 121 1 may be made simultaneously.

[00180] In the embodiment illustrated in Figure 12, each of the objects 121 1 is the same design. Alternatively, for example, the processing machine 10, 610, 910, 1010, 1 1 10 may be controlled so that one or more different types of objects 121 1 are made simultaneously.

[00181 ] In Figure 12, the material bed assembly 1216 includes a relatively large support platform 1266, and a plurality of separate, spaced apart build assemblies 1268 that are positioned on and supported by the support platform 1266. The number of separate build assemblies 1268 can be varied. In Figure 12, the material bed assembly 1216 includes six separate build assemblies 1268, one for each object 121 1 . With this design, a single object 121 1 is made in each build assembly 1268. Alternatively, more than one object 121 1 may be built in each build assembly 1268. Still alternatively, the material bed assembly 1216 can include more than six or fewer than six separate build assemblies 1268.

[00182] In one, non-exclusive embodiment, the support platform 1266 with the build assemblies 1268 can be rotated like a turntable during printing of the objects 121 1 in a moving direction 1262 about a support rotation axis 1262A (illustrated with a“+”, e.g. the Z axis). With this design, each build assembly 1268 is rotated about at least one axis 1262A during the build process. Further, in this embodiment, the separate build assemblies 1268 are positioned and spaced apart on the large common support platform 1266. The build assemblies 1268 can be positioned on or embedded into the support platform 1266. As non-exclusive examples, the support platform 1266 can be disk-shaped or rectangular-shaped.

[00183] As provided herein, each of the build assemblies 1268 defines a separate, discrete build region. For example, each build assembly 1268 can include a build platform 1232, and a sidewall assembly 1234. In one embodiment, each build assembly 1268 is an open container in which the object 121 1 can be built. In this design, after the object 121 1 is printed, the build assembly 1268 with the printed object 121 1 can be removed from the support platform 1266 via a robotic arm (not shown in Figure 12) and replaced with an empty build assembly 1268 for subsequent fabrication of the next object 121 1 .

[00184] The shape of each build assemblies 1268 may be square, rectangular, cylindrical, trapezoidal, or a sector of an annulus.

[00185] In an alternative embodiment, one or more of the build platforms 1232 can be moved somewhat like an elevator vertically (along the Z axis) relative to its side wall assembly 1234 with a platform mover assembly 1270 (illustrated in phantom with a box) during fabrication of the objects 121 1 . Each platform mover assembly 1270 can include one or more actuators. Fabrication can begin with the build platform 1232 placed near the top of the side wall assembly 1234. The powder supply device (not shown in Figure 12) deposits a thin layer of powder into each build assembly 1268 as it is moved (e.g., rotated) below the powder supply device. At an appropriate time, the build platform 1232 in each build assembly 1268 is stepped down by one layer thickness so the next layer of powder may be distributed properly.

[00186] In some embodiments, one or more platform mover assemblies 1270 can also or alternatively be used to move (e.g., rotate) one or more of the build assemblies 1268 relative to the support platform 1266 and each other in a platform direction 1266A about a platform rotation axis 1266X (illustrated with a“+”, e.g., the Z axis). With this design, each build platform 1232 can be rotated about two, separate, spaced apart and parallel axes 1262A, 1266X during the build process. [00187] In one non-exclusive embodiment, the support platform 1266 can be rotated (e.g., at a substantially constant rate) in the moving direction 1262 (e.g., clockwise), and one or more of the build assemblies 1268 can be moved (e.g., rotated) relative to the support platform 1266 in the opposite direction 1266A (e.g., counterclockwise) during printing process. In this example, the rotational speed of the support platform 1266 about the support rotation axis 1262A can be approximately the same or different from the rotational speed of each build assembly 1268 relative to the support platform 1266 about the platform rotation axis 1266X.

[00188] Alternatively, the support platform 1266 can be rotated (e.g., at a substantially constant rate) in the moving direction 1262 (e.g., clockwise), and one or more of the build assemblies 1268 can be moved (e.g., rotated) relative to the support platform 1266 in the same direction (e.g., clockwise) during the printing process.

[00189] Figure 13 is a simplified top view of a portion of still another embodiment of a processing machine 1310. In this embodiment, the processing machine 1310 includes (i) the powder bed 1326; (ii) the powder depositor (also referred to as powder supply device) 1318; and (iii) the irradiation device 1322 that are somewhat similar to the corresponding components described above. It should be noted that the processing machine 1310 may include the pre-heat device, the measurement device, the cooler device, and the control system, that have been omitted from Figure 13 for clarity. The powder depositor 1318, the irradiation device 1322, the pre-heat device, the cooler device, and the measurement device may collectively be referred to as the top assembly.

[00190] In this embodiment, the problem of building a practical and low cost three dimensional printer 1310 for three dimensional printing of one or more metal parts 131 1 (illustrated as a box) is solved by providing a rotating powder bed 1326, and the powder depositor 1318 is moved linearly across the powder bed 1326 as the powder bed 1326 is rotated in a moving direction 1325 about a rotation axis 1326D that is parallel to the Z axis. The part 131 1 is built in the cylindrical shaped powder bed 1326.

[00191 ] In one embodiment, the powder bed 1326 includes the support surface 1326B having an elevator platform that may be moved vertically along the rotation axis 1326D (e.g. parallel to the Z axis), and the cylindrical side wall 1326C that surrounds an“elevator platform”. With this design, fabrication begins with the support surface 1326B (elevator) placed near the top of the side wall 1326C. The powder depositor 1318 translates across the powder bed 1326 spreading a thin powder layer across the support surface 1326B.

[00192] In Figure 13, the irradiation device 1322 directs the irradiation beams 1322D to fuse the powder to form the parts 131 1 . In this embodiment, the irradiation device 1322 includes multiple (e.g. three), separate irradiation energy sources 1322C (each illustrated as a solid circle) that are positioned along the irradiation axis 1322B. In this embodiment, each of the energy sources 1322C generates a separate irradiation beam 1322D (illustrated with dashed circle). In the embodiment shown, three energy sources 1322C are arranged in a line along the irradiation axis 1322B (transverse to the rotation axis 1326D) so that together they may cover at least the radius of the support surface 1326B. Further, the three energy sources 1322C are substantially tangent to each other in this embodiment, and the irradiation beams 1322D are overlapping. Because the irradiation beams 1322D cover the entire radius of the powder bed 1326, every point in the powder bed 1326 may be reached by at least one of the irradiation beams 1322D. This prevents an exposure“blind spot” at the center of rotation of the powder bed 1326.

[00193] In an alternative embodiment, where lower throughput is acceptable, a single energy source may be used with the beam being steered in the radial direction to smay in the radial direction. In this embodiment, the beam is scanned parallel to the irradiation axis 1322B that is transverse to the rotation axis 1326D and that crosses the movement direction. In another alternative embodiment, a single energy source with sufficient beam deflection width to cover the desired part radius may expose every point within the build volume.

[00194] The powder depositor 1318 distributes the powder across the top of the powder bed 1326. In this embodiment, the powder depositor 1318 includes a powder spreader 1319A and a powder mover assembly 1319B that moves the powder spreader 1319A linearly, transversely to the powder bed 1326.

[00195] In this embodiment, the powder spreader 1319A deposits the powder on the powder bed 1326. In some embodiments, the powder spreader 1319A comprises features that control the width of the powder distribution area to minimize or prevent powder from falling outside the cylindrical powder bed 1326. In other embodiments, the side walls 1326C may include flanges that extend into the corners of the powder spreading area, wherein the flanges prevent excess powder from being spread outside the cylindrical powder bed 1326.

[00196] The powder mover assembly 1319B moves the powder spreader 1319A linearly with respect to the powder bed 1326, while the powder bed 1326 and powder depositor 1318 are rotating together about the rotation axis 1326D. In one embodiment, the powder mover assembly 1319B includes a pair of spaced apart actuators 1319C (e.g. linear actuators) and a pair of spaced apart linear guides 1319D (illustrated in phantom) that move the powder spreader 1319A along the Y axis, transversely (perpendicular) to the rotation axis 1326D and the powder bed 1326. The powder spreader 1319A may be moved across the powder bed 1326 to the empty “parking space” 1319C shown in dotted lines at the top of the Figure 13.

[00197] After the powder spreader 1319A is parked at the opposite side of the rotating system, the irradiation device 1322 may be energized to selectively melt or fuse the appropriate powder into a solid part 131 1 .

[00198] In yet another embodiment, the powder bed 1326 may be rectangular and hold a larger volume of powder, but the maximum part volume is confined to a cylindrical volume within the rectangular powder bed 1326.

[00199] With this design, because the powder bed 1326 rotates relative to the irradiation device 1322, it is possible to reach every point in the part volume without requiring any acceleration or deceleration time. This feature provides a substantial throughput improvement over prior art systems. Because the only scanning part is the powder spreader 1319A with relatively low mass, high acceleration may be used to maintain high throughput.

[00200] Moreover, because the powder spreader 1319A is moved in a linear fashion relative to the powder bed 1326, the powder may be easily distributed in a flat and thin layer. This avoids an excess or lack of powder at the rotation center.

[00201 ] In another embodiment, the processing machine 1310 (i) may include more than one irradiation devices 1322 and more than one exposure areas (irradiation zones); and/or (ii) multiple parts 131 1 may be made on the powder bed 1326 at one time to increase throughput. For example, the processing machine 1310 may include two irradiation devices 1322 that define two exposure areas, or three irradiation devices 1322 that define three exposure areas.

[00202] In certain embodiments, (i) the powder bed 1326 and the entire powder depositor 1318 are rotating at a substantially constant velocity about the rotation axis 1326D relative to irradiation device 1322, the pre-heat device, the cooler device, and/or the measurement device, and (ii) the powder depositor 1318 is moved linearly, with respect to the powder bed 1326 during the powder spreading operation. Alternatively,

(i) the powder bed 1326 is rotated at a substantially constant velocity relative to the powder depositor 1318, irradiation device 1322, the pre-heat device, the cooler device, and/or the measurement device about the rotation axis 1326D, and (ii) the powder depositor 1318 is moved linearly relative to the irradiation device 1322, the pre-heat device, the cooler device, and/or the measurement device during the powder spreading operation.

[00203] Further, in yet another embodiment, (i) the powder bed 1326 is stationary,

(ii) the irradiation device 1322, the pre-heat device, the cooler device, and/or the measurement device are rotated relative the powder bed 1326 about the rotation axis 1326D, and (iii) the powder depositor 1318 is moved linearly, transversely to the rotation axis 1326D, with respect to the stationary powder bed 1326 during the powder spreading operation.

[00204] In certain embodiments, the powder bed 1326 or the top assembly is continuously moved along the Z axis while printing to maintain a substantially constant height. Alternatively, the powder bed 1326 or the top assembly may be moved in a stepped like fashion along the Z axis. As another alternative, the powder bed 1326 or the top assembly may be ramped down gradually to the next print level.

[00205] The embodiments in which the powder bed 1326 is stationary and the top assembly is rotated may have the following benefits: (i) eliminate centrifugal forces on the melted metal and the dry powder at the surface, and, below the printing surface, on the powder bed’s varied mixture of unused powder and parts in progress; (ii) eliminating the Z-stepping of the powder bed leaves the powder/melted metal/parts agglomeration truly undisturbed; (iii) Z-movement control may be easier with the much lighter and constant-mass top assembly than with the massive and growing powder bed; (iv) the top assembly could finish one complete rotation, then do nothing for 20 degrees of rotation, then start a new layer: this would distribute and perhaps average out any discontinuities or metallurgical differences at the stepping point, and each layer would start 20 degrees farther on, for example; (v) easier cooling system connections to the powder bed, if any are required; (vi) reduce controls complexity for the rotating part and Z-movement: a rotating powder bed is constantly gaining mass, but it needs a steady rotational speed and a steady Z-movement (or a uniform Z-step distance), so the control system has to adjust for that; (vii) a rotating top assembly is far lighter and of roughly constant mass (depending on whether powder replenishment is continuous or periodic); (viii) possibly simplify measurement system because everything is measured against the fixed floor of the powder bed 1326. In one embodiment, wireless communications and batteries may be used in the rotating top assembly. Further, printing could pause periodically to replenish power (via capacitors) and powder. Alternatively, if a pause would introduce build discontinuities, then continuous printing could be performed, and electricity might be supplied by continuous inductive charging or another non-contact method, and the powder hopper could be continuously replenished.

[00206] As provided above, in one embodiment, the powder bed 1326 is moved along the rotation axis 1326D, and the top assembly is rotated about the rotation axis 1326D at a constant angular velocity. If the powder bed 1326 is moved along the rotation axis 1326D at a constant speed, the relative motion between the powder bed 1326 and the top assembly will be spiral shaped (i.e. , helical). In one embodiment, the flat surfaces in the parts 131 1 may be inclined to match the trajectory of the powder bed 1326, or the axis of rotation 1326D may be tilted slightly with respect to the Z axis so that the exposure surface of the part 131 1 is still planar.

[00207] In one embodiment, the powder depositor 1318 is designed to continuously feed powder to the powder bed 1326. In this embodiment, the powder depositor 1318 could include a powder hopper (not shown) with a funnel on the rotating top assembly that covers the rotation axis 1326D (center zone), and a non-rotating feeder (not shown) (e.g. a screw drive, conveyor belt, etc.) that terminates directly over the funnel. If the center zone is not available due to the needs of other components, then a donut shaped funnel would have one at least one point in its annular opening under a stationary off-axis feeder point at all times. In both of these embodiments it is advantageous to make the large and heavy powder supply mechanism stationary and feed the powder into the rotating top assembly.

[00208] If the “melting zone” of each column of the irradiation beam 1322D is approximately linear, it may be aligned to the slightly sloped radial surface of a helical surface. It doesn’t matter if the helical surface is not planar, as long as it has a sufficiently straight radial line segment. It is also possible that some embodiments may treat a helical powder surface as“approximately flat” since the powder layer thickness is small compared to the part size, the powder bed size, and the energy beam depth of focus.

[00209] Figure 14 is a simplified top view of a portion of still another embodiment of a processing machine 1410 for forming the three dimensional part 141 1 . In this embodiment, the processing machine 1410 includes (i) the powder bed 1426; (ii) the powder depositor 1418; and (iii) the irradiation device 1422 that are somewhat similar to the corresponding components described above. It should be noted that the processing machine 1410 may include the pre-heat device, the cooler device, the measurement device, and the control system, that have been omitted from Figure 14 for clarity. The powder depositor 1418, the irradiation device 1422, the pre-heat device, the cooler device, and the measurement device may collectively be referred to as the top assembly.

[00210] In the embodiment illustrated in Figure 14, the powder bed 1426 includes a large support platform 1427A and one or more build chambers 1427B (only one is illustrated) that are positioned on the support platform 1427A. In one embodiment, the support platform 1427A is holds and supports each build chamber 1427B while each part 141 1 is being built. For example, the support platform 1427A may be disk shaped, or rectangular shaped.

[00211 ] In Figure 14, the build chamber 1427B contains the metal powder that is selectively fused or melted according to the desired part geometry. The size, shape and design of the build chamber 1427B may be varied. In Figure 14, the build chamber 1427B is generally annular shaped and includes (i) a tubular shaped, inner chamber wall 1427C, (ii) a tubular shape, outer chamber wall 1427D, and (iii) an annular disk shaped support surface 1427E that extends between the chamber walls 1427C, 1427D.

[00212] In this embodiment, the support surface 1427E may function as an annular “elevator platform” that may be moved vertically relative to the chamber walls 1427C, 1427D. In certain embodiments, fabrication begins with the elevator 1427E placed near the top of the chamber walls 1427C, 1427D. The powder depositor 1418 deposits a preferably thin layer of metal powder into the build chamber 1427B during relative movement between the build chamber 1427B and the powder depositor 1418. During fabrication of the part 141 1 , the elevator support surface 1427E may be slowly lowered down by one layer thickness per revolution so the next layer of powder may be distributed properly in a continuous fashion. In this way, instead of building parts as a stack of thin parallel planar layers, the part(s) are built in a continuous helical layer that spirals on itself many times.

[00213] In the embodiment illustrated in Figure 14, the support platform 1427A and the build chamber 1427B may be rotated about the rotation axis 1426D in the rotation direction 1425 at a substantially constant velocity with a mover (not shown) during the manufacturing process relative to at least a portion of the top assembly. Alternatively, at least a portion of the top assembly may be rotated relative to the support platform 1427A and the build chamber 1427B. Still alternatively, instead of the support surface 1427E including the elevator platform that moves down, the support platform 1427A may be controlled to move downward along the rotation axis 1426D during fabrication and/or the top assembly may be controlled to move upward along the rotation axis 1426D during fabrication.

[00214] With the present design, the problem of building a practical and low cost three dimensional printer 1410 for high volume 3D printing of metal parts 141 1 is solved by providing a rotating turntable 1427A that supports a large annular build chamber 1427B suitable for continuous deposition of myriad small parts 141 1 or individual large parts that fit in the annular region.

[00215] In Figure 14, the irradiation device 1422 again includes multiple (e.g. three) separate irradiation energy sources 1422C (each illustrated as a circle) that are positioned along the irradiation axis 1422B. In this embodiment, the three energy sources 1422C are arranged in a line along the irradiation axis 1422B so that together they may cover the full radial width of the build chamber 1427B. Because the exposure area covers the entire radial dimension of the desired build volume, every point in the required build volume may be reached by at least one of the irradiation beams. Alternatively, a single irradiation energy source 1422C may be utilized with a scanning irradiation beam.

[00216] As provided herein, this processing machine 1410 requires no back and forth motion (no turn motion), so throughput may be maximized. Many parts 141 1 may be built in parallel in the build chamber 1427B. Very large parts that fit within the annular shape may be fabricated. There are many applications that require large round parts with a central hole, so this capability may be valuable in some applications (such as jet engines).

[00217] Figure 15 is a simplified side illustration of a portion of yet another embodiment of the processing machine 1510. In this embodiment, the processing machine 1510 includes (i) the powder bed 1526 that supports the powder 151 1 ; and (ii) the irradiation device 1522. It should be noted that the processing machine 1510 may include the powder depositor, pre-heat device, the cooler device, the measurement device, and the control system, that have been omitted from Figure 15 for clarity. The powder depositor, the irradiation device 1522, the pre-heat device, the cooler device, and the measurement device may collectively be referred to as the top assembly.

[00218] In this embodiment, the irradiation device 1522 generates the irradiation energy beam 1522D to selectively heat the powder 151 1 in each subsequent powder layer 1513 to form the part. In the embodiment of Figure 15, the energy beam 1522D may be selectively steered to any direction within a cone shaped workspace. In Figure 15 three possible directions for the energy beam 1522D are represented by three arrows.

[00219] Additionally, in Figure 15, the support surface 1526B of the powder bed 1526 is uniquely designed to have a concave, curved shape. As a result thereof, each powder layer 1513 will have a curved shape.

[00220] As provided herein scanning the energy beam 1522D across a large angle at a planar powder surface would create focus errors because the distance from the deflection center to the powder changes with the cosine of the deflection angle. To avoid focus errors, in one embodiment of the system shown in Figure 15, the support surface 1526B and each powder layer 1513 have a spherical shape with the center of the sphere at the center of deflection 1523 of the energy beam 1522D. As a result thereof, the energy beam 1522D is properly focused at every point on the spherical surface of the powder 151 1 , and the energy beam 1522D has a constant beam spot shape at the powder layer 1513. In Figure 15, the powder 151 1 is spread on the concave support surface 1526B centered at a beam deflection center 1523. For a processing machine 1510 having a single irradiation energy source as illustrated in Figure 15, the powder 151 1 may be spread over the single concave support surface 1526B. Alternatively, for a processing machine 1510 having multiple, irradiation energy sources, the powder 151 1 may optionally be spread on multiple curved surfaces, each centered on the deflection center 1523 of the respective energy sources.

[00221 ] For an alternative embodiment of the processing machine 1510 that uses linear scanning of the powder bed 1526 (or the column) into and out of the page, the curved support surface 1526B would be cylindrical shape. Alternatively, for an embodiment where the powder bed 1526 is rotated about a rotation axis, the curved surface support surface 1526B would be designed to have a spherical shape.

[00222] In these embodiments, the size and shape of the curved support surface 1526B is designed to correspond to (i) the beam deflection of the energy beam 1522D at the top powder layer 1513, and (ii) the type or relative movement between the energy beam 1522D and the powder layer 1513. Stated in another fashion, the size and shape of the curved support surface 1526B is designed so that the energy beam 1522D has a substantially constant focal distance to the top powder layer 1513 during relative movement between the energy beam 1522D and the powder layer 1513. As used herein the term substantially constant focus distance shall mean variations in the focal distance of less than five percent. In alternative embodiments, the term substantially constant focus distance shall mean the focus distance changes no more than ten, five, four, three, two, or one percent.

[00223] In Figure 15, the problem of building a three dimensional printer 1510 with focus variations caused by a large beam deflection angle is solved by providing at least one cylindrical or spherical, bowl-shaped support surface 1526B that maintains a constant focal distance for the irradiation energy beam 1522D. In other words, the embodiment of the Figure 15 comprises the support device which includes a non-flat (e.g. the curved) support surface, the powder supply device which supplies the powder to the support device and which forms the curved powder layer, and the irradiation device which irradiates the curved powder layer. In this situation, the irradiation device sweeps the energy beam in at least a swept plane (paper plane of Figure 15) which includes a swept direction. And the curved support surface includes a curvature in the swept plane. The non-flat support surface may be a part of polygonal shape (a shape made of a plurality of straight lines which cross each other).

[00224] Figure 16A is a simplified side illustration of a portion of yet another embodiment of the processing machine 1610. In this embodiment, the processing machine 1610 includes (i) the powder bed 1626 that supports the powder 161 1 ; and (ii) the irradiation device 1622. It should be noted that the processing machine 1610 may include the powder depositor, pre-heat device, the cooler device, the measurement device, and the control system, that have been omitted from Figure 16A for clarity. The powder depositor, the irradiation device 1622, the pre-heat device, and the measurement device may collectively be referred to as the top assembly.

[00225] In this embodiment, the irradiation device 1622 includes multiple (e.g. three) irradiation energy sources 1622C that each generates a separate irradiation energy beam 1622D that may be steered (scanned) to selectively heat the powder 161 1 in each subsequent powder layer 1613 to form the part. In Figure 16A, each energy beam 1622D may be controllably steered throughout a cone shaped workspace that diverges from the respective energy source 1622C. In Figure 16A, the possible directions of each energy beam 1622D are each represented by three arrows.

[00226] In Figure 16A, the support surface 1626B of the powder bed 1626 is uniquely designed to have three concave, curved shaped regions 1626E. Stated in another fashion, the support surface 1626B includes a separate curved shaped region 1626E for each irradiation energy source 1622C. As a result thereof, each powder layer 1613 will have a dimpled curved shape.

[00227] As provided above, scanning each energy beam 1622D across a large angle would create focus errors if the surface of the powder 161 1 were a flat plane because the distance from the deflection center to the powder 161 1 would change with the cosine of the deflection angle. In the embodiment illustrated in Figure 16A, however, the powder 161 1 is spread on the three lobed, curved support surface 1626B and the distance between the deflection center of each energy beam 1622D and the surface of the powder 161 1 is constant so there are no significant focus errors.

[00228] In certain embodiments, such as a system where the powder support surface 1626B is rotating in a manner similar to the previously described embodiments, it may be more practical to distribute the powder across a single curved spherical surface. In this case, the columns providing each energy beam 1622D may be offset from each other in the vertical direction to more closely align the focal surface of each energy beam 1622D with the powder surface. In other words, the shape of the surface of the powder 161 1 is not precisely matched to the focal distance of each energy beam 1622D, but the deviations from optimal focus are small enough with respect to the depth of focus of each energy beam 1622D that the proper part geometry may be formed in the powder 161 1 .

[00229] The processing machine 1610 illustrated in Figure 16A, may be used with a linear scanning powder bed 1626, or a rotating powder bed 1626. For a rotating system, it may be preferable to distribute the multiple columns across the powder bed 1626 radius, not its diameter. In this case, the powder bed axis of rotation would be at the right edge of the diagrams.

[00230] In these embodiments, the size and shape of the curved support regions 1626E are designed to correspond to (i) the beam deflection of each energy beam 1622D at the top powder layer 1613, and (ii) the type of relative movement between the energy beam 1622D and the powder layer 1613. Stated in another fashion, the size and shape of each curved support region 1626E is designed so that the energy beam 1622D has a substantially constant focus distance at the top powder layer 1613 during relative movement between the energy beam 1622D and the powder layer 1613. Stated in yet another fashion, the shape of the support region 1626E, and the position of the energy beams 1622D are linked to the type of relative movement between the support region 1626E and the energy beams 1622D so that the energy beams 1622D have a substantially constant focus distance at the top powder layer 1613.

[00231 ] For example, Figure 16B is a top view of a support bed 1626 in which the curved support regions 1626E are shaped into linear rows. In this embodiment, there is linear relative movement along a movement axis 1625 between the powder bed 1626 and the irradiation device 1622 (illustrated in Figure 16A) while maintaining a substantially constant focus distance. A sweep (scan) direction 1623 of each beam 1622D (illustrated in Figure 16A) is illustrated with a two headed arrow in Figure 16B.

[00232] Alternatively, for example, Figure 16C is a top view of a support bed 1626 in which the curved support regions 1626E are shaped into annular rows. In this embodiment, there is rotational relative movement along a movement axis 1625 between the powder bed 1626 and the irradiation device 1622 (illustrated in Figure 16A) while maintaining a substantially constant focus distance. A sweep (scan) direction 1623 of each beam 1622D (illustrated in Figure 16A) is illustrated with a two headed arrow in Figure 16C.

[00233] As provided herein, maintaining a constant focal distance will improve the part quality by controlling aberrations and the beam spot size.

[00234] Referring back Figure 16A, in this embodiment, (i) the powder bed 1626 has a non-flat support region (support surface) 1626E, (ii) the powder supply device (not shown in Figure 16A) supplies the powder 161 1 to the powder bed 1616 to form the curved powder layer 1613; and (iii) the irradiation device 1622 irradiates the layer 1613 with an energy beam 1622D to form the built part (not shown in Figure 16A) from the powder layer 1613. In this embodiment, the non-flat support surface 1626E may have a curvature. Further, the irradiation device 1622 may sweep the energy beam 1622D back and forth along a swept direction 1623, and wherein the curved support surface 1626E includes the curvature in a plane where the energy beam 1622D pass through.

[00235] Figure 17 is a simplified side illustration of a portion of still another embodiment of the processing machine 1710. In this embodiment, the processing machine 1710 includes (i) the powder bed 1726 that supports the powder 171 1 ; and (ii) the irradiation device 1722 that are somewhat similar to the corresponding components described above and illustrated in Figure 16A. It should be noted that the processing machine 1710 may include the powder depositor, pre-heat device, the cooler device, the measurement device, and the control system, that have been omitted from Figure 17 for clarity. The powder depositor, the irradiation device 1722, the pre-heat device, and the measurement device may collectively be referred to as the top assembly.

[00236] In this embodiment, the irradiation device 1722 includes multiple (e.g. three) irradiation energy sources 1722C that each generates a separate irradiation energy beam 1722D that may be steered (scanned) to selectively heat the powder 171 1 in each subsequent powder layer 1713 to form the part. In Figure 17, each energy beam 1722D may be controllably steered throughout a cone shaped workspace that diverges from the respective energy source 1722C. In Figure 17, the possible directions of each energy beam 1722D are each represented by three arrows.

[00237] In Figure 17, the support surface 1726B of the powder bed 1726 is uniquely designed to have large concave curved surface. Stated in another fashion, the support surface 1726B is curved shaped.

[00238] As provided above, scanning each energy beam 1722D across a large angle would create focus errors if the surface of the powder 171 1 were a flat plane because the distance from the deflection center to the powder 171 1 would change with the cosine of the deflection angle. In the embodiment illustrated in Figure 17, however, the powder 171 1 is spread on the curved support surface 1726B, and the irradiation energy sources 1722C are tilted relative to each other so that the distance between the deflection center of each energy beam 1722D and the surface of the powder 171 1 is substantially constant so there are no significant focus errors.

[00239] In the embodiment illustrated in Figure 17, the powder support surface 1726B is rotating in a manner similar to the previously described embodiments, and the powder 171 1 is distributed across a single curved spherical surface 1726B. In this case, the columns providing each energy beam 1722D may be offset from each other in the vertical direction (and angled) to more closely align the focal surface of each energy beam 1722D with the powder surface. In other words, the shape of the surface of the powder 171 1 is not precisely matched to the focal distance of each energy beam 1722D, but the deviations from optimal focus are small enough with respect to the depth of focus of each energy beam 1722D that the proper part geometry may be formed in the powder 171 1 .

[00240] The processing machine 1710 illustrated in Figure 17, may be used with a linear scanning powder bed 1726, or a rotating powder bed 1726. In these embodiments, the size and shape of the curved support surface 1726B is designed and the irradiation energy sources 1722C are oriented and positioned (i) so that each energy beam 1722D has a substantially constant focus distance at the top powder layer 1713, and (ii) to match the type of relative movement between the energy beam 1722D and the powder layer 1713. Stated in yet another fashion, the shape of the support region 1726E, and the position of the energy beams 1722D are linked to the type of relative movement between the support region 1726E and the energy beams 1722D so that the energy beams 1722D have a substantially constant focus distance at the top powder layer 1713.

[00241 ] Figure 18 is a simplified side perspective illustration of a portion of yet another embodiment of the processing machine 1810 for making a three dimensional part 181 1. In this embodiment, the processing machine 1810 is a wire feed, three dimensional printer that includes (i) the material bed assembly 1814 that supports the three dimensional part 181 1 ; and (ii) a material depositor 1850.

[00242] In Figure 18, the material bed assembly 1814 includes the material bed 1826 and a device mover 1828 that rotates the material bed 1826 about the support rotation axis 1826D.

[00243] Further, in Figure 18, the material depositor 1850 includes (i) an irradiation device 1852 that generates an irradiation energy beam 1854; and (ii) a wire source 1856 that provides a continuous feed of wire 1858. In this embodiment, the irradiation energy beam 1854 illuminates and melts the wire 1858 to form molten material 1860 that is deposited onto the material bed 1826 to make the part 181 1 .

[00244] As provided herein, the problem of manufacturing high precision rotationally symmetric parts 181 1 by three dimensional printing is solved by using a rotating material bed 1826 (build platform), the wire source 1856 (wire feed mechanism) that supplies the wire 1858, and the irradiation energy beam 1854 for melting the wire 1858.

[00245] In one embodiment, as the material bed 1826 is rotated about the rotation axis 1826D, the material depositor 1850 may provide the molten material 1860 to form the part 181 1 . Further, material depositor 1850 (irradiation device 1852 and wire source 1856) may be moved transversely (e.g. along arrow 1862) with a depositor mover 1864 relative to the rotating material bed 1826 to build the part 181 1 . Further, the material bed 1826 and/or the material depositor 1850 may be moved vertically (e.g. by one of the movers 1828, 1864) to maintain the desired height between the material depositor 1850 and the part 181 1 .

[00246] Alternatively, the depositor mover 1864 may be designed to rotate the material depositor 1850 about a rotation axis and move the material depositor 1850 transversely to the rotation axis relative to the stationary material bed 1826. Still alternatively, the depositor mover 1864 may be designed to rotate the material depositor 1850 about a rotation axis relative to the material bed 1826, and the material bed 1826 may be moved transversely to the rotation axis with the device mover 1828.

[00247] Round, substantially rotationally symmetric parts 181 1 may be built by rotating the material bed 1826 and depositing metal by using the energy beam 1854 to melt the wire feed 1858. The basic operation is analogous to a normal metal cutting lathe, except that the“tool” is depositing metal 1860 instead of removing it.

[00248] It is understood that although a number of different embodiments of the processing machine 10 have been illustrated and described herein, one or more features of any one embodiment can be combined with one or more features of one or more of the other embodiments, provided that such combination satisfies the intent of the present disclosure.

[00249] While a number of exemplary aspects and embodiments of the processing machine 10 have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub combinations as are within their true spirit and scope.

Claims

What is claimed is:

1 . A processing machine for building a three-dimensional object from powder, the processing machine comprising:

a build platform that supports a first powder layer; and

an energy system that (i) generates a sintered portion in the first powder layer, the sintered portion being smaller than the first powder layer; and (ii) generates a melted portion in the sintered portion, the melted portion of the first powder layer comprising a first section of the object.

2. The processing machine of claim 1 , wherein the melted portion is smaller than the sintered portion.

3. The processing machine of any of claims 1 and 2, wherein the melted portion is encircled by the sintered portion.

4. The processing machine of any of claims 1 to 3, wherein the sintered portion has a sintered outer perimeter, and wherein the melted portion is positioned within the sintered outer perimeter.

5. The processing machine of claim 4 wherein the melted portion is spaced apart a separation distance from the sintered outer perimeter that is less than twenty millimeters and greater than 0.5 millimeters.

6. The processing machine of claim 4, wherein the melted portion is spaced apart a separation distance from the sintered outer perimeter that is less than ten millimeters and greater than one millimeter.

7. The processing machine of claim 4, wherein the melted portion is spaced apart a separation distance from the sintered outer perimeter that is less than five millimeters and greater than one millimeter.

8. The processing machine of any of claims 1 to 7, wherein (i) the first powder layer has a layer surface area; (ii) the sintered portion has a sintered surface area; (iii) the melted portion has a melted surface area; (iv) the layer surface area is larger than the sintered surface area; and (v) the sintered surface area is larger than the melted surface area.

9. The processing machine of claim 8, wherein the layer surface area is at least ten percent larger than the sintered surface area, and the sintered surface area is at least one percent larger than the melted surface area.

10. The processing machine of claim 8, wherein the layer surface area is at least twenty-five percent larger than the sintered surface area, and the sintered surface area is at least two percent larger than the melted surface area.

1 1 . The processing machine of any of claims 1 -10, wherein the build platform supports a second powder layer positioned on top of the first powder layer; and wherein the energy system (i) generates a sintered portion in the second powder layer that is smaller than the second powder layer; and (ii) generates a melted portion in the sintered portion of the second powder layer, the melted portion of the second powder layer comprising a second section of the object.

12. The processing machine of claim 1 1 wherein the sintered portion of the second powder layer at least partly overlaps the sintered portion of the first powder layer.

13. The processing machine of any of claims 1 1 or 12 wherein the melted portion of the second powder layer at least partly overlaps the melted portion of the first powder layer.

14. The processing machine of any of claims 1 1 -13 wherein the melted portion of the second powder layer is fused with the melted portion of the first powder layer.

15. The processing machine of any of claims 1 -14, wherein the energy system includes an electron beam generator that generates an electron beam that generates the sintered portion of the first powder layer and subsequently melts the melted portion of the first powder layer.

16. The processing machine of any of claims 1 -14, wherein the energy system includes a laser beam generator that generates a laser beam that generates the sintered portion of the first powder layer and subsequently generates the melted portion of the first powder layer.

17. The processing machine of any of claims 1 -14, wherein the energy system includes (i) a sinter system that heats the powder for generating the sintered portion; and (ii) a melting system that melts the powder the melted portion.

18. The processing machine of claim 17, wherein the sinter system generates an electron beam, and the melting system generates an electron beam.

19. The processing machine of claim 17, wherein the sinter system generates an electron beam, and the melting system generates a laser beam.

20. The processing machine of claim 17, wherein the sinter system generates a laser beam, and the melting system generates an electron beam.

21 . The processing machine of claim 17, wherein the sinter system generates an infrared beam, and the melting system generates an electron beam.

22. The processing machine of claim 17, wherein the sinter system includes an irradiation device that generates an irradiation beam.

23. The processing machine of claim 17, wherein the sinter system generates at least one of the following: a laser beam, a proton beam, a particle beam, an ion beam, an infrared beam, an ultraviolet beam, or a visible beam.

24 The processing machine of any of claims 1 -23, wherein the melted portion melted by the energy system comprises a section of a containment structure.

25. The processing machine of claim 24, wherein the containment structure retains at least some of the powder on the build platform.

26. The processing machine of claim 26, wherein the containment structure retains the object.

27. The processing machine of claim 26, further comprising a robotic arm that selectively moves the containment structure with the object from build platform.

28. The processing machine of any of claims 1 -27, wherein the build platform is movable relative to the energy system.

29. The processing machine of any of claims 17-28, wherein the sinter system and the melting system are calibrated relative to each other.

30. The processing machine of claim 1 further comprising (i) a mover that moves the build platform so a specific position on the build platform is moved along a moving direction; (ii) a powder supply device which supplies the powder to the moving build platform; (iii) wherein the energy system irradiates at least a portion of the powder layer with an energy beam to form at least a portion of the part from the powder layer during a first period of time; and (iv) a measurement device which measures at least portion of the object during a second period of time; wherein at least part of the first period in which the energy system device irradiates the powder with the energy beam and at least part of the second period in which the measurement device measures are overlapped.

31 . The processing machine of claiml further comprising: (i) a mover which moves the build platform so as to move a specific position on the build platform along a moving direction; and (ii) a powder supply device which supplies a powder to the build platform which moves, and forms a powder layer; wherein the energy system changes an irradiation position where the energy beam is irradiated to the powder layer along a direction crossing the moving direction.

32. The processing machine of claim 1 further comprising: (i) a mover which moves the build platform so as to move a specific position on the build platform along a moving direction; (ii) a powder supply device which supplies a powder to the build platform which moves, and forms a powder layer; and wherein the energy system includes a plurality of irradiation systems which irradiate the layer with an energy beam to form a built part from the powder layer, wherein the irradiation systems arranged along a direction crossing the moving direction.

33. The processing machine of claim 1 further comprising: (i) a powder supply device that deposits the powder onto the build platform; and (ii) a mover that rotates at least one of the build platform and the powder supply device about a rotation axis while the powder supply device deposits the powder onto the build platform.

34. The processing machine of claim 1 further comprising: (i) a mover which moves the build platform so a specific position on the build platform is moved along a moving direction; (ii) a powder supply device which supplies the powder to the moving build platform to form a powder layer during a powder supply time; and (iii) wherein the energy system irradiates at least a portion of the powder layer with an energy beam to form at least a portion of the object from the powder layer during an irradiation time; and wherein at least part of the powder supply time and the irradiation time are overlapped.

35. The processing machine of claim 1 , (i) wherein the build platform includes a non-flat support surface; (ii) further comprising a powder supply device which supplies a powder to the support surface and which forms a curved powder layer; and (iii) wherein the energy system irradiates the layer with an energy beam to form a portion of the object from the powder layer.

36. A method for building a three-dimensional object from powder, the method comprising the steps of:

supporting a first powder layer with a build platform;

generating a sintered portion in the first powder layer with an energy system, the sintered portion being smaller than the first powder layer; and

generating a melted portion in the sintered portion of the first powder layer with the energy system, the melted portion of the first powder layer comprising a first section of the object.

37. The method of claim 36, wherein the step of melting includes the melted portion being smaller than the sintered portion.

38. The method of any of claims 36 and 37, wherein the step of melting includes the melted portion being encircled by the sintered portion.

39. The method of any of claims 36 to 38, wherein the step of generating a sintered portion includes the sintered portion having a sintered outer perimeter, and wherein the step of generating a melted portion includes the melted portion being positioned within the sintered outer perimeter.

40. The method of claim 39 wherein the step of generating a melted portion includes the melted portion being spaced apart a separation distance from the sintered outer perimeter that is less than twenty millimeters and greater than 0.5 millimeters.

41 . The method of claim 39, wherein the step of generating a melted portion includes the melted portion being spaced apart a separation distance from the sintered outer perimeter that is less than ten millimeters and greater than one millimeter.

42. The method of claim 39, wherein the step of generating a melted portion includes the melted portion being spaced apart a separation distance from the sintered outer perimeter that is less than five millimeters and greater than one millimeter.

43. The method of any of claims 36 to 42, wherein (i) the first powder layer has a layer surface area; (ii) the sintered portion has a sintered surface area; (iii) the melted portion has a melted surface area; (iv) the layer surface area is larger than the sintered surface area; and (v) the sintered surface area is larger than the melted surface area.

44. The method of claim 43, wherein the layer surface area is at least ten percent larger than the sintered surface area, and the sintered surface area is at least one percent larger than the melted surface area.

45. The method of claim 43, wherein the layer surface area is at least twenty- five percent larger than the sintered surface area, and the sintered surface area is at least two percent larger than the melted surface area.

46. The method of any of claims 36-45, further comprising the steps of supporting a second powder layer positioned on top of the first powder layer with the build platform; generating a sintered portion in the second powder layer with the energy system, the sintered portion of the second powder layer being smaller than the second powder layer; and generating a melted portion in the sintered portion of the second powder layer with the energy system, the melted portion of the second powder layer comprising a second section of the object.

47. The method of claim 46 wherein the step of generating a sintered portion of the second powder layer includes the sintered portion of the second powder layer at least partly overlapping the sintered portion of the first powder layer.

48. The method of any of claims 46 or 47 wherein the step of generating a melted portion in the second powder layer includes the melted portion of the second powder layer at least partly overlapping the melted portion of the first powder layer.

49. The method of any of claims 46-48 further comprising the step of fusing the melted portion of the second powder layer with the melted portion of the first powder layer.

50. The method of any of claims 36-49, wherein the energy system includes an electron beam generator that generates an electron beam that generates the sintered portion of the first powder layer and subsequently generates the melted portion of the first powder layer.

51 . The method of any of claims 36-49, wherein the energy system includes a laser beam generator that generates a laser beam that generates the sintered portion of the first powder layer and subsequently generates the melted portion of the first powder layer.

52. The method of any of claims 36-49, wherein the energy system includes (i) a sinter system that heats the powder in the sintered portion; and (ii) a melting system that melts the powder in the melted portion.

53. The method of claim 52, wherein the sinter system generates an electron beam, and the melting system generates an electron beam.

54. The method of claim 52, wherein the sinter system generates an electron beam, and the melting system generates a laser beam.

55. The method of claim 52, wherein the sinter system generates a laser beam, and the melting system generates an electron beam.

56. The method of claim 52, wherein the sinter system generates an infrared beam, and the melting system generates an electron beam.

57. The method of claim 52, wherein the sinter system includes an irradiation device that generates an irradiation beam.

58. The method of claim 52, wherein the sinter system generates at least one of the following: a laser beam, a proton beam, a particle beam, an alpha particle beam, an infrared beam, an ultraviolet beam, or a visible beam.

59. The method of any of claims 36-58, wherein the melted portion melted by the energy system comprises a section of a containment structure.

60. The method of claim 59, wherein the containment structure retains at least some of the powder on the build platform.

61 . The method of claim 60, wherein the containment structure retains the object.

62. The method of claim 61 further comprising the step of selectively moving the containment structure with the object from build platform with a robotic arm.

63. The method of any of claims 36-62 further comprising the step of moving the build platform relative to the energy system.

64. The method of any of claims 52-63, wherein the sinter system and the melting system are calibrated relative to each other.

65. A processing machine for building a three-dimensional object from powder, the processing machine comprising:

a build platform including a support surface that supports the powder; a measurement device that provides measurement feedback;

an energy system that generates an energy beam that is adapted to melt at least a portion of the powder; and

a control system that controls the energy system to direct the energy beam and the measurement feedback to calibrate the energy system.

66. The processing machine of claim 65, wherein the support surface includes a fiducial mark that is irradiated by the energy beam from the energy system to calibrate the energy system.

67. The processing machine of claim 66, wherein the measurement device monitors backscattered light to generate the measurement feedback used to calibrate the energy system.

68. The processing machine of claim 65, wherein the measurement device includes an image sensor that monitor heat generated in the powder to generate the measurement feedback used to calibrate the energy system.

69. The processing machine of claim 65, wherein the energy system includes a sinter system that directs a sinter beam at the powder to sinter the powder, and a melting system that generates a melting beam at the powder to melt the powder, and wherein the control system uses measurement feedback to calibrate the sinter system and the melting system.

70. A processing machine for building a three-dimensional object from powder, the processing machine comprising:

a build platform including a support surface that supports a powder layer of powder, the support surface that includes a fiducial mark; and

an energy system that generates an energy beam to irradiate the fiducial mark.

71 . The processing machine of claim 70 further comprising a measurement device monitors backscatter light to generate a measurement feedback used to calibrate the energy system.