Patent Description:
Traditionally, an additive manufacturing process may create parts in a linear fashion. That is, the parts may be sliced into a set of layers at a pre-determined (often equally spaced) heights, each of which may then be built sequentially by moving a laser beam in a pre-designed two-dimensional trajectory (the "scan path").

Creation of an industrial asset item may be facilitated via a "rotary" additive manufacturing process. For example, a build plate may rotate about a vertical axis and move, relative to a print arm, along the vertical axis during printing. That is, the build platform might be lowered with respect to the print arm, the print arm might be raised with respect to the build platform, etc. Two improvements that may be associated with rotary machines as compared to linear counterparts include decreasing (or even eliminating) scanner idle time (increasing throughput as a result) and better space utilization for parts having certain shapes (e.g., a tube). <CIT> discloses a 3D printing technique for continuously forming a 3D object on a continuously rotating disc.

When the build platform of a rotary machine continuously rotates and drops down simultaneously (a downward spiral motion), however, it may not be feasible to slice the part into horizontal layers as is done for traditional machines. It would therefore be desirable to efficiently and accurately facilitate creation of an industrial asset item via a rotary additive manufacturing process.

In an aspect, there is provided a system to facilitate creation of an industrial asset item via a rotary additive manufacturing process, in accordance with claim <NUM>.

In a further aspect, there is provided a computer-implemented method to facilitate creation of an industrial asset item via a rotary additive manufacturing process, in accordance with claim <NUM>.

In a further aspect, there is non-transitory, computer-readable medium in accordance with claim <NUM>.

Technical effects of some embodiments of the invention are improved and computerized ways to efficiently and accurately facilitate creation of an industrial asset item via a rotary additive manufacturing process. With these and other advantages and features that will become hereinafter apparent, a more complete understanding of the nature of the invention can be obtained by referring to the following detailed description and to the drawings appended hereto.

In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of embodiments. However, it will be understood by those of ordinary skill in the art that the embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components and circuits have not been described in detail so as not to obscure the embodiments.

The creation of an industrial asset item is facilitated via a "rotary" additive manufacturing process. A build plate rotates about a vertical axis and moves, relative to a print arm, along the vertical axis during printing. That is, the build platform might be lowered with respect to the print arm, the print arm might be raised with respect to the build platform, etc. Two improvements that may be associated with rotary machines as compared to linear counterparts include decreasing (or even eliminating) scanner idle time (increasing throughput as a result) and better space utilization for parts having certain shapes. When the build platform of a rotary machine continuously rotates and drops down simultaneously (a downward spiral motion), it may not be feasible to slice the part into horizontal layers as is done for traditional machines. A part may be created in a continuous helical slice as opposed to building it up from a collection of stacked horizontal slices. An advantage of slicing in this fashion may be that the build substantially continuously without waiting for powder dispense and recoat between layers, and, as a result, laser/scanner utilization (and throughput) may be increased. Some embodiments approximate a helical slice with a collection of locally linear frames that can be built sequentially within practical error tolerances. Although embodiments may be associated with a single laser system, the approaches described herein may be extended to multiple lasers (e.g., by adjusting a downward speed of the platform to increase throughput).

<FIG> is an illustration <NUM> of an industrial asset item <NUM> traditionally sliced for an additive manufacturing process. Traditionally, the item <NUM>, having a radius of r and a height of h, would be sliced into a set of horizontal layers as shown in <FIG>. The layers would be provided to a three-dimensional printer that could then create the item on a build plate <NUM>. For a rotary machine, however, another approach might be more appropriate. For example, <FIG> is an illustration <NUM> of a helical slice <NUM> for a single-laser rotary additive manufacture process. The slice <NUM> might represent, for example, vertical movement of a build plate combined with a simultaneous rotation about an axis <NUM>. Note that the techniques described herein are by no means limited to cylinders, and that any arbitrary shape may be sliced according to embodiments. Moreover, note that embodiments may be associated with systems having more than one print arm or laser. For example, <FIG> is an illustration <NUM> of helical slices <NUM>, <NUM> for a two-laser rotary additive manufacture process. One slice <NUM> (illustrated with a solid line in <FIG>) might be associated with one print arm while the other slice <NUM> (illustrated with a dashed line in <FIG>) is associated with the other print arm. The two slices <NUM>, <NUM> may, according to some embodiments, be intertwined.

The system slices data defining an industrial asset item to create a series of two-dimensional, locally linear frames helically arranged as a "spiral staircase" of steps. For example, <FIG> illustrates a "spiral staircase" <NUM> approximation of a helical slice for an additive manufacturing process according to some embodiments. The staircase <NUM> is comprised of a series of two-dimensional steps <NUM>, with each step being oriented normal to a vertical axis <NUM> (in the "Z" direction). Note that the staircase is two-dimensional slicing and scanning strategy (as opposed to a three-dimensional approach). Note that as used herein, the phrase "spiral staircase" might refer to a series of frames that include at least some overlapping neighboring frames and/or at least some frames having a gap or space between a neighboring frame. Moreover, embodiments might be associated with frames with different radial dimensions, frames having "radial edges" that are not actually radial, frames having "circumferential edges" that are not actually circumferential," etc. Moreover, embodiments may be associated with a spiral staircase including both: (i) a series of inner frames or steps, and (ii) a series of outer frames or steps each at the same Z position as a corresponding inner step. The inner and outer steps might represent stair step in two more pieces (which might be divided arbitrarily).

The helical slice may be sub-divided into a collection of overlapping steps <NUM> or frames. According to some embodiments, the helical slice may be approximated by a collection of overlapping frames <NUM> each of which is oriented normally to the axis of the cylinder. According to some embodiments, each step <NUM> or frame is scanned sequentially. Moreover, as illustrated <NUM> in <FIG>, each frame <NUM> might be associated with a particular height Δh. Note that for a uniform section of the geometry in the z direction (vertical), the system may increase stair step height to reduce computational cost. This might be possible, for example, when the geometry contained within the frames will not change significantly. Consider, for example, a hollow cylinder. The geometry contained within the frames may be exactly identical. In this case, the system may just generate the scan path for the first frame and repeat it until it is determined that a hatch angle should be adjusted. Even at that point, the system does not need to compute the geometric boundary contained within the frame. This represents increasing the step height with a much wider horizontal section.

The frames <NUM> may then be sent to a three-dimensional printer to create an industrial asset item. <FIG> is a high-level diagram of a system <NUM> according to some embodiments. The system includes a rotary additive printing platform <NUM> that executes a frame creation engine <NUM>. The rotary additive printing platform <NUM> can access an item definition data store <NUM> that includes electronic records defining an industrial asset item (e.g., Computer Aided Design ("CAD") files). Note that the rotary additive printing platform <NUM> could be completely de-centralized and/or might be associated with a third party, such as a vendor that performs a service for an enterprise.

The rotary additive printing platform <NUM> and/or other elements of the system might be, for example, associated with a Personal Computer ("PC"), laptop computer, a tablet computer, a smartphone, an enterprise server, a server farm, and/or a database or similar storage devices. According to some embodiments, an "automated" rotary additive printing platform <NUM> may automatically create frames <NUM> associated with the industrial asset item that may be stored (e.g., in the item definition data store <NUM>) and/or provided to a three-dimensional printer <NUM>. As used herein, the term "automated" may refer to, for example, actions that can be performed with little (or no) intervention by a human.

As used herein, devices, including those associated with the rotary additive printing platform <NUM> and any other device described herein, may exchange information via any communication network which may be one or more of a Local Area Network ("LAN"), a Metropolitan Area Network ("MAN"), a Wide Area Network ("WAN"), a proprietary network, a Public Switched Telephone Network ("PSTN"), a Wireless Application Protocol ("WAP") network, a Bluetooth network, a wireless LAN network, and/or an Internet Protocol ("IP") network such as the Internet, an intranet, or an extranet. Note that any devices described herein may communicate via one or more such communication networks.

The rotary additive printing platform <NUM> may store information into and/or retrieve information from data stores, including the item definition data store <NUM>. The data stores might, for example, store electronic records representing prior item designs, three-dimensional printer information, etc. The data stores may be locally stored or reside remote from the rotary additive printing platform <NUM>. Although a single rotary additive printing platform <NUM> is shown in <FIG>, any number of such devices may be included. Moreover, various devices described herein might be combined according to embodiments of the present invention. For example, in some embodiments, the rotary additive printing platform <NUM>, item definition data store <NUM>, and/or other devices might be co-located and/or may comprise a single apparatus.

Note that the system <NUM> of <FIG> is provided only as an example, and embodiments may be associated with additional elements or components. According to some embodiments, the elements of the system <NUM> automatically facilitate creation of an industrial asset item via a rotary additive manufacturing process. For example, <FIG> illustrates a method <NUM> that might be performed according to some embodiments of the present invention. The flow charts described herein do not imply a fixed order to the steps, and embodiments of the present invention may be practiced in any order that is practicable. Note that any of the methods described herein may be performed by hardware, software, or any combination of these approaches. For example, a computer-readable storage medium may store thereon instructions that when executed by a machine result in performance according to any of the embodiments described herein.

Note that the method of <FIG> may facilitate creation of an industrial asset item via a rotary additive manufacturing process. A build plate rotates about a vertical axis and moves, relative to a print arm, along the vertical axis during printing. At <NUM>, the system receives data defining the industrial asset item. The information is received from an industrial asset item definition data store containing at least one electronic record defining the industrial asset item. The at least one electronic record defining the industrial asset item might be associated with, for example, an image, a manufactured design, a cross-section, a binary CAD file, a geometry file, etc..

At <NUM>, the system may slice the data defining the industrial asset item to create a series of two-dimensional, locally linear frames helically arranged as a spiral staircase of steps. As illustrated in <FIG>, each step may be oriented normal to the vertical axis.

At <NUM>, the system outputs (e.g., store or transmit) indications of the series of two-dimensional frames to be provided to a rotary three-dimensional printer to create the industrial asset item. The rotary three-dimensional printer may be, for example, associated with a Direct Metal Laser Melting ("DMLM") process. According to some embodiments, the three-dimensional printer has a single print arm. According to other embodiments, the printer has two or more print arms and the system creates a first series of two-dimensional frames associated with one print arm and a second series of two-dimensional frames associated with the other print arm (and the first and second series may be arranged as intertwined spiral staircases). Note that the rotational speed may remain the same but vertical travel speed may increase contributing to increased throughput. According to still other embodiments, the three-dimensional printer has two or more print arms and one print arm processes one frame in the series simultaneously as another print arm processes another frame in the series. Note that the frames may be assigned to a print arm in a pre-defined schedule or a dynamically created schedule. That is, multiple lasers may work on different segments (predefined or dynamically scheduled) of the same helix or spiral staircase. Different segments are may be particularly easy to identify if the item being printed has geometric segments. For example, one laser might work on an inner liner of a tube while another laser works on an outer liner. In this embodiment, rotational speed may be increased increase throughput.

As used herein, the term "frame" may refer to, for example, a geometry contained within a sector of angle θ as shown in <FIG>. As illustrated <NUM>, frame Fn is currently being scanned, frame Fn-<NUM> has already been scanned, and frame Fn+<NUM> is next in line to be scanned. According to some embodiments, the frames are chosen so as to occupy only a fraction fr (e.g., <NUM> to <NUM>) of a working scan field <NUM> of the scanning system (illustrated by a dotted box in <FIG>) to help ensure that the frame being scanned is always within the scan field <NUM>. According to some embodiments, a rotational velocity ω is adjusted so that the wait time between scanning of frames may be minimized (that is, the wait time indicates ω can be increased) and the frames do not "walk away" from the scan field <NUM> (which indicates ω needs to be decreased). According to some embodiments, ω is adjusted on the fly to minimize wait (and thus maximize throughput) and avoid gaps in the scan. Note that the phrase "wait time" may refer to, for example, a time during which the laser is idle. The build platform continuously rotates and moves down (or the print arm moves up).

<FIG> illustrates <NUM> the generation of frames from a linear slice in accordance with some embodiments. In particular, frame Fn has an angular width of θ. Note that software tools and algorithms may exist to do linear slicing. According to some embodiments, such tools may be adapted to support helical slicing. For example, frames may be derived from a linear slicing tool to leverage the existing machinery as follows. Once the system has decided on a Δh, it can slice the geometry at a layer thickness Δh. The frame Fi may then then be extracted from the layer Li by having an intersection operation with a mask Mi as Fi = Li ∩ Mi. The mask Mi may be derived, according to some embodiments, by offsetting the center and increasing the sector angle θ by a small amount to ensure overlap between successive frames. In <FIG>, the solid lines bound the actual frame Fn while the dotted lines (increased by δ on both sides for an overall width of θ + 2δ) represent the corresponding mask. Note that if kΔh < ε, where k is an integer, then then the system may slice at layer height kΔh and extract k frames from each layer. Note that this method can be extended for n lasers as the system only needs to speed up the z motion of the build plate n-fold.

Once the frames are extracted, they can be scanned with various scan patterns as appropriate for a particular application. <FIG> includes <NUM> different examples <NUM>, <NUM>, <NUM> of scan patterns according to some embodiments. Another approach may be to collapse the helical surface into a plane, generate the frames on the resulting self-overlapping planar surface and apply commercial tools to those segments. The system may then translate the scan paths generated within these frames to the axial position so that they approximate the original helical surface. Still another approach may be to create scan paths along the entirety of a collapsed helical surface, and then translate or project those paths back onto the original three-dimensional helix. Note that the masking method described herein to extract frames from a linear slicing or flattened helix might also be applied to an already generated linear scan path or set of paths. In that case, the system may compensate for the fact that it is trying to achieve a trajectory intended for a stationary frame in a rotating frame. According to some embodiments, a scanner's marking/processing on the fly methods may be adapted to achieve this compensation.

<FIG> is a method <NUM> of reducing alignment zipper faults in accordance with some embodiments. At <NUM>, the system may receive data defining the industrial asset item. At <NUM>, the system may slice the data defining the industrial asset item to create a series of two-dimensional, locally linear frames helically arranged as a spiral staircase of steps. According to this embodiment, a frame creation computer processor incorporates an overlapping frame boundary avoidance technique when creating the series of frames. At <NUM>, the system may output (e.g., store or transmit) indications of the series of two-dimensional frames to be provided to a rotary three-dimensional printer to create the industrial asset item.

Several different overlapping frame boundary avoidance techniques might be implemented. For example, when a planar frame approximation to a helical surface is used, the difference in z height between the left edge and the right edge of a frame (Δh) may need to be within some tolerance ε. Also, if θ is chosen to be a factor of <NUM>°, then the seams of the frames may line up causing a "zipper" fault in the build. One approach to avoid that would be to set <MAT> where m is an irrational or prime number. If m is irrational, the seams will never (theoretically) line up, whereas when m is a prime number, the seams will line up at a thickness equal to m times the layer thickness of an equivalent linear slice. If the intended layer thickness of an equivalent linear slice is t, then Δh = t/m < ε. By way of example only, for a typical parameter set, Δh might be approximately <NUM> µ. According to some embodiments, m may be selected to a be a non-integer. Note that this situation may rarely arise if the system make the sector angle variable from frame to frame as described with respect to <FIG> and <FIG>. Although some embodiments are described with respect to overlapping frame boundary avoidance techniques, note that embodiments might also allow for overlapping frame boundaries (if desired). That is, a technique may be applied to ensure that an overlapping frame boundary exists.

According to some embodiment, a sector width for a rotary part may comprise a whole number multiple of a rotary stage position resolution. This is because if the width of a sector is not an integer multiple of the rotary stage position resolution, a part may be printed distorted due to rounding. For example, <FIG> illustrate various sector widths as compared to stage resolution in accordance with various embodiments. In particular, <FIG> illustrates a desirable situation <NUM> where sector width (of actual sectors <NUM> through <NUM>) is an integer multiple of stage resolution <NUM> and, as a result, sectors do not process or recess around the circle. <FIG> illustrates an undesirable situation <NUM> where sector width (of actual sectors <NUM> through <NUM>) is less than an integer multiple of stage resolution <NUM> (e.g., rounds down <NUM> count per sector). As a result, the sectors recess around the circle and there is a gap <NUM> such that process does not form a complete circle. <FIG> illustrates an undesirable situation <NUM> where sector width (of actual sectors <NUM> through <NUM>) is greater than an integer multiple of stage resolution <NUM> (e.g., rounds up <NUM> count per sector). As a result, the sectors process around the circle and there is an overlap <NUM>.

The hatch angle is defined as the angle between the scan line and the centerline of the frame (that is, the line that connects the origin of the scan field to the center of rotation). In traditional DMLM, the hatch angle is changed from layer to layer to avoid defect stack ups in vertical direction. The systems changes the hatch angle from revolution to revolution. For example, the system may change the hatch angle after the frame that is closest to one revolution. According to another embodiment, the system may subdivide the hatch angle increment among frames within a single revolution. For example, if the intended hatch angle rotation is <NUM>° per revolution and each revolution has <NUM> equal spaced frames, then the system might increment the hatch angle by <NUM>° degree for each frame to have a more uniform change gradient. Note that in some embodiments, hatches might be created ahead of time before the printing process is initiated. According to other embodiments, hatches might instead be created directly by a print machine processor as the item is being printed.

According to some embodiments, all of the frames created for an industrial asset item are of same shape. According to other embodiments, different frames in a series may have different shapes. For example, <FIG> illustrates <NUM> various hatch angles <NUM>, <NUM> in accordance with some embodiments. In particular, the shape of the frames varies based on the changes to the hatch angle. Note that the frames might cover the same area despite their shape difference. Making the frame shape dependent on hatch angle may help minimize the number of overlapping seams between two adjacent frames when hatch lines crosses frame boundaries. According to some embodiments, the area of frames varies based on the area of the geometry contained within them. The sector angle (angle that the inner arc produces at the center of rotation) might thus be varied to make sure the area of geometry contained in each frame remains substantially equal.

<FIG> is a method <NUM> of adjusting frame shapes according to the invention as defined in the claims. At <NUM>, the system receives data defining the industrial asset item. At <NUM>, the system slices the data defining the industrial asset item to create a series of two-dimensional, locally linear frames helically arranged as a spiral staircase of steps. A first frame in the series has a shape different than a shape of a second frame in the series. At <NUM>, the system outputs (e.g., store or transmit) indications of the series of two-dimensional frames to be provided to a rotary three-dimensional printer to create the industrial asset item. According to some embodiments, a first frame in the series has a width different than a width of a second frame in the series. According to other embodiments, a first frame in the series has vertical height different than a vertical height of a second frame in the series.

<FIG> illustrates a display <NUM> in accordance with some embodiments. The display <NUM> may include an interactive user interface <NUM> that graphically displays the status of various elements in a scan path generation system. According to some embodiments, selection of one or more elements in the display <NUM> may result in the appearance of more detailed information about the system, allow an operator to make parameter adjustments, etc. According to some embodiments, selection of an icon <NUM> (e.g. via a computer mouse) may initiating a scan generation process, a printing operation, etc..

Embodiments described herein may comprise a tool that facilitates creation of an industrial asset item via a rotary additive manufacturing process and may be implemented using any number of different hardware configurations. For example, <FIG> illustrates a platform <NUM> that may be, for example, associated with the system <NUM> of <FIG> (as well as other systems described herein). The platform <NUM> comprises a processor <NUM>, such as one or more commercially available Central Processing Units ("CPUs") in the form of one-chip microprocessors, coupled to a communication device <NUM> configured to communicate via a communication network (not shown in <FIG>). The communication device <NUM> may be used to communicate, for example, with one or more remote expert devices. Note that communications exchanged via the communication device <NUM> may utilize security features, such as those between a public internet user and an internal network of an insurance enterprise. The security features might be associated with, for example, web servers, firewalls, and/or PCI infrastructure. The platform <NUM> further includes an input device <NUM> (e.g., a mouse and/or keyboard to enter information about a design file, an industrial asset item, etc.) and an output device <NUM> (e.g., to output design reports, generate production status messages, etc.).

The processor <NUM> also communicates with a storage device <NUM>. The storage device <NUM> may comprise any appropriate information storage device, including combinations of magnetic storage devices (e.g., a hard disk drive), optical storage devices, mobile telephones, and/or semiconductor memory devices. The storage device <NUM> stores a program <NUM> and/or network security service tool or application for controlling the processor <NUM>. The processor <NUM> performs instructions of the program <NUM>, and thereby operates in accordance with any of the embodiments described herein. The processor <NUM> facilitates creation of an industrial asset item via a rotary additive manufacturing process. An industrial asset item definition data store contains at least one electronic record defining the industrial asset item. The processor <NUM> then slices the data defining the industrial asset item to create a series of two-dimensional, locally linear frames helically arranged as a spiral staircase of steps and each step is oriented normal to the vertical axis. Indications of the series of two-dimensional frames may then be output by the processor <NUM> to be provided to a rotary three-dimensional printer.

The program <NUM> may be stored in a compressed, uncompiled and/or encrypted format. The program <NUM> may furthermore include other program elements, such as an operating system, a database management system, and/or device drivers used by the processor <NUM> to interface with peripheral devices.

As used herein, information may be "received" by or "transmitted" to, for example: (i) the platform <NUM> from another device; or (ii) a software application or module within the platform <NUM> from another software application, module, or any other source.

In some embodiments (such as shown in <FIG>), the storage device <NUM> further stores an industrial asset item definition data store <NUM>, scan definition parameters <NUM> (e.g., operator preferences, printer capabilities, etc.), and a frame database <NUM>. An example of a database that might be used in connection with the platform <NUM> will now be described in detail with respect to <FIG>. Note that the database described herein is only an example, and additional and/or different information may be stored therein. Moreover, various databases might be split or combined in accordance with any of the embodiments described herein. For example, the item definition data store <NUM> and/or frame database <NUM> might be combined and/or linked to each other within the program <NUM>.

Referring to <FIG>, a table is shown that represents the frame database <NUM> that may be stored at the platform <NUM> in accordance with some embodiments. The table may include, for example, entries identifying designs that have been created for industrial asset items. The table may also define fields <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> for each of the entries. The fields <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> may, according to some embodiments, specify: a design identifier <NUM>, an item description <NUM>, a frame identifier <NUM>, a height <NUM>, an angular width <NUM>, and a scan pattern <NUM>. The frame database <NUM> may be created and updated, for example, based on information electrically received from an operator, a rotary additive printing platform, a frame creation engine, etc..

The design identifier <NUM> may be, for example, a unique alphanumeric code identifying an industrial asset as indicated by the item description <NUM>. The frame identifier <NUM> may identify each of a series of frames that comprise a spiral staircase representation of the item. The height <NUM> might represent a vertical or z height of each step in the staircase and the angular width <NUM> might define the area associated with the frame. The scan pattern <NUM> might define how the print arm or laser should be moved during printing (e.g., including hatch angles, part geometries, etc.).

Thus, some embodiments described herein may provide technical advantages, including a continuously rotating machine that improves throughput by minimizing scanner idle time (in the ideal case) while also improving machine space utilization for certain classes of part geometries. Combining multiple scan heads also becomes relatively easier from a scan path generation point of view as compared to a cartesian machine. Approximating the helical surface with a series of planar frames in two dimensions may also allow existing scan path generation toolchains to work in connection with a helical surface. Embodiments provide system and methods to generate a scan path to build a part additively on a continuously rotating machine. Moreover, some embodiments leverage the existing linear slicing algorithms and software to achieve these goals.

The following illustrates various additional embodiments of the invention. These do not constitute a definition of all possible embodiments, and those skilled in the art will understand that the present invention is applicable to many other embodiments. Further, although the following embodiments are briefly described for clarity, those skilled in the art will understand how to make any changes, if necessary, to the above-described apparatus and methods to accommodate these and other embodiments and applications.

Although specific hardware and data configurations have been described herein, note that any number of other configurations may be provided in accordance with embodiments of the present invention (e.g., some of the information described herein may be combined or stored in external systems). Moreover, although embodiments have been described with respect to industrial systems, note that embodiments might be associated with other types of computing systems, including non-industrial systems, consumer items, etc. Similarly, the displays shown and described herein are provided only as examples, and other types of displays and display devices may support any of the embodiments. For example, <FIG> illustrates a tablet computer <NUM> with a scan path generation design display <NUM> that might utilize a graphical user interface. The display <NUM> might include a depiction of a series of frames that have been automatically generated for an industrial asset item. Note that selection of an element on the display <NUM> might result in a display of further information about that element. Moreover, the display <NUM> might comprise an interactive user interface (e.g., via a touchscreen) and includes "import asset item" and "print item" <NUM> icons in accordance with any of the embodiments described herein.

Some embodiments have been described with respect to the creation of an "industrial asset item," which might be, for example, an engine part, a generator component, etc. Note, however, that as used herein the phrase "industrial asset item" might refer to any other type of item, including: consumer electronics parts, toys, household goods, automotive parts, etc. In general, embodiments may address the challenges creating scan paths for rotary additive manufacturing machines.

Claim 1:
A system (<NUM>) to facilitate creation of an industrial asset item via a rotary additive manufacturing process wherein a build plate rotates about a vertical axis and moves, relative to a print arm, along the vertical axis during printing, comprising:
an industrial asset item definition data store (<NUM>, <NUM>) containing at least one electronic record defining the industrial asset item; and
a frame creation platform (<NUM>), coupled to the industrial asset item definition data store (<NUM>, <NUM>), including:
a communication port to receive data defining the industrial asset item, and
a frame creation computer processor (<NUM>) coupled to the communication port and adapted to:
slice the data defining the industrial asset item to create a series of two-dimensional, locally linear frames helically arranged as a spiral staircase (<NUM>) of steps, wherein each step is oriented normal to the vertical axis (<NUM>), and wherein a hatch angle associated with a frame of one revolution of the build plate is different than the hatch angle associated with a frame of another revolution of the build plate, or wherein the hatch angle is incremented within frames of a single revolution of the build frame, and
output indications of the series of two-dimensional frames to be provided to a rotary three-dimensional printer (<NUM>); wherein
the hatch angle associated with a frame is defined as the angle between a scan line and a centerline of that frame.