Irradiation devices with optical modulators for additively manufacturing three-dimensional objects

A computer-readable medium comprising computer-executable instructions, which when executed by a processor associated with an additive manufacturing machine, cause the additive manufacturing machine to perform a method comprising:

• generating an energy beam from a beam generation device, the energy beam becoming incident upon an optical modulator disposed downstream from the beam generation device, the optical modulator comprising a micromirror array, the micromirror array comprising a plurality of micromirror elements;
• reflecting a plurality of beam segment of the energy beam with the micromirror array, the micromirror array comprising a plurality of micromirror elements configured to reflect the plurality of beam segment of the energy beam along a beam path incident upon one or more lenses of a focusing lens assembly;
• and
• focusing the plurality of beam segments upon a build plane comprising a build array defining a plurality of build points such that for respective ones of a plurality of modulation groups comprising a subset of micromirror elements from among the plurality of micromirror elements, a corresponding subset of beam segments become incident upon a corresponding subset of build points from among the plurality of build points;
• and propagating the plurality of beam segments incrementally across the build array by way of relative motion between the build plane and the plurality of beam segments, such that for respective ones of the plurality of modulation groups, the corresponding subset of build points receive irradiation sequentially from the corresponding subset of beam segments.

An irradiation device for an apparatus for additively manufacturing three-dimensional objects, the irradiation device comprising:

• a beam generation device configured to provide an energy beam;
• an optical modulator comprising a micromirror array disposed downstream from the beam generation device;
• and
• a focusing lens assembly disposed downstream from the optical modulator;
• wherein the micromirror array comprises a plurality of micromirror elements configured to reflect a corresponding plurality of beam segment of the energy beam along a beam path incident upon the focusing lens assembly;
• and
• wherein the focusing lens assembly comprises one or more lenses configured to focus the plurality of beam segments upon a build plane comprising a build array defining a plurality of build points such that for respective ones of a plurality of modulation groups comprising a subset of micromirror elements from among the plurality of micromirror elements, a corresponding subset of beam segments become incident upon a corresponding subset of build points from among the plurality of build points, and wherein with relative motion between the build plane and the plurality of beam segments, the corresponding subset of beam segments propagate incrementally across the build array such that the corresponding subset of build points receive irradiation sequentially from the corresponding subset of beam segments.