WO2019055570A1

WO2019055570A1 - Additive manufacturing apparatus and method

Info

Publication number: WO2019055570A1
Application number: PCT/US2018/050754
Authority: WO
Inventors: Yi-Hsien Harry TENG; Xing TENG
Original assignee: Teng Yi Hsien Harry; Teng xing
Priority date: 2017-09-12
Filing date: 2018-09-12
Publication date: 2019-03-21
Also published as: CN111201124A

Abstract

An additive manufacturing system that is operable to produced a cross-sectional slice layer set of a three dimensional computer aided drawing of an object and create a data file for operation of the apparatus of the present invention. The additive manufacturing system includes a controller that provides software configured to create a cross sectional slice layer set and operate the apparatus. The apparatus includes a frame assembly having a plurality of support members that are configured to support a plurality of shaping elements. The apparatus further includes a build plate configured to receive layers of building material thereon. During the manufacturing process of the present invention, layers of material are superposed preceding layers and each layer is formed and joined so as to facilitate production of an object that is represented by a computer aided drawing.

Description

ADDITIVE MANUFACTURING APPARATUS AND METHOD

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Patent Application No. 16/128,468, filed September 11, 2018, which claims priority benefit of U.S. Patent Application No.

62/606,186, filed September 12, 2017, which are hereby incorporated by reference for all purposes.

FIELD OF THE INVENTION

The present invention relates generally to a manufacturing system, more specifically but not by way of limitation, a manufacturing system that is configured to manufacture three dimensional objects through additive layers of material wherein the dimensions of each layer of material is generated through a software application and wherein the apparatus of the present invention provides forming and assembly of each provided layer to create a finished object.

BACKGROUND

Numerous types of manufacturing methods and apparatus have been utilized over the last century in a variety of industries. While developed a couple of decades ago, three- dimensional printing, also known as additive manufacturing has increased in popularity. This type of manufacturing provides a technique for rapid prototyping and is utilized to construct objects from various materials such as but not limited to plastic and metal.

Conventional three-dimensional manufacturing utilizes software that maps a three- dimensional object into a series of sliced two-dimensional cross sections stacked to represent layers wherein the layers are typically thin measuring approximately fifty to one hundred and fifty microns in thickness. The slices are generated from a three dimensional CAD model utilizing software which typically constructs each slice with a fixed X-Y cross section geometry throughout the layer having a consistent thickness in Z. These produced layers all have right-angle edge design as the layer is a cross-sectional cut of the three- dimensional CAD object. The cross-sectional layers of the three-dimensional CAD object results in inaccuracies when reproducing the object through three-dimensional printing. In particular, any portion of an object that has a curved geometry will have geometrical inaccuracies when produced through a conventional method of three-dimensional printing due to stacking of the aforementioned right-angle edge of each layer. The right-angle edge slices of existing technology results in the loss of resolution and surface smoothness.

Liquid materials and fine powders are utilized in many three-dimensional printing methods. One issue with three dimensional printing is edge formation. Edge formation with liquid materials or fine powders for each layer is deficient in the ability to accurately formed specific edge geometry designs despite the ability to do so with the software slicing ability. Droplets jetted from nozzles or similar elements limit the throughputs of resins or binder material and as such poor layer edge formation occurs with extrusion of molten polymers and jetting of liquid materials if the layers are not thin enough. This application and technique typically requires support structures and metal cannot be extruded due to high melting temperatures. High melting points and complex composition- processing-microstructure-property relationships make metal additive manufacturing a challenging task. Defects or poor quality such as porosity, oxidation, undesired microstructures, unsatisfactory or anisotropic properties, thermal residual stresses, distortion, cracking, dimensional deviation, and surface roughness are common issues that are influenced by process parameters and capabilities. As a result, it is difficult to build confidence in process qualification and control for delivery of consistent, satisfactory quality.

Accordingly, there is a need for an additive manufacturing process that utilizes a software application capable of creating slices of a three-dimensional object wherein each slice is a three-dimensional geometry in a slice set that can represent or closely approximate the true geometry of object to be manufactured, so that thicker layers will not create the aforementioned geometrical inaccuracy. Further, a manufacturing apparatus is needed that shapes and/or prepares suitable forms of feedstock materials corresponding to the three dimensional slice layer geometries in an additive manufacturing process to create an object with improved geometrical and dimensional accuracies as well as an increased productivity and reduced feedstock material cost.

SUMMARY OF THE INVENTION

It is the objective of the present invention to provide an additive manufacturing system and method capable of producing a three-dimensional object that includes a software application capable of producing three-dimensional cross-sectional slices of a 3D CAD. Another objective of the present invention is to provide an additive manufacturing system and method capable of producing three-dimensional objects having improved geometrical accuracy that further includes utilization of sheets of feedstock material for supply to the apparatus of the present invention.

A further objective of the present invention is to provide an additive manufacturing system and method that utilizes sheet-like material to construct a three-dimensional object wherein the apparatus of the present invention consists of a frame structure, robotic arms, or a combination thereof.

Still another objective of the present invention is to provide an additive manufacturing system and method_capable of producing three-dimensional objects having improved geometrical accuracy wherein each layer of sheet-like material deposited onto the build plate is shaped and/or prepared utilizing a plurality of tools or devices such as but not limited to laser cutters, milling units, grinders, pressing and heating equipment that are integrated in the apparatus or separated in different locations.

An additional objective of the present invention is to provide an additive manufacturing system and method that is operable to produce three-dimensional objects from a computer file compiled with cross-sectional slice layers of the object wherein the system utilizes a plurality of methods to join each layer of sheet material in apparatus such as but not limited to adhesion, welding, fusion or sintering.

Yet a further objective of the present invention is to provide an additive manufacturing system capable of producing three-dimensional objects having improved geometrical accuracy wherein the apparatus of the present invention includes a heating source that is movable in a vertical or three-dimensional path.

Another objective of the present invention is to provide an additive manufacturing system that is operable to produce a three-dimensional object from a computer generated set of cross-sectional slices wherein each layer is capable of being formed to have an edge design having an angle that is an alternative angle to a right angle.

To the accomplishment of the above and related objectives the present invention may be embodied in the form illustrated in the accompanying drawings. Attention is called to the fact that the drawings are illustrative only. Variations are contemplated as being a part of the present invention, limited only by the scope of the claims. BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be had by reference to the following Detailed Description and appended claims when taken in conjunction with the accompanying Drawings wherein:

Figure 1 is a schematic view of the apparatus of the present invention in certain embodiments; and

Figure 2 is an exemplary process flowchart of the manufacturing method of the present invention.

DETAILED DESCRIPTION

Referring now to the drawings submitted herewith, wherein various elements depicted therein are not necessarily drawn to scale and wherein through the views and figures like elements are referenced with identical reference numerals, there is illustrated an additive manufacturing system 100 constructed according to the principles of the present invention.

An embodiment of the present invention is discussed herein with reference to the figures submitted herewith. Those skilled in the art will understand that the detailed description herein with respect to these figures is for explanatory purposes and that it is contemplated within the scope of the present invention that alternative embodiments are plausible. By way of example but not by way of limitation, those having skill in the art in light of the present teachings of the present invention will recognize a plurality of alternate and suitable approaches dependent upon the needs of the particular application to implement the functionality of any given detail described herein, beyond that of the particular implementation choices in the embodiment described herein. Various modifications and embodiments are within the scope of the present invention.

It is to be further understood that the present invention is not limited to the particular methodology, materials, uses and applications described herein, as these may vary. Furthermore, it is also to be understood that the terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. It must be noted that as used herein and in the claims, the singular forms "a", "an" and "the" include the plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to "an element" is a reference to one or more elements and includes equivalents thereof known to those skilled in the art. All conjunctions used are to be understood in the most inclusive sense possible. Thus, the word "or" should be understood as having the definition of a logical "or" rather than that of a logical "exclusive or" unless the context clearly necessitates otherwise. Structures described herein are to be understood also to refer to functional equivalents of such structures. Language that may be construed to express approximation should be so understood unless the context clearly dictates otherwise.

References to "one embodiment", "an embodiment", "exemplary embodiments", and the like may indicate that the embodiment(s) of the invention so described may include a particular feature, structure or characteristic, but not every embodiment necessarily includes the particular feature, structure or characteristic.

Referring in particular to Figure 1 herein, the additive manufacturing system 100 includes a controller 5 and an apparatus 10 that are operably coupled and combine to facilitate the manufacturing process of the present invention. The controller 5 is a conventional computing device having the necessary electronics to store, receive, transmit and manipulate data files. It is contemplated within the scope of the present invention that the controller 5 could be an integrated computer, a stand-alone computer or a networked computer. The controller 5 includes a software application that is configured to provide and execute a computer file compiled or coupled with cross-sectional slice geometries from of a three-dimension computer aided design wherein each slice is a X-Y axis cross- section of a portion of an object. It is intended within the scope of the present invention that the software of the present invention utilizes software protocols that provide cross- sectional slices converting three-dimensional models to three-dimensional slice designs as opposed to having a straight-cut right angled edge design in Z as created by a stack of two- dimensional cross-sections by_existing conventional software. Furthermore an additionally contemplated slice design could be wherein each of the cross sectional sliced layers created by the software has layer thickness that is equal to, less than or greater than alternate cross-sectional sliced layers for the object. The controller 5 is communicably coupled to the apparatus 10 utilizing conventional elements and protocols such as but not limited to network cables and/or wireless communication protocols.

The apparatus 5 includes a frame assembly 15 wherein the frame assembly 15 includes a first rail support member 20 and a second rail support member 22. The first rail support member 20 and second rail support member 22 are manufactured from a durable rigid material such as but not limited to metal and are configured in a parallel manner. The first rail support member 20 and second rail support member 22 have movably coupled thereto a plurality of vertical support members 30. The vertical support members 30 are movably coupled to the first rail support member 20 and second rail support member 22 utilizing suitable durable techniques. The vertical support members 30 traverse along either the first rail support member 20 or the second rail support member 22 as required during the manufacturing process to position a shaping element in order to engage with the exemplary building material 99 as further discussed herein. Operably coupled to each opposing pair of vertical support members 30 is a cross support member 35. The cross support members 35 are manufactured from a suitable rigid material and are secured to the vertical support members 30 utilizing suitable durable techniques. The cross support members 35 have movably secured thereto various shaping elements 60 that are discussed further herein wherein each shaping element is operable to engage the exemplary building material and provide an action thereon such as but not limited to cutting, milling or grinding. While three cross support members 35 are illustrated herein being operably coupled to the vertical support members 30, it is contemplated within the scope of the present invention that the frame assembly 15 could have alternate quantities of vertical support members 30 and cross support members 35 in order to provide support and operation of alternate quantities of shaping elements 60 or additional elements required in the manufacturing process of the present invention. Furthermore, while an exemplary frame assembly 15 is illustrated and discussed herein, it is contemplated within the scope of the present invention that the frame assembly 15 could be constructed in alternate styles and designs in order to achieve the desired function described herein.

Mounted intermediate the first rail support member 20 and second rail support member 22 is a build plate 40. The build plate 40 is movably mounted with rod member 42 and is configured to be moved in a upwards-downwards direction. The build plate 40 is manufactured from a suitable durable material such as but not limited to metal and is rectangular in shape. The build plate 40 includes upper surface 43 that is of suitable size to receive the exemplary building material 99 thereon. As will be further discussed herein, the building material 99 is superposed the building plate 40 in layers. As each layer is superposed the preceding layer the shaping elements 60 will perform the required activity in order to form the programmed three-dimensional object as directed by the controller 5. The build plate 40 can receive a single sheet or layer of the building material 99 or be configured to have a continuous supply thereof be introduced thereto. It is contemplated within the scope of the present invention that the build plate 40 could be manufactured in alternate sizes so as to facilitate manufacturing of various sized objects.

Axially aligned with the build plate 40 and positioned thereabove is the compression member 50. The compression member 50 is moveably mounted on rod 51 and is configured to be moved in an upwards-downwards manner. The compression member 50 is manufactured from a suitable rigid material such as but not limited to metal. The compression member 50 is utilized to provide a downward compression force onto the object 98 being manufactured on the building plate 40. By way of example but not limitation, if the object 98 is being manufactured wherein the exemplary building material layers 99 are being chemically adhered together subsequent be superposed the preceding layer than the compression member 50 can be utilized to apply a compression force to the object 98 in order to ensure bonding of the layers. The compression member 50 further includes heating elements 52 that can be utilized to increase the temperature of the compression member 50 to a temperature that is higher than that of the environmental temperature in which the additive manufacturing system 100 is disposed. It is

contemplated within the scope of the present invention that compression member 50 could be heated to various different temperatures as required for proper manufacturing of the object 98.

The additive manufacturing system 100 includes a plurality of shaping elements

60. The shaping elements are movably coupled to the cross support members 35 utilizing suitable durable techniques. The shaping elements 60 are utilized during the process steps of the manufacturing process of the present invention as required to facilitate the desired step. As each additive layer is superposed the preceding layer at least one manufacturing step is performed. These steps can include but are not limited to cutting, fusion, welding, grinding, sintering, milling, polishing and drilling. The shaping elements 60 are coupled to the cross support members 35 and traverse therealong utilizing conventional motorized techniques. Additionally, the shaping elements 60 are contemplated to be any of the following types of manufacturing process equipment: laser beam cutter, electron beam cutter, water jet cutter, milling device, sawing device, abrading device, shearing device, torch cutter or electrical discharge machine. Additionally, each shaping element 60 is movable in an upwards-downwards motion, a rotational motion and a pivotal motion so as to provide positioning thereof as needed to completed the desired manufacturing step. While three shaping elements 60 are illustrated herein it is contemplated within the scope of the present invention that the additive manufacturing system 100 could have more or less than three shaping elements 60 operably coupled to the frame assembly 15. All of the shaping elements 60 are operably coupled to the frame assembly 15 so as to have five axis movements.

While a single build plate 40 has been illustrated herein, it is contemplated within the scope of the present invention that the frame assembly 15 could be manufactured of varying lengths and have alternate quantities of build plates 40 in order to resemble assembly line style of manufacturing. It is desired within the scope of the present invention that the additive manufacturing system 100 is configured to utilize metal. As is known in the art during manufacturing processes utilizing metal have a metal oxidation issue and certain risks are inherently present such as but not limited to fire or explosion. It is contemplated within the scope of the present invention that the additive manufacturing system 100 could be configured to be operated in an environmental atmosphere that has a substantially reduced level of oxygen therein. It should be understood that this could be accomplished by such tactics as introducing an alternative gas like nitrogen or argon.

Furthermore the additive manufacturing system 100 is configured to utilize thermal fusion or sintering to join layers of building material 99. The thermal fusion or sintering is performed utilizing a device capable of executing a technique selected from a group of techniques consisting of but not limited to the following techniques: electric arc heating, electric arc welding, plasma arc heating, laser beam heating, electron beam heating, electromagnetic induction heating, microwave heating, infrared radiant heating, radio frequency radiant heating, friction heating, resistance heating, resistance welding, gas torch heating, or pressing.

It is further contemplated within the scope of the present invention that in addition to a complete layer of building material 99 that the additive manufacturing system 100 is configured to utilize at least two adjacent strips of material wherein the at least two adjacent strips of material are configured to comprise a layer of the three dimensional object. It should be understood within the scope of the invention that the at least two adjacent strips could be varying widths and that the term strip does not serve to provide limitation. Further, the controller 5 constructs the three-dimensional object utilizing a surface mesh model or solid model. Now referring to Figure 2 herein, a flow chart of an exemplary process of the additive manufacturing system 100 is illustrated therein. In step 201 , a user will utilize the software on the controller 5 to model a computer aided design (CAD) of a three- dimensional object. The three dimensional object can be of any size or shape. Step 203, the software of the present invention creates a set of three dimensional sequentially layered slices of the three dimensional object created in step 201. Each of the three dimensional layered slices is constructed by the software of the controller 5 utilizing data points mathematically transformed, approximated, interpolated or extrapolated from the corresponding geometries of the three dimensional CAD object created in step 201. All of the created sequentially layered slices are represented by two or more different cross sections normal to the sliced layer height. Additionally, each of the sequentially layered slices has at least one cross section and a vector for each data point of the edge surfaces thereof. While no particular thickness of each sequentially layered slice is required, good results have been achieved utilizing a thickness of at least one hundred microns.

In step 205, the software of the present invention will complete any additional data processing required to manipulate and/or simplify the set of sequentially sliced layers for manufacturing process requirements. It should be understood within the scope of the present invention that the data processing could include but not be limited to creation of a execution file, a data file or any combination of computer files required to facilitate completion of the data processing. The aforementioned computer file creation is utilized for tasks such as but not limited to operation of the additive manufacturing system 100. Step 207, a completed data file of the sequentially sliced layers of the three dimensional object is created and saved in the memory of the controller 5. In step 209, the data file is loaded into a user interface of the software of the controller for transfer to the apparatus 10 of the additive manufacturing system 100. In step 21 1 , an operator of the additive manufacturing system 100 will place manufacturing feedstock in position for use by the apparatus 10. It is contemplated within the scope of the present invention that the feedstock could be supplied as a continuous roll of sheet material or as a single sheet of building material. Additionally, it should be understood by those skilled in the art that introduction, placement and manipulation of the feedstock material could be implemented through automated and/or manual labor. In step 213, the first layer of feedstock is prepared. Depending upon the requirements for the manufacture of the three dimensional object, preparations of the first layer are executed. This can include but is not limited to cutting or milling. Step 215, the first layer of feedstock material is superposed the build plate 40. During this step, if any securing to the build plate is required such as but not limited to clamping such a process will be executed. Additionally, if additional support structures are required to assist during the manufacturing process, any required support structures can be placed on the build plate 40 so as to engage the object 98. Additionally, placement and/or manipulation of any support structures required for manufacturing of the obj ect 98 can be performed in any subsequent step of the process as outlined herein. In step 217, a second layer of feedstock material is prepared. As previously discussed herein, any required processing steps to prepare the second layer in compliance with the second layer of the sequentially layered slice set generated and stored in the data file will be executed. This can be but is not limited to drilling, sintering, cutting, or grinding. All preparation of the processing steps discussed herein are executed by the shaping elements 60 discussed previously herein. Step 219, the second layer of feedstock material is superposed the first layer of feedstock. In step 221, the shaping elements 60 facilitate the necessary processing steps of the second layer so as to continue execution of the manufacturing process.

Step 223, subsequent superposing the second layer of feedstock and completing the processing thereof, the second layer is joined to the first layer through a desired technique. The joining of the second layer to the first layer can be implemented through techniques such as but not limited to chemical adhesion or welding. It is contemplated within the scope of the present invention that the joining of the sequential layers and processing thereof can occur interchangeably as respect to order. In step 225, additional layers of feedstock material are prepared. Step 227, ensuing preparation of the additional feedstock materials the processing previously discussed herein for the first and second layer are executed on each additional layer wherein each additional layer is prepared, processed and formed with the previous layer. In step 229, all layers required to complete the manufacture of the object 98 as required by the sequentially layered slice set of stored in the data file are finished wherein each layer has undergone preparation and processing to produce the object 98 that is in compliance with the three dimensional model created in step 201. Step 231, any additional surface processing is executed by the shaping elements so as to produce an object 98 having accurate surface geometry in compliance with the three dimensional model produced in step 201. In the preceding detailed description, reference has been made to the

accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments, and certain variants thereof, have been described in sufficient detail to enable those skilled in the art to practice the invention. It is to be understood that other suitable embodiments may be utilized and that logical changes may be made without departing from the spirit or scope of the invention. The description may omit certain information known to those skilled in the art. The preceding detailed description is, therefore, not intended to be limited to the specific forms set forth herein, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents, as can be reasonably included within the spirit and scope of the appended claims.

Claims

WHAT IS CLAIMED IS;

1. An additive manufacturing system configured to construct a three-dimensional object utilizing a plurality of layers of material comprising:

a computer, said computer being integrated, a standalone or network-based operable to provide data and run a software program to operate said system;

an apparatus, said apparatus being operably coupled to said computer, said apparatus configured to shape or prepare at least two sheet-like layers and further being configured to join said at least two sheet-like layers so as to construct a three-dimensional object;

wherein the three dimensional object is modeled in the computer in a data file or an execution file compiled with a sliced layer set wherein the sliced layer set is a compilation of cross-sectional slice layer geometries sequentially sliced from a model of the three dimensional object; and

wherein each layer of said at least two sheet-like layers is shaped or prepared to reproduce each of the cross-sectional slice layer geometries by the apparatus wherein each of the at least two sheet-like layers are joined to a preceding layer to complete

manufacture of the three dimensional object.

2. The additive manufacturing system as recited in claim 1, wherein the apparatus is configured to shape or prepare a three dimensional object utilizing a device that is selected from a group consisting of at least one of the following: laser beam cutter, electron beam cutter, water jet cutter, milling device, sawing device, abrading device, shearing device, torch cutter or electrical discharge machine.

3. The additive manufacturing system in claim 1, wherein the apparatus is configured to shape or prepare the three dimensional object utilizing a technique selected from a group consisting of at least one of the following: cutting, milling, grinding, de-burring, polishing, drilling, heating, sintering, welding, joining, fastening, adhesion, pressing.

4. The additive manufacturing system in claim 1, wherein the apparatus is configured to be operated in an environmental atmosphere that has a substantially reduced level of oxygen therein

5. The additive manufacturing system as recited in claim 1, wherein each of the cross sectional sliced layer created by the software is a cross-section in the slicing planes, and has layer thickness that is equal to, less than or greater than alternate cross-sectional sliced layers.

6. The additive manufacturing system as recited in claim 1, wherein each of said plurality of layers of building material is at least one hundred microns in thickness.

7. The additive manufacturing system as recited in claim 1, wherein the apparatus is configured to shape or prepare the at least two sheet-like layers three dimensionally.

8. The additive manufacturing system as recited in claim 1, wherein each of the sliced layers in the sliced layer set is a three-dimensional sliced layer geometry.

9. The additive manufacturing system as recited in claim 1, wherein the apparatus utilizes a process of thermal fusion or sintering to join said at least to sheet-like layers.

10. The additive manufacturing system as recited in claim 9, wherein the thermal fusion or sintering is performed utilizing a device capable of executing a technique selected from a group of techniques consisting of at least one of the following techniques: electric arc heating, electric arc welding, plasma arc heating, laser beam heating, electron beam heating, electromagnetic induction heating, microwave heating, infrared radiant heating, radio frequency radiant heating, friction heating, resistance heating, resistance welding, gas torch heating, or pressing.

11. The additive manufacturing system as recited in claim 1, wherein the apparatus is configured to shape or prepare the three dimensional object utilizing a movement having at least five axis_^

12. The additive manufacturing system as recited in claim 1, wherein the apparatus has a frame assembly, robotic arms, or a combination thereof, so as to facilitate X, Y and Z axis movement.

13. An additive manufacturing method to process and join a plurality of sheet-like layers so as to construct a three-dimensional object comprising the steps of:

generating an execution file utilizing a software program, said execution file is compiled or coupled with a set of cross-sectional slice layer geometries sequentially sliced from a model for a three dimensional object to be manufactured;

providing an apparatus, said apparatus being configured to shape or prepare layers of sheet-like material corresponding to said set of cross-sectional slice layer geometries in said data file , said apparatus operable to join the plurality of sheet-like layers to construct the three dimensional object;

shaping or preparing one of said plurality of sheet-like layers that corresponds to one of the set of cross-sectional slice layer geometries sequentially sliced from the model; j oining a layer from said plurality of sheet-like layers to a preceding layer in sequence to manufacture the three-dimensional object;

wherein a first sheet-like layer is secured to a build plate, or joined to a support structure or a different object.

14. The additive manufacturing method as recited in claim 13, wherein the shaping or preparation of one of said plurality of sheet-like layers is executed in three dimensions or in three-dimensional orientations.

15. The additive manufacturing method configured to construct a three-dimensional object as recited in claim 13, wherein each layer geometry of the cross sectional sliced layer set is represented by at least one cross section and a vector for each data point on edges.

16. The additive manufacturing method configured to construct a three-dimensional object as recited in claim 13, and further including the step of constructing the sliced layer set, wherein each layer geometry of the sliced layer set is constructed by data points mathematically transformed, approximated, interpolated, extrapolated or optimized from corresponding geometries of the computer aided design of the obj ect.

17. The additive manufacturing method configured to construct a three-dimensional object as recited in claim 13, wherein each layer geometry of the cross sectional sliced layer set is represented by at least two different cross sections normal the layer height and a thickness for each layer of the sliced layer set.

18. The additive manufacturing method configured to construct a three-dimensional object as recited in claim 13, wherein each layer of the sliced layer set has a minimum thickness of one hundred microns.

19. The additive manufacturing method configured to construct a three-dimensional object as recited in claim 13, wherein the method includes manufacturing techniques selected from a group of manufacturing techniques consisting of at least one of the following: cutting, milling, grinding, deburring, polishing, drilling, welding, joining, fastening, adhesion, pressing, heating, and robotics.

20. The additive manufacturing method configured to construct a three-dimensional object as recited in claim 19, wherein at least one of said manufacturing techniques is operable in at least fives axis.

21. The additive manufacturing method configured to construct a three-dimensional object as recited in claim 13, wherein each of said sheet-like layer can be produced from said set of cross-sectional slice layer geometries in a separate location by a different apparatus.

22. The additive manufacturing method configured to construct a three-dimensional object as recited in claim 13, and further including a step of utilizing at least two adjacent strips of material wherein the at least two adjacent strips of material are configured to comprise a layer of the three dimensional object.

23. The additive manufacturing method configured to construct a three-dimensional object as recited in claim 13, wherein each of the sliced layers in the sliced layer set is a three- dimensional sliced layer geometry.

24. The additive manufacturing method configured to construct a three-dimensional object as recited in claim 13, and further including a step of finishing a layer or a plurality of layers that have been joined to a preceding layer, wherein said finishing step configured to improve the dimensional and geometrical accuracy and the surface finish and increase the density _utilizing at least one of the following techniques: grinding, milling, polishing, cutting, drilling, welding, heating, pressing, pressurizing, or a combination thereof.

25. The additive manufacturing method configured to construct a three-dimensional object as recited in claim 13, wherein the software program generates three dimensional sliced layer geometries and compile said geometries into an execution file.

26. The additive manufacturing method configured to construct a three-dimensional object as recited in claim 13, and further including the step of operating the apparatus in an environmental atmosphere that has a substantially reduced level of oxygen therein.

27. The additive manufacturing method configured to construct a three-dimensional object as recited in claim 13, wherein the shaping or preparation of one of said plurality of said sheet-like layers includes a fusion or sintering process performed by a technique consisting of one of the following techniques: electric arc heating, electric arc welding, laser beam heating, electron beam heating, plasma arc heating, electromagnetic induction heating, resistance heating, resistance welding, microwave heating, IR radiant heating, RF radiant heating, gas torch welding, friction heating, pressing.

28. The additive manufacturing method configured to construct a three-dimensional object as recited in claim 19, wherein the manufacturing technique of cutting is performed by a technique consisting of one of the following techniques: laser beam cutting, electron beam cutting, plasma arc cutting, water jet cutting, milling, sawing, abrading, shearing, torch cutting, electrical discharge machining.