Additive manufacturing using light source arrays to provide multiple light beams to a build medium via a rotatable reflector

A system for additive manufacturing, the system comprising:

• a print head configured to move with respect to a build structure;
• rotatable reflectors coupled to the print head, wherein each rotatable reflector has a width;
• light source arrays, each light source array in working relation with a respective rotatable reflector of the rotatable reflectors and configured to direct light beams at the respective rotatable reflector during a build pass, wherein the light source arrays and the rotatable reflectors are configured to simultaneously redirect light beams from a plurality of the light source arrays onto a build medium on the build structure during the build pass, wherein the light beams from a light source array of the plurality of the light source arrays comprise a heating beam directed to the build medium from a first portion of the rotatable reflector that corresponds to a first region of the width, wherein the heating beam generates fused build medium, wherein the light beams comprise a trim beam directed toward the build medium from a second portion of the rotatable reflector that corresponds to a second region of the width that is offset a lateral distance from the first region of the width, and wherein the trim beam trims the fused build medium;
• and
• a controller coupled to the print head, to each light source array, and to the rotatable reflectors, wherein the controller is configured to control application of light beams from the light source arrays onto the build medium via the rotatable reflectors to control formation of one or more objects from the build medium by selective fusion of portions of the build medium due to contact of the portions with the light beams.

A method of additive manufacturing, the method comprising:

• controlling, via a controller, a print head drive to move a print head relative to a build structure, wherein the print head includes rotatable reflectors, each rotatable reflector having a width, and each rotatable reflector configured to redirect multiple light beams directed at the rotatable reflector onto a build medium on the build structure during a build pass;
• and
• controlling, via the controller, activation of light source arrays to direct light beams at the rotatable reflectors as the print head moves during the build pass, wherein each light source array is configured to direct a plurality of light beams at a respective rotatable reflector of the rotatable reflectors, wherein the plurality of light beams directed at a first rotatable reflector of the rotatable reflectors comprises a heating beam directed to the build medium from a first portion of the first rotatable reflector that corresponds to a first region of the width, wherein the heating beam generates fused build medium, wherein the plurality of light beams comprises a trim beam directed toward the build medium from a second portion of the first rotatable reflector that corresponds to a second region of the width that is offset a first lateral distance from the first region of the width, wherein the first trim beam trims the fused build medium, wherein the light source arrays and the rotatable reflectors are configured to simultaneously redirect light beams from a plurality of the light source arrays onto the build medium, and wherein the rotatable reflectors reflect the light beams onto the build medium to form one or more objects from the build medium by selective fusion of portions of the build medium due to contact of the portions with the light beams.

An additive manufacturing system, the additive manufacturing system comprising:

• a first print head configured to move in a first direction with respect to a build structure;
• a plurality of first rotatable reflectors coupled to the first print head, each rotatable reflector of the plurality of first rotatable reflectors configured to redirect light beams directed at the rotatable reflector across a build medium on the build structure during a build pass;
• a plurality of light source arrays, each light source array associated with a corresponding reflector of the plurality of first rotatable reflectors and each light source array of the plurality of light source arrays having light sources, wherein a first light source array of the plurality of light source arrays is configured to direct light beams from the light sources at a first rotatable reflector of the plurality of first rotatable reflectors, wherein the light beams include a heating beam directed to the build medium from a first portion of the first rotatable reflector that corresponds to a first region of a width of the first rotatable reflector, wherein the heating beam generates fused build medium, wherein the light beams include a trim beam directed toward the build medium from a second portion of the first rotatable reflector that corresponds to a second region of the width that is offset a first lateral distance from the first region of the width, and wherein the first trim beam trims the fused build medium;
• and
• a controller coupled to the first print head and coupled to the plurality of light source arrays, the controller configured to control application of light beams from the plurality of light source arrays onto the build medium via the plurality of first rotatable reflectors during the build pass to control formation of one or more objects from the build medium by selective fusion of portions of the build medium due to contact of the portions with the light beams.