Method of forming an article

1. A method of forming an article from a computer software file representing the article, wherein the method comprises a layer-wise manufacturing process of fusing metal or polymer powder by applying a point source of heat to the powder in such a way as to create layers of the article one at a time, and includes:

(i) dividing the file into sub-files each representing at least a respective one of features of the article to be created, based on differences in characteristics of the features,

wherein the sub-files overlap such that respective parts of the sub-files each represent the same region in at least one of the layers of the article to be created;

(ii) correlating with each of the sub-files a value of a parameter of the manufacturing process in dependence on the characteristic of the feature represented by the sub-file; and

(iii) subsequently loading data of the correlated sub-files into a layer-wise manufacturing apparatus, and operating the apparatus to manufacture the article using the process controlled in accordance with the data of the correlated sub-files, wherein the parameter of the manufacturing process is varied in creating the layer and the process is performed on the same portion of the metal or polymer in accordance with data of each of the correlated sub-files during the course of forming the layer such that said region in the layer is processed more than once during the course of forming the layer and before the forming of a subsequent layer thereon has begun.

2. A method as claimed in claim 1 wherein the parameter is the value of an offset of the spot from a feature of the article to be created within the layer.

3. A method as claimed in claim 1 wherein the features are geometrical features.

4. A method as claimed in claim 1 wherein the sub-files are loaded into the layer-wise manufacturing apparatus as separate files.

5. A method as claimed in claim 1 wherein the sub-files are aggregated into a single file and the single file is loaded into the layer-wise manufacturing apparatus.

6. A method of forming an article in a manufacturing process from a computer software file representing the article wherein the article has a body and solid elements lying within openings in the body, respectively, and the method comprises a layer-wise manufacturing process of fusing metal or polymer powder by applying a point source of heat to the powder in such a way as to create layers of the article one at a time, and includes:

(i) creating a first sub-file representing the body of the article and a number of openings in the body having a dimension above a first predetermined value;

(ii) creating a second sub-file representing solid elements to lie within the openings such that final openings of the article have a dimension of a second predetermined value less than the first predetermined value,

wherein the first and second sub-files overlap such that part of the first sub-file and part of the second sub-file both represent the same region in at least one of the layers of the article to be created; and

(iii) subsequently loading data of the sub-files into a layer-wise manufacturing apparatus, and operating the apparatus to manufacture the article in accordance with the sub-files so that the process is performed on the same portion of the metal or polymer in accordance with data of each of the first and second sub-files during the course of forming the layer and before the forming of a subsequent layer thereon has begun such that the body and the elements are formed integrally in the layer.

7. A method of fabricating an article layer by layer from a computer software file representing the article, wherein the method comprises a layer-wise manufacturing process of fusing metal or polymer powder by applying a point source of heat to the powder in such a way as to create layers of the article one at a time; and includes:

(i) dividing the computer software file into surface geometry files each representing a respective layer of the article to be built using the manufacturing process;

(ii) manipulating at least one of the surface geometry files into sub-files that overlap such that parts of each of the sub-files represent the same portion of the article to be created within a region of the layer, and wherein each of the sub-files contain data of a value of a parameter of the manufacturing process, and the value of the parameter represented by the data contained in one of the sub-files differs from the value of the same parameter represented by the data contained in another of the sub-files;

(iii) manufacturing the article using the manufacturing process controlled in accordance with the data contained in the sub-files, wherein said portion of the article within the layer is formed by first applying the point source of heat to a portion of the metal or polymer powder according to the parameter represented by the data contained in one of the sub-files and subsequently applying the point source of heat to said portion of the metal or polymer powder according to the parameter represented by the data contained in another of the sub-files during the course of forming the layer and before the subsequent forming of a layer thereon has begun.

8. A method as claimed in claim 7 wherein the values of the parameter is the amount of offset of the spot from a location where said portion of the article is being created.

9. A method as claimed in claim 7 wherein said portion of the article is a geometrical feature.

10. A method as claimed in claim 7 , wherein the surface geometry files are Standard Tessellation Language (STL) files.