Patent ID: 11911822
Assignee: ENTEGRIS, INC.
Field: Materials, metallurgy (Chemistry)
Classification: CPC B  Y | IPC B

Claim 0:
1. A method of forming a three-dimensional body by additive manufacturing steps, the method comprising:
designating a target thickness and a thickness tolerance for the three-dimensional body;
forming multiple solidified coarse feedstock layers, each having a thickness that is greater than a magnitude of the thickness tolerance;
forming at least one solidified fine feedstock layer that has a thickness that is less than the magnitude of the thickness tolerance; and
forming the three-dimensional body from the multiple solidified coarse feedstock layers and the at least one solidified fine feedstock layer,
wherein the three-dimensional body has a measured thickness that differs from the target thickness by not more than the magnitude of thickness tolerance,
wherein forming each solidified coarse feedstock layer and at least one solidified fine feedstock layer comprises:
forming a coarse feedstock layer having a coarse feedstock layer thickness,
solidifying a portion of the coarse feedstock layer to form a solidified coarse feedstock layer having a solidified coarse feedstock layer thickness,
before or after forming the solidified coarse feedstock layer, forming at least one fine feedstock layer having a fine feedstock layer thickness that is less than the coarse feedstock layer thickness, and
solidifying a portion of the at least one fine feedstock layer to form the at least one solidified fine feedstock layer having a solidified fine feedstock layer thickness that is less than the solidified coarse feedstock layer thickness.