Lattice Structure and Method of Manufacture

A lattice structure includes a first layer and a second layer disposed on and overlaying the first layer. The first layer includes a plurality of interior cells, and adjacent interior cells along both a first axis and a second axis are interconnected. The second layer includes a plurality of exterior cells, and adjacent exterior cells are connected along the second axis but not the first axis. A channel is formed between unconnected adjacent exterior cells above interconnected adjacent interior cells. The lattice structure may be formed during a method of manufacturing a protective pad that further includes folding the lattice structure according to a pattern to form an articulated protective structure.

FIELD OF THE DISCLOSURE

The present disclosure relates to a 3D printed lattice structure, and specifically relates to an open cell tubular lattice structure that, when incorporated into protective gear, provides air-permeable impact absorption with stretch and flexibility.

BACKGROUND

Various sports and professions involve activity that can cause soft-tissue damage or other injuries. For example, some sports involve high impact contact and collisions as a part of regular play (e.g., American football, ice hockey, and water polo). Even sports with limited or no player contact may involve a risk of collisions with equipment, a risk of crashing, or a risk of falling (e.g., baseball, skiing, and horseback riding). Professionals in certain industries, such as law enforcement, military, and construction, are also at risk for soft-tissue damage when performing their work duties.

Protective padding can reduce the risk of soft-tissue damage or other injuries, but traditional protective padding is hot, bulky, and can limit a wearer's mobility. Unless protective padding is required by sport or work regulations, many athletes and professionals opt to take the risk of injury rather than compromise their performance.

SUMMARY

In accordance with an example, a lattice structure includes a first layer, a second layer, and a channel. The first layer includes a plurality of interior cells arranged along a first axis and a second axis that is perpendicular to the first axis, adjacent interior cells along the first axis being interconnected and adjacent interior cells along the second axis being interconnected. The second layer is disposed on and overlays the first layer and is located above the first layer. The second layer includes a plurality of exterior cells arranged along the first axis and the second axis, adjacent exterior cells along the first axis being unconnected. The channel is formed between unconnected adjacent exterior cells above interconnected adjacent interior cells.

In some forms, adjacent exterior cells along the second axis may be interconnected.

In some forms, adjacent exterior cells along the second axis may be unconnected. The channel may be a first channel formed by the adjacent exterior cells along the first axis being unconnected. The lattice structure may further include a second channel formed by the adjacent exterior cells along the second axis being unconnected.

In some forms, each exterior cell may have an upper tubular frame and a lower tubular frame, the adjacent exterior cells along the second axis being interconnected by sharing a portion of the upper tubular frame that is oriented along the first axis and a portion of the lower tubular frame that is oriented along the first axis.

In some forms, the adjacent exterior cells along the first axis may be offset from one another along the second axis.

In some forms, the adjacent exterior cells along the second axis may be offset from one another along the first axis.

In some forms, each exterior cell may have an upper tubular frame and a lower tubular frame, a portion of the upper tubular fame and the lower tubular frame that is not oriented along the first axis defining a side of the channel.

In some forms, each interior cell may have a base tubular frame, the adjacent interior cells along the second axis being interconnected by sharing a portion of the base tubular frame that is oriented along the first axis.

In some forms, each interior cell may have a plurality of compound connections, each compound connection connected by a base tubular extension to a base eye, by a base segment to a base tubular frame, and by a joining tubular extension to a lower eye of an exterior cell, the compound connection defining a bottom of the channel.

In some forms, each exterior cell may have a central axis, an upper eye, upper tubular extensions, an upper tubular frame, a lower tubular frame, lower tubular extensions, and a lower eye. The upper eye may be defined by a tubular structure surrounding the central axis and having a first opening at the central axis. The upper eye may be positioned at a top of the second layer. The upper tubular extensions may be connected to the upper eye, and the upper tubular extensions may extend downward from the upper eye. The upper tubular frame may have upper segments. The upper segments may be connected to one another and to the upper tubular extensions at upper joints. The upper segments may be connected to one another and unconnected to the upper tubular extensions at frame connections. The upper joints may be disposed above the frame connections. The lower tubular frame may have lower segments. The lower segments may be connected to one another and to the upper segments at the frame connections. The lower segments may be connected to one another and unconnected to the upper segments at lower joints. The frame connections may be disposed above the lower joints. The lower tubular extensions may be connected to the lower tubular frame at the lower joints, and the lower tubular extensions may extend downward from the lower joints. The lower eye may be defined by a tubular structure surrounding the central axis and having a second opening at the central axis. The lower eye may be connected to the lower tubular extensions.

In some forms, each interior cell may have a central axis, a base eye, base tubular extensions, a base tubular frame, a dampening tubular frame, and joining tubular extensions. The base eye may be defined by a tubular structure surrounding the central axis and having a base opening at the central axis. The base eye may be positioned at a bottom of the first layer. The base tubular extensions may be connected to the base eye and extend upward. The base tubular frame may have base segments. The base segments may be connected only to one another and to the base tubular extensions at base joints. The dampening tubular frame may have dampening extensions. The dampening extensions may be connected to the base segments at base connections. The base connections may be disposed above the base joints, and joining tubular extensions may be configured to connect to the second layer. The joining tubular extensions may be connected to the dampening extensions at dampening joints. The dampening joints may be disposed above the base connections. The joining tubular extensions may be connected to the base segments and the base tubular extensions at compound connections.

In accordance with an example, a lattice structure includes a first layer, a second layer, and a channel. The first layer has a plurality of cells arranged along a first axis and a second axis that is perpendicular to the first axis, adjacent cells of the first layer along the first axis being interconnected and adjacent cells of the first layer along the second axis being interconnected. The second layer is disposed on and overlays the first layer, the second layer including a plurality of cells arranged along the first axis and the second axis, adjacent cells of the second layer along the first axis being unconnected. The channel is formed between unconnected adjacent cells of the second layer and interconnected adjacent cells of the first layer.

In some forms, adjacent cells of the second layer along the second axis may be interconnected.

In some forms, adjacent cells of the second layer along the second axis may be unconnected. The channel may be a first channel formed by the adjacent cells of the second layer along the first axis being unconnected. The lattice structure may further include a second channel formed by the adjacent cells of the second layer along the second axis being unconnected.

In some forms, the lattice structure may include a first area where adjacent cells of the second layer along the second axis are interconnected and a second area where adjacent cells of the second layer along the second axis are unconnected.

In some forms, each cell of the first layer may have an upper tubular frame and a lower tubular frame. The adjacent cells of the first layer along the second axis may be interconnected by sharing a portion of the upper tubular frame that is oriented along the first axis and a portion of the lower tubular frame that is oriented along the first axis.

In some forms, the adjacent cells of the first layer along the first axis may be offset from one another along the second axis.

In some forms, each cell of the first layer may have an upper tubular frame and a lower tubular frame. A portion of the upper tubular fame and the lower tubular frame that is not oriented along the first axis may define a side of the channel.

In some forms, each cell of the second layer may have a base tubular frame. The adjacent cells of the second layer along the second axis may be interconnected by sharing a portion of the base tubular frame that is oriented along the first axis.

In some forms, each cell of the second layer may have an upper tubular frame that is not shared with an adjacent cell and a lower tubular frame that is not shared with an adjacent cell.

In some forms, each cell of the second layer may have a plurality of compound connections. Each compound connection may be connected by a base tubular extension to a base eye, by a base segment to a base tubular frame, and by a joining tubular extension to a lower eye of a cell of the first layer. The compound connection may define a bottom of the channel.

In accordance with an example, a method of manufacturing a protective pad including a lattice structure includes identifying a pattern for a lattice structure to facilitate folding the lattice structure to form an articulated protective structure. The method further includes forming a lattice structure by additive manufacturing according to the pattern. The lattice structure includes a first layer including a plurality of interior cells, a second layer disposed on and overlaying the first layer and including a plurality of exterior cells, and a plurality of channels formed between unconnected adjacent exterior cells above interconnected adjacent interior cells. The method further includes folding the lattice structure according to the pattern to form the articulated protective structure.

In some forms, the articulated protective structure may be configured to protect a human body part.

In some forms, the pattern may include tabs for connecting areas of the lattice structuring during folding.

In some forms, the articulated protective structure may be secured within a garment.

In some forms, the method may include securing the lattice structure within a housing comprising air-permeable fabric. The air-permeable fabric may be mesh.

DETAILED DESCRIPTION

The disclosed lattice structure may be 3D printed using elastomers that provide sufficient stability for open cell tubular lattices. The open cells allow air flow, thereby preventing overheating. Another result of the open tubular cells is that the lattice structure is lightweight. The dual layer arrangement and channel provides impact protection while simultaneously allowing the lattice structure to flex with the wearer's body, thereby limiting the impact on a wearer's range of motion. The lattice structure can be warped to contour to various body parts. Because the lattice structure is 3D printed, diversity in sizing can be achieved without significant increases in cost. For example, typical bra cups require expensive molds for foam cups. In contrast, a 3D printed bra cup using the disclosed lattice structure requires no such molds and can be offered in a variety of sizes to better fit diverse chest contours. The lattice structure may be manufactured using a custom material stiffness for the particular application desired, and the material may be biocompatible to limit the environmental impact.

FIG.1is a top view of a first anisotropic lattice structure100for protective gear prior to folding and jointing. The first lattice structure100may be used in a variety of applications. For example, the first lattice structure100may be used in modular base layers, such as chest cups, pelvic cups, rib pads, and hip pads. The first lattice structure100may be incorporated as a breast cup in an impact bra. The first lattice structure100may be used in a strike plate, such as a chest plate, back plate, or side plate. The first lattice structure100may be folded to form protective padding and/or may be incorporated into a garment comprising other materials.

FIG.2Ais a bottom view of a portion of a first layer102of the first anisotropic lattice structure100ofFIG.1. The first layer102would typically be placed next to or closest to the skin of a wearer when the first lattice structure100is incorporated into protective gear. The first layer102includes a plurality of interior cells104.FIG.2Billustrates a bottom view of an interior cell104of the first layer102. As shown inFIG.2A, the plurality of interior cells104are arranged along a first axis (the x-axis) and a second axis (the y-axis) that is perpendicular to the first axis. Adjacent interior cells104along the first axis are interconnected and adjacent interior cells along the second axis are interconnected. Because the adjacent interior cells104are connected along both the first axis and the second axis, the first layer102provides stability for the first lattice structure100

FIG.3Ais a top view of a second layer106of the first anisotropic lattice structure100ofFIG.1. The second layer106is disposed on and overlays the first layer102(shown inFIG.2A). The second layer106is located above the first layer102on a third axis (the z-axis) that is perpendicular to both the first axis (the x-axis) and the second axis (the y-axis). The second layer106includes a plurality of exterior cells108arranged along the first axis and the second axis.FIG.3Bis a top view of an exterior cell108of the second layer106ofFIG.3A. As shown inFIG.3A, adjacent exterior cells108along the first axis are unconnected and adjacent exterior cells108along the second axis are interconnected. A channel110is formed between unconnected adjacent exterior cells108above interconnected adjacent interior cells104(shown inFIG.2A). In some arrangements, adjacent exterior cells108along the second axis may be unconnected in order to increase flexibility in certain regions of the first lattice structure100. When the adjacent exterior cells108are arranged as shown inFIG.3A, the channel110has a zig-zag pattern. The channel110allows the second layer106some freedom of movement along both the first and second axes, thereby providing flexibility within the first lattice structure100.

FIG.4Ais an exploded view of the exterior cell108ofFIG.3Balong the third axis (the z-axis). The exterior cell108has a central axis A extending along the third axis. The size of the exterior cell108(for example, the width W1relative to the central axis A) may be larger or smaller within certain regions or depths of the first lattice structure100. An upper eye112is defined by a tubular structure surrounding the central axis A. The upper eye112has a first opening114at the central axis A. In the arrangement shown, the upper eye has four sides116that each meet at upper eye junctures118. The upper eye112is positioned at a top of the second layer106. Upper tubular extensions120are connected to the upper eye112. The upper tubular extensions120extend downward from the upper eye112. In the arrangement shown, four upper tubular extensions120are connected at the upper eye junctures118, two of the four upper tubular extensions120extending outward from the upper eye112along the first axis and the other two of the four upper tubular extensions120extending outward from the upper eye112along the second axis.

As shown inFIG.4A, the exterior cell108has an upper tubular frame122having upper segments124. In the arrangement shown, the upper tubular frame122has eight upper segments124. The upper segments124are connected to one another and to the upper tubular extensions120at upper joints126. In the arrangement shown, the upper tubular frame122has four upper joints126. The upper segments124are connected to one another and unconnected to the upper tubular extensions120and frame connections128. In the arrangement shown, the upper tubular frame122has four frame connections128. The upper joints126are disposed above the frame connections128. During impact, the upper joints126and the frame connections128may become at least partially interlocked, helping to absorb the impact and distribute the load across the second layer106.

The exterior cell108also has a lower tubular frame130having lower segments132. The lower segments132are connected to one another and to the upper segments124at the frame connections128. The lower segments132are connected to one another and unconnected to the upper segments124at lower joints134. In the arrangement shown, the lower tubular frame130has four lower joints134. The frame connections128are disposed above the lower joints134. In the arrangement shown, the lower tubular frame130and the upper tubular frame122are coplanar along the third axis. That is, each lower segment132is aligned with a respective upper segment124such that the exterior cell108, when viewed from the top as shown inFIG.4C, appears to have only one frame because the upper tubular frame122covers all of the lower tubular frame130.

As shown inFIG.4A, lower tubular extensions136are connected to the lower tubular frame130at the lower joints134. The lower tubular extensions136extend downward from the lower joints134. In the arrangement shown, the exterior cell108has four lower tubular extensions136, two of the four lower tubular extensions136extending inward from the lower tubular frame130along the first axis and the other two of the four upper tubular extensions136extending inward from the lower tubular frame130along the second axis. The two of the four lower tubular extensions136extending inward along the first axis are coplanar (in the x-z plane) with respective two of the four upper tubular extensions120. The other two of the four lower tubular extensions136extending inward along the second axis are coplanar (in the y-z plane). A lower eye138is defined by a tubular structure surrounding the central axis A and having a second opening140at the central axis. The lower eye138is connected to the lower tubular extensions136at lower eye junctures142. In the arrangement shown, the lower eye138has four sides144.

FIG.4Bis a side view of the exterior cell ofFIGS.3B and4A.FIG.4Cis a top view of the exterior cell ofFIGS.3B and4Aillustrating placement of the exterior cell108,108arelative to other exterior cells108b,108c.As shown inFIG.4C, a first exterior cell108ais adjacent a second exterior cell108balong the first axis and is adjacent a third exterior cell108calong the second axis. The adjacent exterior cells108aand108balong the first axis are offset from one another along the second axis. That is, the central axis A of the first exterior cell108ais offset along the second axis from the central axis A of the second exterior cell108b.The staggering of the exterior cells108aand108bimproves the stretch of the first lattice structure100while simultaneously providing adequate coverage for protection. The adjacent exterior cells108aand108calong the second axis are interconnected by sharing a portion of the upper tubular frame122that is oriented along the first axis and a portion of the lower tubular frame130(shown inFIGS.4A and4B) that is oriented along the first axis. For each of the exterior cells108a,108b,108c,a portion of the respective upper tubular fame122and respective lower tubular frame130that is not oriented along the first axis defines a side of the channel110. In particular, as shown inFIG.4C, the side of the channel110is defined by a first upper segment124and a first lower segment132(shown inFIGS.4A and4B) coplanar along the third axis and disposed at a first angle α relative to the first axis of exterior cell108a.As also shown inFIG.4C, the side of the channel110is further defined by a second upper segment124and a second lower segment132(shown inFIGS.4A and4B) coplanar along the third axis and disposed at a second angle β relative to the first axis.

FIG.5Ais an exploded view of the interior cell104ofFIG.2Balong the third axis (the z-axis). The interior cell104has a central axis A. The size of the interior cell104(for example, the width W2relative to the central axis A) may be larger or smaller within certain regions or depths of the first lattice structure100. A base eye146defined by a tubular structure surrounds the central axis A. The base eye146has a base opening148at the central axis A. In the arrangement shown, the base eye146has four sides150that each meet at base eye junctures152. The base eye146is positioned at a bottom of the first layer102. Base tubular extensions154connect to the base eye146and extend upward. In the arrangement shown, six base tubular extensions154are connected to the base eye146. At two of the base eye junctures152, two of the six base tubular extensions154are connected and extend outward from the base eye146at angles relative to the first axis. At two of the base eye junctures152, just one of the six base tubular extensions154are connected and extend outward from the base eye146along the second axis.

As shown inFIG.5A, a base tubular frame156has base segments158. The base segments158are connected only to one another and to the base tubular extensions154at base joints160. A dampening tubular frame162has dampening extensions164. The dampening extensions164are connected to the base segments158at base connections166that are disposed above the base joints160.

Joining tubular extensions168are configured to connect to the second layer106. Specifically, the joining tubular extensions168are configured to connect to the lower eye junctures142of the lower eye138. The arrangement shown has six joining tubular extensions168. At two of the lower eye junctures142, two of the six joining tubular extensions168are configured to connect and to extend outward from the lower eye138at angles relative to the first axis. At two of the lower eye junctures142, just one of the six joining tubular extensions168are configured to connect and extend outward from the lower eye138along the second axis. The joining tubular extensions168are connected to the dampening extensions164at dampening joints170. The dampening joints170are disposed above the base connections166.

The joining tubular extensions168are connected to the base segments158and the base tubular extensions154at compound connections172. Each compound connection172is connected by a base tubular extension154to the base eye146, by a base segment158to the base tubular frame156, and by a joining tubular extension168to the lower eye138of an exterior cell108, and each compound connection172defines a bottom of the channel110.

FIG.5Bis a side view of the exterior cell ofFIGS.2B and5A.FIG.5Cis a bottom view of the interior cell104ofFIGS.2B,5A, and5Billustrating placement of an interior cell104,104arelative to other interior cells104,104b,104c,104d.Specifically,FIG.5Cshows a first interior cell104abeside a second interior cell104balong the first axis, beside a third interior cell104calong the first axis, and beside a fourth interior cell104dalong the second axis. The base tubular frame156aof the first interior cell104ais interconnected with the base tubular frame156bsecond interior cell104bby sharing a compound connection172x,and the base tubular frame156aof the first interior cell104ais interconnected with the base tubular frame156cof the third interior cell104cby sharing a compound connection172y.The compound connection172xis further connected to a base tubular extension154a1of the first interior cell, a base tubular extension154bof the second interior cell, a joining tubular extension168of the first interior cell104a(seeFIG.5A), and a joining tubular extension168of the second interior cell104b(seeFIG.5A). The compound connection172yis further connected to a base tubular extension154a2of the first interior cell104a,a base tubular extension154cof the third interior cell104c,a joining tubular extension168of the first interior cell104a(seeFIG.5A), and a joining tubular extension168(seeFIG.5A) of the third interior cell104c.A portion of the base tubular frame156aof the first interior cell104athat is oriented along the first axis is shared with the fourth interior cell104d.

FIG.6is a cross-sectional view of the first anisotropic lattice structure100ofFIG.1. The central axis A of an interior cell104is aligned with the central axis A of an exterior cell108. The base eye146is positioned below the lower eye138and the lower eye138is positioned below the upper eye112. As shown by the arrows, a force applied to the first layer102(including the exterior cell108) is distributed throughout the first lattice structure100, enabling the first lattice structure100to distribute and dissipate the impact force over the entire area of the first lattice structure100. The first layer102has a first height H1, and the second layer104has a second height H2. In the arrangement shown, the first height H1and the second height H2are substantially the same. In other arrangements, the first height H1and the second H2may differ.

FIG.7Ais an isometric view of a lattice structure200for groin protection prior to folding and jointing. As shown, the anisotropic lattice structure200includes tabs202for securing the lattice structure200during in a folded configuration.FIG.7Bis an isometric view of the anisotropic lattice structure ofFIG.7Aafter folding and jointing.

FIG.8Aillustrates schematically the second layer106of the first anisotropic lattice structure100in a manner like the depiction described with respect toFIG.3Aabove.FIG.8Billustrates schematically a second anisotropic lattice structure200. The second anisotropic lattice structure200is substantially similar to the first anisotropic lattice structure100. Elements of the second anisotropic lattice structure200depicted inFIG.8Bare designated by similar reference numbers indicated on the arrangements illustrated inFIGS.1-8Aincreased by100. Accordingly, these features will not be described in substantial detail. Further, it is appreciated that any combination or sub-combination of features described in regard to the first anisotropic lattice structure100may be incorporated into the second anisotropic lattice structure200, and vice versa.

As shown, the second anisotropic lattice structure200includes second layer206that is disposed on and overlays the first layer202. The second layer206is located above the first layer202on a third axis (the z-axis) that is perpendicular to both the first axis (the x-axis) and the second axis (the y-axis). The second layer206includes a plurality of exterior cells208arranged along the first axis and the second axis. Unlike the first anisotropic lattice structure100depicted inFIG.8A, where adjacent exterior cells108along the first axis are unconnected and adjacent exterior cells108along the second axis are interconnected, adjacent exterior cells208in the second lattice structure200depicted inFIG.8Bare unconnected along both the first and second axes.

More specifically, adjacent exterior cells208aand208calong the second axis are unconnected so do not share a portion of the upper tubular frame122that is oriented along the first axis or a portion of the lower tubular frame130as described with respect to the first lattice structure100. Instead, each of the adjacent exterior cells208has an upper tubular frame222that is offset from the upper tubular frame222of other adjacent exterior cells208, and a lower tubular frame230that is offset from the lower tubular frame230of other adjacent exterior cells208. (The lower tubular frame230is not visible inFIG.8Bbecause it is located below the upper tubular frame222but is substantially similar to the lower tubular frame depicted inFIGS.4A and4B). Therefore, the second lattice structure200includes both a plurality of first channels210and a plurality of second channels280. As a result, the second lattice structure200has greater freedom of movement along the first and second axes than the first lattice structure100and provides greater flexibility.

Turning toFIGS.9-11, a composite structure282is depicted that is formed from both the first lattice structure100and the second lattice structure200. Here, the composite structure282is a knee pad depicted on a mannequin. The first lattice structure100is used in a first area284of the composite structure282that benefits from the stability of additional structural connections, and the second lattice structure200is used in a second area286that benefits from greater flexibility. For example, when the composite structure282is a protective pad for a knee as shown, the first area284covers and protects the knee cap of a wearer with the stability of additional structural connections and the second area286is located below the knee cap to facilitate bending of the knee by the wearer.FIG.11illustrates the flexibility of the second area286as a result of use of the second lattice structure200in the composite structure286.

In the composite structure286, the first lattice structure100may be integral with the second lattice structure200or may be formed separately and later connected. The composite structure286includes at least a first area284of the first lattice structure100and a second area284of the second lattice structure200but may also optionally include additional areas with the first lattice structure200, second lattice structure200, another type of lattice structure, or a different structure or material.

FIG.12illustrates schematically a method300of manufacturing a protective pad including a lattice structure (such as first anisotropic lattice structure100, second lattice structure200, or a composite structure286). At box302, the method300includes identifying a pattern for a lattice structure to facilitate folding the lattice structure to form an articulated protective structure. The articulated protective structure may be configured to protect a human body part, such as the groin or breasts. The pattern may include tabs (such as tabs202) for connecting areas of the first lattice structure100and/or second lattice structure200during folding. At box304, the method300includes forming a first lattice structure100, second lattice structure200, or composite structure286by additive manufacturing. As described above the first lattice structure100includes a first layer102including a plurality of interior cells104, a second layer106disposed on and overlaying the first layer102and including a plurality of exterior cells108, and a plurality of channels110formed between unconnected adjacent exterior cells108above interconnected adjacent interior cells104. The second lattice structure200includes a first layer202including a plurality of interior cells204, a second layer206disposed on and overlaying the first layer202and including a plurality of exterior cells208, and a plurality of channels210and a plurality of channels280formed between unconnected adjacent exterior cells108above interconnected adjacent interior cells104. The composite structure286includes a first area284with the first lattice structure100and a second area284with the second lattice structure200. At box306, the method includes folding the lattice structure (i.e., lattice structure100, lattice structure200, or a composite structure284including both the lattice structure100and the lattice structure200) according to the pattern to form the articulated protective structure. In some executions, the articulated protective structure may be secured within a garment. In some executions, the lattice structure may be secured within a housing comprising an air-permeable fabric such as mesh.

In additional executions, the method300may include providing a molded form. In some executions, providing a molded form includes milling a three-dimensional shape mimicking a human body part. The method300may include warping the first lattice structure100, the second lattice structure200, and/or a composite structure including both the first lattice structure100and the second lattice structure200by placing the chosen lattice structure over the molded form during heat curing. In some executions, the first layer is placed adjacent the molded form during the warping of the chosen lattice structure.

An additive manufacturing technique of the foregoing method(s) using additive manufacturing and/or 3D printing may be any additive manufacturing technique or process that builds three-dimensional objects by adding successive layers of material on a material. The additive manufacturing technique may be performed by any suitable machine or combination of machines. The additive manufacturing technique may typically involve or use a computer, three-dimensional modeling software (e.g., Computer Aided Design, or CAD, software), machine equipment, and layering material. Once a CAD model is produced, the machine equipment may read in data from the CAD file and layer or add successive layers of liquid, powder, sheet material (for example) in a layer-upon-layer fashion to fabricate a three-dimensional object. The additive manufacturing technique may include any of several techniques or processes, such as, for example, a stereolithography (“SLA”) process, a fused deposition modeling (“FDM”) process, multi-jet modeling (“MJM”) process, a selective laser sintering (“SLS”) process, an electronic beam additive manufacturing process, and an arc welding additive manufacturing process. In some embodiments, the additive manufacturing process may include a directed energy laser deposition process. Such a directed energy laser deposition process may be performed by a multi-axis computer-numerically-controlled (“CNC”) lathe with directed energy laser deposition capabilities.