WO2017035217A1

WO2017035217A1 - 3d manufacturing using multiple material deposition and/or fusion sources simultaneously with single or multi-flute helical build surfaces

Info

Publication number: WO2017035217A1
Application number: PCT/US2016/048363
Authority: WO
Inventors: Michael Davis
Original assignee: New York University
Priority date: 2015-08-25
Filing date: 2016-08-24
Publication date: 2017-03-02

Abstract

Disclosed herein is a method and apparatus to improve the speed of the free-form manufacture of complex systems using the helical build process to 3D print / manufacture objects by using multiple material fusion sources simultaneously with single- or multi-flute helical build surfaces. As a result of the stationary material deposition line in a helical build machine, the speed of the fusion process can be improved by simultaneously using multiple fusion in sources in parallel on each fusion line. The geometry of the fixed location of the fusion line allows for changes in the optics of laser based machines which may lead to improvements in speed of over 100x compared to the speed of a single flute machines. Speed improvements are possible for all types additive manufacturing processes that use the helical build approach.

Description

3D MANUFACTURING USING MULTIPLE MATERIAL DEPOSITION AND/OR FUSION SOURCES SIMULTANEOUSLY WITH SINGLE OR MULTI-FLUTE

HELICAL BUILD SURFACES

PRIORITY

[0001] This application claims priority from U.S. Provisional Application No.

62/209,740, filed August 25, 2015, incorporated herein by reference in its entirety

FIELD OF THE INVENTION

[0002] The present invention generally relates to devices and methods for manufacturing solid objects by layer-by-layer deposition of material for single parts or complex systems which are then incorporated into or used to manufacture complex systems. Certain embodiments extend the 3D printing process from using one material fusion process to using multiple material fusion processes and multiple fusion sources for each process simultaneously.

BACKGROUND OF THE INVENTION

[0003] Continuous Feed 3D printers that use the Helical Build Surface

manufacturer 3D parts and assemblies by using one or more fixed material deposition systems known as a material deposition "line" that is suspended above a rotating build platform and extends from the center of the build platform to the radius of the platform. The material deposition source deposits along a deposition line. Simultaneously as the platform rotates, material is deposited on the top surface of the build platform where the freshly deposited material is fused at the build line by a fusion source. The build line remains in the x-y plane while the build platform is able to travel in the z-direction. The line that extends from the center of the build platform to the radius of the platform along which material is fused is called the fusion line.

[0004] This type of printer can have more than one material deposition line and the corresponding fusion line and can employ more than one type of material deposition and fusion processes simultaneously. A machine with one

deposition/fusion line is said to be a single-flute machine. A machine with three deposition/fusion lines is said to be a three flute machine. With this type of machine a flute may have more than one type of material deposition and fusion process and the same applies to machines with multiple flutes.

[0005] With this type of machine the number of flutes is limited by the geometry of the machine and the deposition/fusion process. Typical with this type of machine each flute has a single material fusion system. For example, if the material fusion is performed with a laser, then a single laser is used along each fusion line. In a three-flute machine each flute would have a separate laser that is dedicated to each fusion line associated with each flute.

[0006] With this type of machine the use of a laser for fusion is typically done using a laser scan head mounted above the build surface at a distance appropriate for the length of the build line. For example, a 250 mm long fusion line requires a focal distance of approximately 330 mm in order to achieve a 50 micron spot size at the surface of the fusion line. When considering the physical size of the lenses and scan heads required to achieve a 250 mm long build line, a limit of four or five flutes is the maximum that can be achieved using a single laser on each build line.

SUMMARY OF THE INVENTION

[0007] One implementation relates to an apparatus for the forming of three- dimensional objects in a single or multi-flute helical build machine and consists of having multiple fusion sources for each fusion line for each flute.

[0008] In one implementation a material deposition line and a fusion line are along the same line because the material fuses as it is deposited and in this case multiple material deposition sources are mounted on a linear translation system that travels back and forth along a material deposition line that extends from the center of the build platform to the radius. The distance traveled is such that each material deposition source covers an equal distance along a deposition line and the entire length of the line is covered by one of the deposition sources.

[0009] In one implementation the fusion source is a laser that operates by focusing the beam from either the side of the build platform or from above the build platform by using a series of mirrors that direct the beam through one or more lenses that are mounted on a linear translation apparatus that moves the lens or lenses back and forth along a fusion line for a fixed distance in a direction that extends from the center of the build platform to the build radius. The distance traveled by the lenses is such that the focal point of each lens travels a distance along a fusion line and the entire length of a fusion line is covered by the focal point of one of the lenses. A laser beam is associated with each lens so that each area along the fusion line can be fused separately from the areas covered by the other lasers and lenses. The lenses are mounted at a distance above the fusion line as appropriate for the desired focal point size of the machine process.

[0010] In one implementation the fusion source is a laser beam or laser beams that operates by using a motor driven mirror system to direct a collimated beam or beams of energy to a series of lenses that are fixed along the build line.

[0011] In one implementation the material deposition system is with multiple ink- jet style print heads which are mounted on a linear translation system with the print line of the inkjet heads aligned with a fixed geometry in relation to the orientation of a deposition line. A linear translation system moves the print heads back and forth along a deposition line that extends from the center of the build platform to the radius in such a way that the entire length of the deposition line can have material deposited on it by one or more of the print heads.

[0012] Additional features, advantages, and embodiments of the present disclosure may be set forth from consideration of the following detailed description, drawings, and claims. Moreover, it is to be understood that both the foregoing summary of the present disclosure and the following detailed description are exemplary and intended to provide further explanation without further limiting the scope of the present disclosure claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The foregoing and other objects, aspects, features, and advantages of the disclosure will become more apparent and better understood by referring to the following description taken in conjunction with the accompanying drawings, in which: [0014] Figure 1 is a schematic drawing of the front view of an embodiment of a device for manufacturing 3D objects and systems using the Helical Build Surface process.

[0015] Figure 2 is a schematic of a top view of an embodiment of the device in Figure 1.

[0016] Figure 3 is a schematic of a detailed view of a moving multiple laser fusion source device referenced in Figure 1 and Figure 2.

[0017] Figure 4 is a schematic of a detailed view of a fixed multiple laser fusion source device referenced in Figure 1 and Figure 2.

[0018] Figure 5 is a schematic of a detailed view of a moving multiple

combination deposition/fusion source device referenced in Figure 1 and Figure 2.

[0019] [Figure 6 is a schematic of a detailed view of a moving multiple ink-jet print head type of deposition/fusion source device referenced in Figure 1 and Figure 2.

[0020] Figure 7 illustrates an implementation of a build plate, which is shown in the implementation as a flat, round disk.

[0021] Figure 8 illustrates one implementation of a helical surface in a single-flute machine following one rotation.

[0022] Figure 9 illustrates an implementation of an example "widget" that may be built by the proposed device using a multi-flute machine.

[0023] Figure 10 illustrates an implementation of an example of the widget as formed by helical layers using the proposed device with a multi-flute machine.

[0024] Figure 1 1 illustrates an implementation where the single flute helical surface from Figure 8 has been divided into sections for the purpose of the fusing process. The "wedges" or sections shown in the figure are greatly exaggerated in size for the purpose of visualizing the build process. [0025] Figure 12 illustrates an implementation where the single layer of the helical surface from Figure 1 1 that has been divided into sub-sections for the purpose of the fusing process where different materials are used and the subsections represent possible material differences. The "wedges" or sections and sub-sections shown in the figure are greatly exaggerated in size for the purpose of visualizing the build process.

[0026] Figure 13 illustrates the overall flow of the build process from part design to post-processing.

[0027] Figure 14 illustrates a computer system for use with certain

implementations.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] In the following detailed description, reference is made to the

accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and made part of this disclosure.

[0029] Described herein are methods and an apparatus adapted for improving the speed of production and quality (resolution) of the free-form manufacture of complex systems using single and multi-flute manufacturing of 3D parts using machines that use the helical surface build process. The build deck, or build plate, is shown in Figure 7. The figure is for conceptual understanding only and for real applications the shape of the build plate will be determined by the requirements of the build. A single rotation of the helical surface is shown in Figure 8. [0030] Figure 1 is a schematic of a machine that manufactures parts using the 3D printing techniques and follows the helical build surface process. 001 is the general orientation of the xyz axis and in a helical build machine the z-axis is aligned along the center of rotation as defined by the z-axis support mechanism, 200. In the helical build machine process the build platform or build deck, 201 is supported by the z-axis movement mechanism, 200, and rotates about the z-axis. 300 is the material deposition system which includes the material feed mechanism, 301 , and the material feed pipeline, 302. The material is deposited on the build platform, 201 , and when fused the material forms the 3D object being manufactured, 500. In a laser based fusion system, the laser source, 400, is located as appropriate in the machine and the laser beam or beams are delivered by the appropriate means as detailed in Figure 3 and Figure 4. If the material deposition and fusion system uses a material that fuses as it is deposited, the fusion mechanism is detailed in Figure 5. Figure 6 details an ink-jet style deposition/fusion system.

[0031] For embodiments using a laser or lasers as the fusion system, collimated lasers may be coupled with a set of fixed mirrors that direct the beam(s) to a set of lenses that are mounted on a translation stage that moves the lenses relative to the fusion line and directs collimated laser beams to the fusion line. In another embodiment, the plurality of fusion sources are collimated lasers coupled with a set of fixed mirrors that direct the beams to a set of rotating mirrors that then direct collimated laser beams to a set of fixed-in-place lenses that focus the collimated laser beams onto the deposited material that is to be fused. While the fusion system is generally described herein with regard to a laser as an example, it should be appreciated that other fusion systems may be used. For example the fusion source may be electric arcs or ionized plasma gas. The fusion source may be located on a translation stage that moves back and forth along the fusion line. The fusion line and fusion source are fixed relative to the rotating build stage (and object being built).

[0032] While the materials deposition source is generally described herein with regard to an ink-jet system, it should be appreciated that other materials deposition sources may be used, include an extrusion system or a wire feed mechanism. The deposition source may utilize multiple flutes to dispense materials. Further, multiple heads or individual sources (e.g., extrusion heads, wire-feed heads, ionic deposition heads, CVD heads, etc) may be located on the materials deposition source, including organized into groups within multiple flutes. The deposition source may be located on a carriage that moves back and forth along the deposition line. The deposition line and deposition source are fixed relative to the rotating build stage (and object being built). In one embodiment where the deposition line and fusion line are co-located, the deposition source and fusion source may be positioned on the same movable carriage or translation stage or separate.

[0033] Further, as described in greater detail below, some embodiments include a plurality of fusion lines and/or a plurality of deposition lines

[0034] Figure 2 is a schematic showing the top view of a helical build machine as shown in Figure 1 . The machine in Figure 2 is a five-flute machine and can manufacture five separate helical surfaces simultaneously. 300 is a material deposition and fusion system that has five material deposition lines, 301 , and five material fusion lines, 302. For machines that deposit and fuse in one step, 301 is both the deposition and fusion line. In one implementation the material deposition is powder and the fusion method is with a laser or lasers, 400, in combination with a beam delivery system, 401 . One implementation uses multiple lasers along each fusion line. If four lasers were used simultaneously on the five fusion lines shown in Figure 2, the machine would be 20x as fast as a single-flute machine that uses a single laser.

[0035] Figure 3 is a schematic showing a fusion line, 302, from Figure 2 that uses a multiple laser sources, 400, and a multiple beam delivery system, 401 , 402 and

403, to deliver the beams to a series of lens that are supported on a moving linear translation system, 600. The mirror delivery system has fixed mirrors on the side of the build platform, 402, that direct the laser beams to the mirrors, 403, that direct the beams to the focusing lenses 601 . The mirrors, 403, that direct the beams into the focusing lens are attached to the linear translation stage and they move with the lenses. 602 is the focal length of the lenses that are mounted on the translation stage and the focal length is determined by the design of the machine. For example, the focal length of the lenses can be reduced from the current typical 330 mm to 30 mm while reducing the spot size from 50 microns to 10 microns which increases the effective resolution of the machine. This arrangement allows the spot size to be tuned to match the needs of the machine and expands the applications that the machine can target. This also increases the number of flutes a machine can have. For example, with a 330 mm focal length, the collimated beam that enters the galvanometer must be on the order of 20mm in diameter. If we reduce the focal length to 30 mm, we can reduce the collimated beam size from 20 mm to 2 mm and maintain the same spot size. A machine that requires a 2mm diameter collimated beam can have 10 times as many flutes as a machine with a 20 mm collimated beam and it becomes physically possible to have a machine with 20 flutes and five lasers/flute which is a machine that is potentially 100 times faster than a single flute machine.

[0036] Figure 4 is a schematic showing a fusion line, 302, from Figure 2 that uses a multiple laser source, 400, and multiple beam delivery system, 401 , 402 and 404, to deliver the beams to a series of lens that are supported on a stationary support system, 700. The mirror delivery system has fixed mirrors on the side of the build platform, 402, that direct the laser beams to moving mirrors, 404, that direct the beams to the focusing lens 701 . The mirrors, 404, that direct the beams into the focusing lens are driven my motors that direct the beams along the fusion line and that keep each beam on each lens as required by the design of the machine. 702 is the focal length of the lenses that are mounted on the support system and is determined by the design of the machine. For example, the focal length of the lenses can be reduced from the current typical 330 mm to 30 mm while reducing the spot size from 50 microns to 10 microns which increases the effective

resolution of the machine. This arrangement allows the spot size to be tuned to match the needs of the machine and expands the applications that the machine can target. This also increases the number of flutes a machine can have. For example, with a 330 mm focal length, the collimated beam that enters the

galvanometer must be on the order of 20mm in diameter. If we reduce the focal length to 30 mm, we can reduce the collimated beam size from 20 mm to 2 mm and maintain the same spot size. A machine that requires a 2mm diameter collimated beam can have 10 times as many flutes as a machine with a 20 mm collimated beam and it becomes physically possible to have a machine with 20 flutes and five lasers/flute which is a machine that is potentially 100 times faster than a single flute machine.

[0037] Figure 5 is a schematic showing a combination material deposition and fusion line, 302, from Figure 2 that uses multiple deposition and fusion sources, 801 , which are supported on a moving or stationary support system, 800, to deliver the material onto the build platform where it fuses to form the 3D object, 803. 805 is the material transportation system that supplies the material to the

deposition/fusion heads, 801 , which deposit the material which is transferred through the deposition path, 804, and is deposited on the top of the build

surface, 803, where it fuses and forms the 3D object, 803. 802 is the distance between the deposition heads and the top of the build surface and is determined by the requirements of the material and the process. A machine that uses 4

deposition/fusion heads with five flutes is a machine that is potentially 20 times faster than a single flute machine. A combination material deposition/fusion line may consist of extruded plastics or other molten material that solidifies once it lands on the build plate. Other types of material deposition/fusion lines may consist of material that is deposited by using welding techniques such as MIG or TIG or plasma melted metal powders or other deposition techniques such as ionic deposition or chemical vapor deposition.

[0038] Figure 6 is a schematic showing a combination material deposition and fusion line, 302, from Figure 2 that uses multiple inkjet deposition sources, 801 , which are supported on a moving or stationary support system, 800, to deliver the material onto the build platform where it fuses to form the 3D object, 803. 805 is the material transportation system that supplies the material to the print heads, 801 , which deposit the material which is transferred through the deposition path, 804, and is deposited on the top of the build surface, 803, where it fuses and forms the 3D object, 803. 802 is the distance between the inkjet print heads and the top of the build surface and is determined by the requirements of the material and the process. A machine that uses 4 inkjet print heads with five flutes is a machine that is potentially 20 times faster than a single flute machine.

[0039] In various implementations, structures to be created with voids are formed by not fusing material and then removing the un-fused material such as by use of "supports" and "support materials" that are easily removed in the post-build processing. It should be appreciated that Figures 1 1 and 12 are divided into wedges and sub-sections for understanding the concepts of the math associated with the fusing process and how the process requires additional information when multiple fusion sources are used simultaneously with each fusion line or flute.

[0040] Certain embodiments of the invention relate to devices adapted to build complex systems using 3D printing in combination with previously manufactured parts stocked within the machine to build complex 3D objects using multiple additive and or subtractive manufacturing processes. Figure 1 is a schematic of a front view of one embodiment of the apparatus 100 for making a solid object 500. Figure 2 is a top view of the embodiment of the device shown in Figure 1 . Figure 3 is a close-up of the schematic of the material handling system shown in Figures 1 and 2. The device may include an outer casing as appropriate to safely contain the processes used within. One embodiment of the device can be described in

Cartesian coordinates 001. The 3D space of the build environment is described by a 3D Cartesian coordinate system where the +Z-axis points up. Following this definition of the coordinate system the X-Y plane defines the orientation of the horizontal surface and the Z-axis is the axis of rotation with +Z pointing up. The apparatus 100 consists of a build chamber 101 and which contains a rotating, in one embodiment circular, region that serves as a build container 202. In one embodiment, the build chamber is generally as is typical with 3D printers. It should be appreciated that the build chamber can be scaled as required for the types of products the machine will produce. In various implementation the systems and methods can be scaled up (or down) to accommodate the creation of large (or small) objects.

[0041] Figure 1 illustrates an embodiment of material deposition 300 for depositing a single material of equal layer thickness across all or a portion of the entire build surface extending from the center of rotation to the perimeter of the build surface. Other embodiments of the material deposition system 300 may include the ability to selectively deposit multiple materials in parallel along all or a portion of the line across the build surface that is formed by the material deposition system that extends from the center of rotation to the perimeter of the build surface. [0042] Certain apparatus and methods of the present invention may be utilized with numerical control, either mechanically or in combination with computer control, including through the use of design software providing data points for the 3-D object. In one implementation, the build process is controlled by a purpose-built controller that uses a multi-tasking operating system, for example but not limited to Linux or Windows. The purpose-built controller may be combined with a standard machine controller such as is typically found on a computer numerically controlled (CNC) machine. In one embodiment, a main processing unit will process the appropriate model files to produce a set of G-code instructions that are passed to the CNC machine controller.

[0043] The standard processing of the 3D object files must be adapted to accommodate the helical build surface as well as the new options for build processes and multiple materials that may be available. In one embodiment, the processing software is changed from the sliced X-Y layer approach to incorporate a continuous single or multi-flute helical slice approach using multiple or single material fusion sources simultaneously. In other words, instead of slicing the object into X-Y planes in the Z-direction, the software for this method will require that the 3D object(s) be sliced using a moving helical layer or layers which will be

continuous in the Z-direction and the machine instructions will be built to follow the helical build surface model. Additional processing instructions will have to be included in the model to incorporate any additional build processes that will be included in the manufacturing process such as the parallel operation of the multiple fusion sources.

[0044] Figure 8 shows a single rotation of a helical surface and a 3D object would have to be sliced into a continuous helical surface as shown in Figure 12. For example, processing a widget as shown in Figure 9 would require that the widget be sliced into a continuous helical surface as shown in Figure 10. Figure 1 1 shows how the helical surface will have to be sliced into wedges that are built as material is deposited. For example, when the widget is processed with the intent to build with powdered metal, the material is deposited on the build surface 500 by the material deposition line 300 the laser system 400/401 would fuse together the portions of the segments of fresh powder as shown in Figure 10 and by following this procedure repeatedly the widget will be formed into a single unit as shown in Figure 9 which will be comprised of helical layers as demonstrated in Figure 10. These figures are for example only and in a real system the layers and segments or wedges will be sized according to the requirements of the build. Figure 12 shows how each wedge is divided into sub-sections that allow for the processing of different materials that are deposited simultaneously. For example, when the widget is processed with the intent to build with multiple powdered materials, the material is deposited on the build surface 500 by the material deposition line 300 the laser system 400/401 would fuse together the portions of the segments of fresh powder as shown in Figure 1 1 and Figure 12 using the laser(s) appropriate for the material and by following this procedure repeatedly the widget will be formed into a single unit as shown in Figure 9 which will be comprised of helical layers as demonstrated in Figure 10. These figures are for example only and in a real system the layers and segments or wedges will be sized according to the

requirements of the build.

[0045] In one implementation, the technique for the helical slicing is a simple line intersection computation for each slice on the helical surface. To generate the build pattern, it is important to consider a continuous rotating surface moving in the z-direction yields a helical build surface. This process consists of mapping a continuous helical surface that matches the build path to the orientation of the part and its location in 3D space relative to the part's final placement on the build plate.

Once the part has been mapped to the helical surface that represents the build path, the helical surface is then sliced into thin wedges which are then tested for intersections with the 3D part. From the intersection data, a set of instructions are generated that determine the locations within the wedge where material is processed so as to construct the part. A further processing is required to generate the additional machine instructions required to operate each fusion source in parallel with the other fusion sources during the manufacturing process. As a result of the helical shape of the build surface, a new strategy for determination of the build instructions will be implemented where the 3D objects supplied in the form of

3D description files in formats such as STL, SolidWorks, ProE or others will be processed by slicing the 3D object as a continuous helical spiral and by then slicing the spiral surface into a series of small wedges and wedge sub-sections as shown in Figures 1 1 and 12 that follow a helical path as shown in Figures 5 and 6. The wedges are tested to find where the 3D object intersects the wedge and wedge sub-sections which determines which portion of the wedge should be processed and what materials are deposited to form the 3D object.

[0046] Figure 13 shows an overview of the process of building the widget shown in Figures 9 and 10. The start of the process is the design of the object or assembly of objects or system of components using design software such as SoldWorks or ProE. After the object is designed the user exports the design to an appropriate file format. The slicing software reads the design file or files and the user then places the objects into a virtual representation of the build cylinder and locates the parts as required in reference to the build platform. The slicing software then performs the helical slicing of the object, objects, assemblies, etc. included in the build and maps the location of the helical build surface to the location of the objects and the materials required to construct the object(s) or assemblies and this information is then stored in a slice file. The machine control software loads the slice file(s) and then generates the machine instructions required for the build to be performed and then saves the information in a build file. The build file is loaded into the continuous feed printer and after the machine is prepped, the build initiated. After the build is started, the machine runs until the build completes and then the post-processing is performed as required.

[0047] One implementation may utilize a computer system, such as shown in Figure 14, e.g., a computer-accessible medium 920 (e.g., as described herein, a storage device such as a hard disk, floppy disk, memory stick, CD-ROM, RAM, ROM, etc., or a collection thereof) can be provided (e.g., in communication with the processing arrangement 910). The computer-accessible medium 920 may be a non-transitory computer-accessible medium. The computer-accessible medium 920 can contain executable instructions 930 thereon. In addition or alternatively, a storage arrangement 940 can be provided separately from the computer-accessible medium 920, which can provide the instructions to the processing arrangement 910 so as to configure the processing arrangement to execute certain exemplary procedures, processes and methods, as described herein, for example. [0048] System 900 may also include a display or output device, an input device such as a keyboard, mouse, touch screen or other input device, and may be connected to additional systems via a logical network. Many of the embodiments described herein may be practiced in a networked environment using logical connections to one or more remote computers having processors. Logical connections may include a local area network (LAN) and a wide area network (WAN) that are presented here by way of example and not limitation. Such networking environments are commonplace in office-wide or enterprise-wide computer networks, intranets and the Internet and may use a wide variety of different communication protocols. Those skilled in the art can appreciate that such network computing environments can typically encompass many types of computer system configurations, including personal computers, hand-held devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, network PCs, minicomputers, mainframe computers, and the like. Embodiments of the invention may also be practiced in distributed computing environments where tasks are performed by local and remote processing devices that are linked (either by hardwired links, wireless links, or by a combination of hardwired or wireless links) through a communications network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.

[0049] Various embodiments are described in the general context of method steps, which may be implemented in one embodiment by a program product including computer-executable instructions, such as program code, executed by computers in networked environments. Generally, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. Computer-executable instructions, associated data structures, and program modules represent examples of program code for executing steps of the methods disclosed herein. The particular sequence of such executable instructions or associated data structures represents examples of corresponding acts for implementing the functions described in such steps. [0050] Software and web implementations of the present invention could be accomplished with standard programming techniques with rule based logic and other logic to accomplish the various database searching steps, correlation steps, comparison steps and decision steps. It should also be noted that the words "component" and "module," as used herein and in the claims, are intended to encompass implementations using one or more lines of software code, and/or hardware implementations, and/or equipment for receiving manual inputs.

[0051] With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for the sake of clarity.

[0052] The foregoing description of illustrative embodiments has been presented for purposes of illustration and of description. It is not intended to be exhaustive or limiting with respect to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the disclosed embodiments. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.

Claims

WHAT IS CLAIMED IS:

1 . An apparatus for improving the speed of operation of a 3D

printing/additive manufacturing process, the apparatus comprising:

a rotatable build deck extending along a x-axis and a y-axis, the build deck movable in a z-axis and rotatable about the z-axis;

a material deposition source positioned for deposition of at least one material on the build deck on a deposition line;

at least one flute having a plurality of fusion sources associated therewith;

wherein the plurality of fusion sources are engageable with the at least one material at a fusion line during a build process.

2. The apparatus of claim 1 , further wherein the plurality of fusion sources are each simultaneously engageable along the fusion line.

3. The apparatus of claim 1 , wherein the deposition line and the fusion line are co-located and wherein the deposition of material by the material deposition source and the fusion by the plurality of fusion sources occurs simultaneously.

4. The apparatus of claim 1 , wherein the deposition line and the fusion line are not co-located and wherein the deposition of material by the material deposition source and the fusion by the plurality of fusion sources occurs simultaneously.

5. The apparatus of claim 1 , wherein the material deposition source is an inkjet style device comprising a plurality of inkjet deposition sources, each configured to deposit at an associated position on the deposition line.

6. The apparatus of claim 4, wherein the material deposition source

comprises a powdered material source configured to deposit along the build line and multiple fusion sources that fuse the material along the fusion line. Each fusion source is operated independently from the other fusion sources.

7. The apparatus of claim 6, wherein the plurality of fusion sources are collimated lasers coupled with a set of fixed mirrors that direct the beam(s) to a set of lenses that are mounted on a translation stage that moves the lenses relative to the fusion line and directs collimated laser beams to the fusion line.

8. The apparatus of claim 6, wherein the plurality of fusion sources are

collimated lasers coupled with a set of fixed mirrors that direct the beams to a set of rotating mirrors that then direct collimated laser beams to a set of fixed-in-place lenses that focus the collimated laser beams onto the deposited material that is to be fused.

9. The apparatus of claim 6, wherein the plurality of fusion sources are

electric arcs or ionized gas plasma streams mounted on a translation stage that moves back-and-forth along the fusion line.

10. The apparatus of claim 2 wherein the material deposition source is an extrusion device comprising multiple extrusion heads mounted on a carriage that moves back and forth along the material deposition line.

1 1 . The apparatus of claim 10 wherein one or more of the multiple extrusion heads has more one type of plastic or other material connected for extrusion.

12. The apparatus of claim 1 wherein the material deposition source

comprises is multiple wire-feed heads mounted on a carriage that moves back and forth along the material deposition line.

13. The apparatus of claim 10 where each of multiple wire-feed heads has connected thereto more than one type of wire for deposition.

14. The apparatus of claim 1 wherein the material deposition source is an ionic deposition source having multiple ionic deposition heads which are mounted on a carriage that is either fixed or moves back and forth along the material deposition line.

15. The apparatus of claim 1 wherein the material deposition source is a chemical vapor deposition (CVD) source using multiple CVD heads which are mounted on a carriage that is either fixed or moves back and forth along the material deposition line.

16. The apparatus of claim 1 , wherein the material deposition source

consists of at least one material dispensing mechanism configured for dispensing a material selected from the group consisting of powders, liquids, aerosols, liquefied solids, and liquefied gases.

17. A method of manufacturing a device comprising:

depositing one or more materials onto a rotatable build deck along a deposition line simultaneously from a plurality of material deposition sources, the rotatable build deck allowing for movement along an x-axis, y-axis, and z-axis in three-dimensional space;

fusing deposited one or more material along a fusion line by interacting the deposited one or more material with a plurality of fusion sources; rotating the build deck about the z-axis; and

positioning the build deck along the z-axis;

wherein a helical build surface is created.

18. A nontransitory computer-readable memory having instructions thereon, the instructions comprising:

instructions for depositing a material onto a rotatable build deck, the rotatable build deck allowing for movement along an x-axis, y-axis, and z- axis in three-dimensional space;

instructions for rotating the build deck about the z-axis; and

instructions for positioning the build deck along the z-axis;

wherein a helical build surface is created using multiple material deposition and fusion sources simultaneously along each flute of a single- or multi-flute system.