Systems and methods for microwave additive manufacturing

A microwave additive manufacturing system comprising:

• an electronic controller;
• a microwave energy generator subsystem responsive to the electronic controller for generating a microwave energy signal;
• a beam patterning component for pattering the microwave energy signal into a microwave beam having at least a desired 2D spatial energy distribution profile for at least one of curing or sintering a feedstock material being used to form a part;
• and
• a motion gantry for moving the beam patterning component along at least one axis while the curing or the sintering of the feedstock material is occurring.

A method for additively manufacturing a part, comprising:

• obtaining part data which defines features or characteristics of a part to be manufactured;
• obtaining data relating to a characteristic of a feedstock material to be used to form the part;
• generating a microwave energy signal;
• using the part data and the data relating to the characteristic of the feedstock material to pattern the microwave energy signal to form a patterned microwave energy beam signal with a desired spatial energy distribution profile able to at least one of cure or sinter the feedstock material;
• and
• directing the patterned microwave energy beam signal at the feedstock material for a time sufficient to at least one of cure or sinter the feedstock material to form the part.

A microwave additive manufacturing system comprising:

• an electronic controller;
• a microwave energy generator subsystem responsive to the electronic controller for generating a microwave energy signal;
• a stationary beam patterning component for patterning the microwave energy signal into a microwave beam having a desired spatial energy distribution profile for at least one of curing or sintering a feedstock material being used to form a part;
• and
• the stationary beam patterning component being elevationally aligned with, and spaced apart from, the feedstock material.