The present disclosure relates to additive manufacturing, and more particularly to powder management containers for managing metallic powders in additive manufacturing techniques.
Three-dimensional (3D) printers, like the ProX® DMP 300 series 3D printed part manufacturing system available from 3D Systems Inc. of Circle Rock Hill S.C., are commonly used to print articles by fusing metallic powder. Powder for a given build is typically provided to the system in lot-controlled jars, typically one liter in size, and introduced into the system indirectly, through the system airlock, or directly, by breaching the system by removing a panel. The article is printed from a portion of the powder and the residual powder captured for use in a subsequent build.
Indirect introduction entails sequentially moving jars through the airlock, opening the jars, and pouring the jar contents into a supply piston. Direct introduction bypasses the airlock but still requires that an operator sequentially open each jar and pour the jar contents into the system build chamber. While direct introduction can be relatively quick it can expose the jar contents and build chamber to the atmosphere, potentially contaminating the powder. Both indirect and direct powder introduction techniques can present ergonomic challenges for operators and neither alleviate the problem of uncontrolled lot mixing which can occur when residual powder from one build is recycled for use in a subsequent build.
Such conventional systems and techniques have generally been considered satisfactory for their intended purpose. However, there remains in the art a need for improved powder management containers. The present disclosure provides a solution for this need.
A powder management container includes a keg body having first and second ports. The keg body has an interior for storing a metallic powder. The first port is defined by the keg body and is fluidly coupled to the keg body interior for transferring metallic powder into and from the keg body interior. The second port is defined by the keg body and is fluidly coupled to the keg body interior for controlling the atmosphere within keg body interior.
In certain embodiments, the keg body can be a commodity-type keg body. The keg body can have a volume that is between about 1.32 gallons (5 liters) and about 15.5 gallons (60 liters). The keg body can have a wall thickness that is greater than thickness of a commodity-type beverage keg of substantially equivalent volume. The keg body can be formed from aluminum, an aluminum alloy, or stainless steel. The keg body can define backfill port, fluidly coupled to the keg body interior, the third port arranged on an end of the keg body opposite the first and second ports.
In accordance with certain embodiments, the first port can be centrally located on a first end of the keg body. The first port can have flow area with a width that is about 4 inches (10.2 centimeters). The first port can have a flow area that is greater than a flow area of the second port. A tri-clamp flange can be coupled to the keg body and in fluid communication with the keg body interior through the first port. The keg body can have a food-grade polished weld.
It is contemplated that the first port and the second port can be located on a first end of the keg body. A tri-clamp sanitary flange, a threaded fitting, or a Klein Flansche (KF) fitting can be coupled to the keg body and in fluid communication with the keg body interior through the second port. A third port can be defined by the keg body and fluidly coupled to the keg body interior. The third port can be offset from the first port. The third port can have a flow area that is smaller than a flow area of the first port. A tri-clamp sanitary flange, a threaded fitting, or a KF fitting can be coupled to the keg body and in fluid communication with the keg body interior through the third port.
A method of making a powder management container includes removing a Sankey valve seat (when present) from a keg body. A first port is coupled to the keg body and fluidly coupled to the keg body interior for transferring powder into and from the keg body interior. A second port is coupled to the keg body and fluidly coupled with the keg body interior for controlling the atmosphere in the keg body interior. A third port can be coupled to the keg body and placed in fluid communication with the keg body interior for controlling the atmosphere within the keg body interior. A backfill port can be coupled to the keg body and placed in fluid communication with the keg body interior for transferring powder from the keg body interior. Unused ports can be sealed off with a blank plate to maintain a sealed environment within the keg body.
A method of managing powder for an additive manufacturing technique includes coupling a first port of a powder management container to an additive manufacturing apparatus, coupling a second port of powder management container to a vacuum or inert gas source, and transferring powder into the interior of the keg body from the additive manufacturing apparatus. Atmosphere within the powder management container is controlled by drawing a vacuum or flowing an inert gas through the second port.
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 of the preferred embodiments 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, a partial view of an exemplary embodiment of a powder management container in accordance with the disclosure is shown in
Referring to
As shown in
With reference to
In certain embodiments powder 10 can be retained within interior 102 within an inert atmosphere 30. Inert atmosphere 30 can be provided by an inert gas source 18 disposed in fluid communication with interior 102 through a second port 106, inert gas source 18 providing an inert gas flow 20 through second port 106. Examples of suitable inert gases include nitrogen and argon, which tends to displace air due to relative density. As will be appreciated by those of skill in the art in view of the present disclosure, this separates humidity that may be present within the atmosphere 22 of powder management container 100 from powder 10.
In accordance with certain embodiments gas 24 from atmosphere 22 can be actively withdrawn from interior 102 as powder 10 is transferred to interior 102 of powder management container 100. In this respect a vacuum source 26 can be disposed in fluid communication with interior 102 through a third port 108, vacuum source 26 thereby withdrawing gas 24 from atmosphere 22 via third port 108 at a separate location from first port 104, powder 10 entering into interior 102 through first port 104. As will be appreciated by those of skill in the art in view of the present disclosure, this prevents humidity that may be present in atmosphere 22 from contacting powder 10 as powder 10 enters powder management container 100.
With reference to
In certain embodiments transfer of powder 10 from powder management container 100 can be assisted via fluid communication with the external environment. In this respect powder management container 100 can include a backfill port 116. Backfill port 116 is arranged on an end of powder management container 100 opposite an end defining first port 104 and second port 106. Backfill port 116 is configured for placing interior 102 in fluid communication with the external environment once powder management container 100 is inverted, gas from the external environment thereby flowing into interior 102 through backfill port 116. As will be appreciated by those of skill in the art, backfilling interior through backfill port 116 can simplify transfer of powder 10 from powder management container 100 as powder 10 is less likely to bridge within interior 102 of powder management container 100.
Referring to
To retain lot tracking capability unused powder portion 36 is transferred to second powder management container 114. This prevents powder from prior lots run through additive manufacturing apparatus 34 from intermixing with powder 10 and causes lot information 16 (shown in
It is contemplated that unused powder portion 36 can be transferred to interior 112 of second powder management container 114 under an inert atmosphere 110, inert atmosphere 110 established by inert gas 42 provided by inert gas source 18. It is also contemplated that gas 44 from within interior 112 can be withdrawn by vacuum source 26, thereby preventing humidity that may be present within gas 44 from contaminating unused powder portion 36 as unused powder portion 36 enters interior 112 as gas 44 exits interior 112.
With reference to
Keg body 118 defines first port 104. First port 104 is located on first end 120 of keg body 118, is fluidly coupled to keg body interior 102, and is configured for transferring powder 10 into and from interior 102 of keg body 118. More particularly, first port 104 is configured to receive powder 10 from one or more powder jars, e.g., jar 12 (shown in
Keg body 118 also defines second port 106. Second port 106 is located on first end 120 of keg body 118, is fluidly coupled to keg body interior 102, and is configured for controlling atmosphere 22 (shown in
Keg body 118 additionally defines third port 108. Third port 108 is located on first end 120 of keg body 118, is fluidly coupled to keg body interior 102, and is configured for controlling atmosphere 22 within keg body interior 102 in cooperation with second port 106. In particular, third port 108 is offset from first port 104. As above, being offset from first port 104, keg body interior 102 can be placed in fluid communication with vacuum source 26 or inert gas source 18 while the other of with a vacuum source 26 or inert gas source 18 is in fluid communication with keg body interior 102 without gas exiting from interior 112 contaminating powder 10 as it enters powder management container 100.
In certain embodiments keg body 118 conforms dimensionally to a standard beverage keg. Keg body 118 can be a commodity-type keg body, keg body 118 dimensionally conforming to US keg, DIN keg, or Euro keg standards prior to modification for power storage, e.g., below port 108 and port 106 as shown in
Dimensional conformity can be provided by modifying a commodity-type beverage keg. In this respect a first aperture can be created by removing a first portion of the keg body extending about the Sankey female-threaded portion of the keg, removing a second portion of the keg body offset from the first aperture, and removing a third portion of the keg body offset from the first aperture and laterally offset from the second aperture. The first port can then be welded to the keg body in the first port, the second port welded to the keg body in the second aperture, and the third port welded to the keg body in the third aperture. Welding the ports to the keg body can include defining food-grade polished welds in the keg body, food-grade polished weld preventing lot intermixing by preventing capture of powder in the weld as originally formed.
Also shown in
With reference to
First port 104 defines a flow area 126 with a width 128. Width 128 is greater than a width 130 of a flow area 132 defined by second port 106. Width 128 is also greater than a width 134 of a flow area 136 defined by third port 108. In certain embodiments width 128 is about four inches (10.2 centimeters). Widths of this size allow for metallic powders, e.g., powder 10 (shown in
As also shown in
Weld 146 is a food-grade polished weld. As will be appreciated by those of skill in the art in view of the present disclosure, food-grade polished welds resist capture of particulate, reducing the likelihood of intermixing powders from prior builds, potentially from other lots, into powder subsequently introduced into powder management container 100.
Tri-clamp flange 148 can be coupled to first port 104. Tri-clamp flange 148 is fluidly coupled to keg body 118 through first port 104. Tri-clamp flange 148 allows for connection of powder management container 100 to additive manufacturing apparatus 34 (shown in
In certain embodiments a second tri-clamp sanitary fitting 153, a threaded fitting 154, or a Klein Flansche (KF) fitting 156 can be coupled to keg body 118 at second port 106. More particularly, tri-clamp sanitary fitting 152, threaded fitting 154, or KF fitting 156 can be coupled to keg body 118 at second port 106 such that second port 106 fluidly couples tri-clamp sanitary fitting 152, threaded fitting 154, or KF fitting 156 to keg body interior 102 through second port 106. Use of tri-clamp sanitary fitting 152, threaded fitting 154, or KF fitting 156 simplifies connection of inert gas source 18 (shown in
In accordance with certain embodiments a tri-clamp sanitary fitting 158, a threaded fitting 160, or a KF fitting 162 can be coupled to keg body 118 at third port 108. More particularly, tri-clamp sanitary fitting 158, threaded fitting 160, or KF fitting 162 can be coupled to keg body 118 at third port 108 such that third port 108 fluidly couples tri-clamp sanitary fitting 158, threaded fitting 160, or KF fitting 162 to keg body interior 102 through third port 108. Use of tri-clamp sanitary fitting 158, threaded fitting 160, or KF fitting 162 simplifies connection of vacuum source 26 (shown in
With reference to
With reference to
The methods and systems of the present disclosure, as described above and shown in the drawings provide for powder management with superior properties including the capability to maintain the traceability of metallic powder lots to articles manufactured using the powder. While the apparatus and methods of the subject disclosure have been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure.