System and method for powder bed fusion additive manufacturing with dynamic roller rotational speed adjustment

Abstract

A powder bed fusion additive manufacturing system includes a build platform on which a substrate is supported, an energy generator configured to generate an energy beam directed at the substrate, a roller having an actuator system configured to rotate the roller, and a controller operably connected to the roller and to the energy generator. The controller is configured to produce a build object by rotating the roller at a first rotational speed to spread powder particles at a first porosity, operating the energy generator to selectively melt the powder particles to form a first layer of the build object, rotating the roller at a second rotational speed to spread powder particles at a second porosity, and operating the energy generator to selectively melt the powder particles spread at the second porosity to form a second layer. The first and second rotational speeds are different from one another.