# US 2023/0054516 A1 · Irradiation devices with optical modulators for additively manufacturing three-dimensional objects > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2023/0054516 A1 - Document ID: US20230054516A1 - Status: Published application - Kind: A1 - Application number: 17/892,507 - Filed: 2022-08-22 - Published: 2023-02-23 - Earliest claimed: 2021-08-20 - Assignees: General Electric Company - Applicants: General Electric Company - Inventors: Mary Kathryn Thompson; Joshua Tyler Mook; William Joseph Steele; David Scott Simmermon; Michael Thomas Gansler - Web page: https://patentgrep.com/patent/US20230054516A1 ## CPC - B29C 64/277: using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED] - B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] - B22F 10/36: of energy beam parameters - B22F 10/85: for controlling or regulating additive manufacturing processes - B22F 12/45: Two or more - B22F 12/49: Scanners - B28B 1/001: {Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00)} - B28B 17/0081: {Process control} - B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting - B29C 64/386: Data acquisition or data processing for additive manufacturing - B29C 64/393: for controlling or regulating additive manufacturing processes - B33Y 10/00: Processes of additive manufacturing - B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor - B33Y 50/00: Data acquisition or data processing for additive manufacturing - B33Y 50/02: for controlling or regulating additive manufacturing processes - G02B 26/0816: {by means of one or more reflecting elements} - G02B 26/0833: {the reflecting element being a micromechanical device, e.g. a MEMS mirror, DMD (G02B26/0825 takes precedence; micromechanical devices in general B81B)} - G02B 26/101: {with both horizontal and vertical deflecting means, e.g. raster or XY scanners (colour television using laser beams scanning a display screen H04N9/3129)} - B22F 12/42: Light-emitting diodes [LED] - G02B 26/10: Scanning systems - Y02P 10/25: Process efficiency - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract An irradiation device for additively manufacturing three-dimensional objects may include a beam generation device configured to generate an energy beam, an optical modulator including a micromirror array disposed downstream from the beam generation device, and a focusing lens assembly disposed downstream from the optical modulator. The micromirror array may include 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. The focusing lens assembly may include one or more lenses configured to focus the plurality of beam segments such that for respective ones of a plurality of modulation groups including a subset of micromirror elements, a corresponding subset of beam segments are focused to at least partially overlap with one another at a combination zone corresponding to the respective modulation group. ## Claims ### Claim 1 A method of additively manufacturing a three-dimensional object, the 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 directing 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. ### Claim 2 (depends on 1) The method of claim 1, comprising: modulating respective ones of the plurality of micromirror elements according to beam modulation instructions defining a modulation state corresponding to respective ones of the plurality of micromirror elements and/or corresponding to respective ones of the plurality of modulation groups. ### Claim 3 (depends on 1) The method of claim 1, wherein modulating respective ones of the plurality of micromirror elements according to beam modulation instructions comprises: modulating a plurality of micromirror elements to respective ones of a plurality of modulation states. ### Claim 4 (depends on 1) The method of claim 1, wherein a plurality of beam spots become incident upon respective ones of the plurality of build points based at least in part on modulation instructions configured to cause the optical modulator to modulate respective modulation groups and/or corresponding micromirror elements based at least in part on a build file that defines the build points of the build array to be irradiated by a respective one of the plurality of beam spots. ### Claim 5 (depends on 1) The method of claim 1, wherein the method is performed using the irradiation device of any clause herein. ### Claim 6 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. ### Claim 7 (depends on 6) The computer-readable medium of claim 6, wherein the computer-readable medium, when executed by a processor associated with an additive manufacturing machine, is configured to cause the additive manufacturing machine to perform the method of any clause herein. ### Claim 8 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. ### Claim 9 (depends on 8) The irradiation device of claim 8, comprising: a controller configured to modulate respective ones of the plurality of micromirror elements according to beam modulation instructions defining a modulation state corresponding to respective ones of a plurality of micromirror elements and/or corresponding to respective ones of the plurality of modulation groups. ### Claim 10 (depends on 8) The irradiation device of claim 8, wherein the controller is configured to cause a first build point located at a first location in the build array to receive irradiation sequentially from a plurality of beam segments respectively corresponding to a plurality of micromirror element sequentially located in the micromirror array. ### Claim 11 (depends on 8) The irradiation device of claim 8, wherein the controller is configured to cause respective ones of the plurality of micromirror elements in a modulation group to respectively provide a pro-rata portion or a weighted portion of a total energy imparted to a respective build point. ### Claim 12 (depends on 8) The irradiation device of claim 8, wherein the micromirror array and the build array are related to one another by a mapping relationship, the mapping relationship comprising respective ones of the plurality of micromirror elements associated with respective ones of the plurality of build points. ### Claim 13 (depends on 8) The irradiation device of claim 8, wherein the controller is configured to cause the mapping relationship to increment with relative motion between the build plane and the plurality of beam segments. ### Claim 14 (depends on 8) The irradiation device of claim 8, wherein the controller is configured to cause the mapping relationship to increment such that at a first increment, a first micromirror element located at a first position in the micromirror array provides a first beam segment that becomes incident upon a first build point, and at a second increment, the first micromirror element located at the first position in the micromirror array provides a second beam segment that becomes incident upon a second build point. ### Claim 15 (depends on 8) The irradiation device of claim 8, wherein the controller is configured to cause at least some of the build points in the build array to receive no irradiation, when modulation instructions do not include instructions to irradiate a respective build point, and/or when a respective build point has already received irradiation from a sequence of beam segments sufficient to provide a specified intensity and/or power density for irradiating the build point according to the modulation instructions. ### Claim 16 (depends on 8) The irradiation device of claim 8, wherein the modulation instructions are configured to cause the optical modulator to modulate respective modulation groups and/or corresponding micromirror elements based at least in part on a build file that defines build points of the build array to be irradiated to additively manufacture a three-dimensional object. ### Claim 17 (depends on 8) The irradiation device of claim 8, wherein a total number of micromirror elements that provide a corresponding beam segment to a respective build point is selected based at least in part on a quantity of energy to be imparted to the respective build point. ### Claim 18 (depends on 8) The irradiation device of claim 8, a proportion of energy imparted to a build point by a respective micromirror element is from about 0.01% to about 50%. ### Claim 19 (depends on 8) The irradiation device of claim 8, wherein at least some of the build points are bypassed by a first portion of the micromirror elements in a modulation group corresponding to the build point, and wherein a second portion of the micromirror elements in the modulation group corresponding to the build point provide a beam segment that becomes incident upon the build point. ### Claim 20 (depends on 8) The irradiation device of claim 8, wherein a plurality of beam segments respectively incident upon respective micromirror elements from among respective ones of a first plurality of modulation groups follow an optical path to the focusing lens assembly, and wherein the focusing lens assembly comprises one or more optical elements configured to cause respective ones of the plurality of beam segments corresponding to respective ones of the first plurality of modulation groups to at least partially overlap with one another at least at a respective one of a plurality of combination zones, the plurality of combination zones respectively corresponding to the respective ones of the first plurality of modulation groups; and/or wherein a plurality of beam segments respectively incident upon respective micromirror elements from among respective ones of a second plurality of modulation groups follow an optical path to the focusing lens assembly, and wherein the focusing lens assembly comprises one or more optical elements configured to cause respective ones of the plurality of beam segments corresponding to respective ones of the second plurality of modulation groups to become incident upon the build plane without overlapping with one another.