Three-dimensional printing system optimizing contour formation for multiple energy beams

A computer-readable storage medium for manufacturing a three-dimensional (3D) article, the computer-readable storage medium being non-transitory and having computer-readable program code portions stored therein that in response to execution by a processor cause a three-dimensional (3D) printing system to:

• determine a lateral alignment uncertainty for a system, the system including a powder dispenser for sequentially dispensing individual layers of powder and a fusing apparatus for generating and scanning a plurality of energy beams including a first beam and a second beam to selectively melt the layers of powder, the lateral alignment uncertainty is with respect to at least the first beam and the second beam;
• and
• determine a number N of overlapping scans for forming a contour that bounds a hatch pattern, N is an integer at least equal to one, the determination is based at least partly upon the lateral alignment uncertainty;
• operate the powder dispenser to dispense a layer of powder;
• and
• operate the fusing apparatus to selectively fuse the powder including:
• operate at least the first beam to fuse a first hatch pattern over an area of the layer of powder;
• and
• operate at least the second beam to fuse a contour using the N overlapping scans to form the contour having a contour width that is equal to N times a melt width of a single scan minus a cumulative overlap of the N overlapping scans.