Patent Application
20190118469
The present disclosure relates to additive manufacturing methods and systems.
Complex geometry created by conventional powder bed fusion additive manufacture is directional and can only use a single material.
Such conventional methods and systems have generally been considered satisfactory for their intended purpose. However, there is still a need in the art for improved additive manufacturing methods and systems. The present disclosure provides a solution for this need.
A method can include additively manufacturing a first portion of a part in a first build direction on a first build plate, removing the first portion of the part from the first build plate and inserting the first portion of the part on a second build plate that is configured to receive at least a portion of the first portion of the part. The method can also include additively manufacturing, in a second build direction relative to the first build direction, a second portion on the first portion of the part that is on the second build plate. In certain embodiments, the method can include removing the part from the second build plate.
Inserting the first portion in the second build plate can include aligning the first portion flushly with a surface of the second build plate. A division of the first portion and second portion can be preselected by a user such that the first build direction and second build direction allow building of both the first portion and the second portion without support structure.
The method can include removing the plurality of portions (e.g., the first and second portion or any other suitable number of portions), inserting the plurality of portions into an additional build plate, and additively manufacturing an additional portion of the part in an additional build direction. This can be repeated any suitable and/or desired number of times.
Additively manufacturing the first portion can include using a first material and additively manufacturing the second portion includes using a second material different from the first material. The method can include removing the plurality of portions, inserting the plurality of portions into an additional build plate, and additively manufacturing an additional portion of the part in an additional build direction, such that the additional portion includes an additional material different from the first material and/or the second material. This can be repeated any suitable and/or desired number of times.
A build plate for an additive manufacturing machine can include a build plate body defining a part portion recess that can be configured to receive a portion of a part and to allow additive manufacturing of a second portion of a part on the first portion of the part. The build plate body can be configured to be used as a build surface for an additive manufacturing machine.
In certain embodiments, the part portion recess can include a plurality of apertures defined in the body. In certain embodiments, the part portion recess can include an open volume equal to or greater than a volume of the first portion such that the first portion fits entirely within the part portion recess. For example, the part portion recess can be defined such that the first portion aligns flushly with a build surface of the build plate (e.g., for a roller recoater type system).
The body can be configured to attach to an additive manufacturing build plate as a fixture plate. In certain embodiments, the body can be configured to replace a build plate of an additive manufacturing machine.
The additive manufacturing machine can be any suitable type of additive manufacturing machine (e.g., a powder bed fusion system having a roller recoater). The part can be any suitable part (e.g., a part for an aerospace application).
These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description taken in conjunction with the drawings.
So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, embodiments thereof will be described in detail herein below with reference to certain figures, wherein:
Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, an illustrative view of an embodiment of a method and a system in accordance with the disclosure is shown in
Referring to
Referring to
Inserting the first portion 101 in the second build plate 107 can include aligning the first portion 101 flushly with a surface of the second build plate 107.
Referring to
The method can include removing the plurality of portions (e.g., the first and second portion 101, 109 or any other suitable number of portions), inserting the plurality of portions into an additional build plate (e.g., configured to receive at least a portion of the plurality of portions therein), and additively manufacturing an additional portion of the part in an additional build direction (e.g., the same or different from the first and/or second build direction, and/or any other additional build direction). This can be repeated any suitable and/or desired number of times.
Additively manufacturing the first portion 101 can include using a first material (e.g., any suitable material) and additively manufacturing the second portion can include using a second material (e.g., any suitable material) different from the first material. The method can include removing the plurality of portions, inserting the plurality of portions into an additional build plate, and additively manufacturing an additional portion of the part in an additional build direction, such that the additional portion includes an additional material different from the first material and/or the second material. This can be repeated any suitable and/or desired number of times.
Referring to
As appreciated by those having ordinary skill in the art, the two or more portions 101 and 109 can be combined and/or attached to one another in any suitable manner. For example, in powder bed fusion systems, the act of sintering the powder together can cause the second portion 109 to weld to the first portion 101. In certain embodiments, alternatively or additionally, the one or more portions 101, 109 can be physically linked together based on their geometries being intertwined without the necessity to be welded together. Additionally, or alternatively, any other suitable connection (e.g., adherence with a suitable binding agent) is contemplated herein.
In accordance with at least one aspect of this disclosure, referring to
In certain embodiments, the part portion recess 115 can include a plurality of apertures 117a, 117b defined in the body 113. In certain embodiments, the part portion recess 115 can include an open volume equal to or greater than a volume of the first portion such that the first portion fits entirely within the part portion recess 115. In certain embodiments, any suitable apertures can be defined in the second build plate 107 such that the first portion 101 is caused to be oriented in a particular manner due to the orientation of the apertures in the recess 115. For example, the apertures 117b as shown in
The part portion recess 115 can be defined such that the first portion aligns flushly with a build surface of the build plate 107 (e.g., for a roller recoater type system). This can allow a roller type recoater system to coat the build plate properly for continued additive manufacture, for example.
The additive manufacturing machine can be any suitable type of additive manufacturing machine (e.g., a powder bed fusion system having a roller recoater). The part can be any suitable part (e.g., a part for an aerospace application). For example, as shown the part includes a complex inner network of channels and can be used in a fuel nozzle.
Embodiments as described above include a method for constructing components where the initial shape is additively manufactured, removed from the build plate, inverted or otherwise reoriented, and a second additive build can be used to complete the component/add more to the component. In accordance with certain embodiments, the features selected to be built for the first build direction can be based on geometry (e.g., to prevent overhang and use of support structure) and/or material properties. A standard first build plate can be used, then the component is removed from initial build plate. A second build plate can include any suitable recess to accept the first portion in the reoriented position and can cause the portion to align to second build plate. Then, additive material can be added to the surface of the first portion. The material may be changed to allow for an AM part have two or more different materials. Each selected build direction can allow geometry to be optimized for each build direction (e.g., to minimize or eliminate overhangs).
Embodiments allow for additional part complexity, simplified or eliminated post processing, and the ability to construct an additive component from two different materials. As appreciated by those having ordinary skill in the art, the inverted component can allow for geometry to be manufactured with one or more overhangs eliminated during manufacture.
The methods and systems of the present disclosure, as described above and shown in the drawings, provide for improved additive manufacturing systems and methods. While the apparatus and methods of the subject disclosure have been shown and described with reference to embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the spirit and scope of the subject disclosure.
