Abstract: A method for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The apparatus used in the method includes a build unit and a machining mechanism that are attached to a positioning mechanism, a rotating platform, and a rotary encoder attached to the rotating platform. The method involves rotating the build platform; determining the rotational speed; growing the object and the build wall through repetitive cycles of moving the build unit(s) over and substantially parallel to multiple build areas within the build platform to deposit a layer of powder at each build area, leveling the powder, and irradiating the powder to form a fused additive layer at each build area; machining the object being manufactured; and cutting and removing the build wall. The irradiation parameters are calibrated based on the determined rotational speed.

Abstract: A method for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The apparatus used in the method includes one or more build units and a machining mechanism that are attached to a positioning mechanism, and a rotating build platform. The method involves at least rotating the build platform; repetitive cycles of moving the build unit(s) to deposit powder and irradiating at least a selected portion of the powder to form at least one fused layer to form at least one object and a build wall that retains unfused powder about the object; and removing the build wall by rotational machining.

Abstract: An apparatus for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The build unit(s) of the apparatus includes a powder delivery mechanism, a powder recoating mechanism and an irradiation beam directing mechanism. The build unit and the machining mechanism are attached to a positioning mechanism that provides them with movement. The build platform of the apparatus is rotating and preferably vertically stationary. Embodiments of the build unit that further includes a gas-flow mechanism and the build platform having a dynamically grown wall are also described. A manufacturing method using the apparatus involves rotating the build platform; repetitive cycles of moving the build unit(s) to deposit a powder and irradiating the powder to form a fused additive layer; and machining the object being manufactured.

Abstract: A method for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The apparatus used in the method includes a build unit and a machining mechanism that are attached to a positioning mechanism, a rotating platform, and a rotary encoder attached to the rotating platform. The method involves rotating the build platform; determining the rotational speed; growing the object and the build wall through repetitive cycles of moving the build unit(s) over and substantially parallel to multiple build areas within the build platform to deposit a layer of powder at each build area, leveling the powder, and irradiating the powder to form a fused additive layer at each build area; machining the object being manufactured; and cutting and removing the build wall. The irradiation parameters are calibrated based on the determined rotational speed.

Abstract: A method for large-scale, real-time simultaneous additive and subtractive manufacturing is described. The apparatus used in the method includes a build unit and a machining mechanism that are attached to a positioning mechanism, a rotating platform, and a rotary encoder attached to the rotating platform. The method involves rotating the build platform; determining the rotational speed; growing the object and the build wall through repetitive cycles of moving the build unit(s) over and substantially parallel to multiple build areas within the build platform to deposit a layer of powder at each build area, leveling the powder, and irradiating the powder to form a fused additive layer at each build area; machining the object being manufactured; and cutting and removing the build wall. The irradiation parameters are calibrated based on the determined rotational speed.