Abstract: Methods of additively manufacturing a three-dimensional object by one or more energy beams include selectively directing a first energy beam across a powder bed along a plurality of first hatching paths and a first contour path that defines a first outer contour portion and a first stitching portion, wherein the first outer contour portion at least partially defines a first edge portion of an outer edge of the three-dimensional object, and wherein the first edge portion is non-linear, and selectively directing a second energy beam across the powder bed along a plurality of second hatching paths and a second contour path that at least partially defines a second edge portion of the outer edge of the three-dimensional object, wherein the second edge portion is adjacent the first edge portion, and wherein the first stitching portion extends into the plurality of second hatching paths along a non-linear stitching path.

Abstract: A fluid flow apparatus configured to provide a flow of fluid with particular flow profiles to a process chamber of an additive manufacturing apparatus is provided. The fluid flow apparatus includes a plurality of openings forming a first flow region, a second flow region, a third flow region, and a fourth flow region in adjacent arrangement along an axis in the process chamber between the build platform and the laser window. A controller is configured to execute instructions that perform operations that include flowing, via the second flow region, the flow of fluid along a second distance along the axis at a second velocity range between approximately 1.0 meters per second (m/s) and 6.0 m/s, and flowing, via the fourth flow region, another flow of fluid along a fourth distance along the axis at a fourth velocity range between approximately 0.1 m/s and 4.5 m/s.

Abstract: A method of additively manufacturing a three-dimensional object may be performed using an irradiation sequence that is based at least in part on a predicted location of one or more fume plumes emitted from the powder material when irradiated by a plurality of energy beams. An exemplary method may include determining, with a computing device, an irradiation sequence for selectively consolidating powder material using an energy beam system of an additive manufacturing machine, and providing control commands, from the computing device to the energy beam system, configured to cause the energy beam system to emit a plurality of energy beams to selectively consolidate the powder material.

Abstract: A fluid flow apparatus configured to provide a flow of fluid with particular flow profiles to a process chamber of an additive manufacturing apparatus is provided. The fluid flow apparatus includes a plurality of openings forming a first flow region, a second flow region, a third flow region, and a fourth flow region in adjacent arrangement along an axis in the process chamber between the build platform and the laser window. A controller is configured to execute instructions that perform operations that include flowing, via the second flow region, the flow of fluid along a second distance along the axis at a second velocity range between approximately 1.0 meters per second (m/s) and 6.0 m/s, and flowing, via the fourth flow region, another flow of fluid along a fourth distance along the axis at a fourth velocity range between approximately 0.1 m/s and 4.5 m/s.