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

A method of additively manufacturing a three-dimensional object, the method comprising:

• generating an energy beam with a beam generation device, the energy beam becoming incident upon an optical modulator comprising a micromirror array disposed downstream from the beam generation device;
• 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 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 are focused by the one or more lenses 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 plurality of modulation groups.

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 with a beam generation device, the energy beam becoming incident upon an optical modulator comprising a micromirror array disposed downstream from the beam generation device;
• 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 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 are focused by the one or more lenses 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 plurality of modulation groups.