阅读说明：本技术 增材制造系统和方法 (Additive manufacturing system and method ) 是由 K·T·斯莱特瑞 于 2019-07-04 设计创作，主要内容包括：本发明涉及增材制造系统和方法。增材制造系统(100)和方法包括：粉末床(110、136)；增材制造头(116),其被配置为将第一能量(151、154)发射到粉末床(110、136)中以形成部件(114)的至少一个层(128、130)；零件暴露机构(112),其被配置为操作使得部件(114)在粉末床(110,136)内在第一时间处于第一位置以及在第二时间处于第二位置,在所述第二位置部件(114)的一部分(132)暴露于粉末床(110、136)的外部；和表面平滑头(120),其被配置为在第二位置中将第二能量(151、154)发射到部件(114)的部分(132)上,以使部件(114)的部分(132)平滑。(The invention relates to an additive manufacturing system and a method. An additive manufacturing system (100) and method includes: a powder bed (110, 136); an additive manufacturing head (116) configured to emit first energy (151, 154) into a powder bed (110, 136) to form at least one layer (128, 130) of a component (114); a part exposure mechanism (112) configured to operate such that a part (114) is in a first position at a first time within a powder bed (110, 136) and in a second position at a second time, a portion (132) of the part (114) being exposed to an exterior of the powder bed (110, 136); and a surface smoothing head (120) configured to emit second energy (151, 154) onto the portion (132) of the component (114) in the second position to smooth the portion (132) of the component (114).)

1. An additive manufacturing system (100), comprising:

a powder bed (110, 136);

an additive manufacturing head (116) configured to emit first energy (151, 154) into the powder bed (110, 136) to form at least one layer (128, 130) of a component (114);

a part exposure mechanism (112) configured to operate such that the component (114) is in a first position at a first time within the powder bed (110, 136) and in a second position at a second time in which a portion (132) of the component (114) is exposed to an exterior of the powder bed (110, 136); and

a surface smoothing head (120) configured to emit second energy (151, 154) onto the portion (132) of the component (114) in the second position to smooth the portion (132) of the component (114).

2. The additive manufacturing system (100) of claim 1, further comprising a container (102) defining a forming chamber (108), and wherein the part exposure mechanism (112) is on or within the container (102).

3. The additive manufacturing system (100) of claim 1 or 2, wherein the additive manufacturing head (116) is configured to emit the first energy (151, 154) as one or more laser beams.

4. The additive manufacturing system (100) according to claim 1 or 2, wherein the surface smoothing head (120) is configured to emit the second energy (151, 154) as one or more laser beams.

5. The additive manufacturing system (100) according to claim 1 or 2, wherein the first energy (151, 154) and the second energy (151, 154) are the same type of energy (151, 154), or wherein the first energy (151, 154) and the second energy (151, 154) are different types of energy (151, 154).

6. The additive manufacturing system (100) of claim 1 or 2, wherein the surface smoothing head (120) is coupled to the additive manufacturing head (116) or is movably coupled to the additive manufacturing head (116).

7. The additive manufacturing system (100) of claim 1 or 2, further comprising a molding control unit (124) in communication with the additive manufacturing head (116), the part exposure mechanism (112), and the surface smoothing head (120), wherein the molding control unit (124) is configured to operate the additive manufacturing head (116), the part exposure mechanism (112), and the surface smoothing head (120).

8. The additive manufacturing system (100) of claim 1 or 2, wherein the part exposure mechanism (112) comprises an actuation assembly (135), the actuation assembly (135) being configured to move the component (114) upward into the second position such that the portion (132) of the component (114) extends upward beyond a top surface (134, 142) of the powder bed (110, 136).

9. The additive manufacturing system (100) of claim 8, wherein the actuation assembly (135) comprises a forming bed (136) that supports the component (114), and an actuator (138, 150) operably coupled to the forming bed (136).

10. The additive manufacturing system (100) of claim 1 or 2, wherein the part exposure mechanism (112) comprises an ejection assembly (144) configured to be selectively moved between a closed position and an open position, wherein at least a first portion (132) of powder is ejected through the ejection assembly (144) in the open position to expose the portion (132) of the component (114) in the second position.

11. The additive manufacturing system (100) of claim 10, wherein the discharge assembly (144) comprises a movable cover (146) (146), the movable cover (146) proximate an outlet (148) formed by a container (102) holding the powder bed (110, 136), wherein the movable cover (146) is configured to close the outlet (148) in the closed position and move away from the outlet (148) to open the outlet (148) in the open position, and wherein at least some of the powder bed (110) (136) is discharged from the outlet (148) when the movable cover (146) is in the open position.

12. A method of additive manufacturing, comprising:

emitting first energy (151, 154) from an additive manufacturing head (116) into a powder bed (110) (136) to form at least one layer (128, 130) of a part (114);

operating a part exposure mechanism (112) such that the part (114) is in a first position at a first time within the powder bed (110, 136) and in a second position at a second time in which a portion (132) of the part (114) is exposed to the exterior of the powder bed (110, 136); and

emitting second energy (151, 154) from a surface smoothing head (120) onto the portion (132) of the component (114) at the second location to smooth the portion (132) of the component (114).

13. The additive manufacturing method of claim 12, wherein the operation comprises using an actuation assembly (135) that moves the component (114) upward into the second position such that the portion (132) of the component (114) extends upward beyond a top surface (134, 142) of the powder bed (110, 136).

14. The additive manufacturing method of claim 12 or 13, wherein the operations further comprise supporting the component (114) on a forming bed (136), the forming bed (136) operably coupled to an actuator (138, 150).

15. The additive manufacturing method of claim 12 or 13, wherein the operations comprise selectively moving a discharge assembly (144) between a closed position and an open position, wherein at least a first portion (132) of powder of the powder bed (110, 136) is discharged through the discharge assembly (144) in the open position to expose the portion (132) of the component (114) in the second position, and wherein the operations further comprise:

closing an outlet (148) through a receptacle (102) with a movable lid (146) in the closed position, the receptacle (102) holding the powder bed (110) (136); and

moving the movable lid (146) away from the outlet (148) in the open position to open the outlet (148), wherein at least a first portion (132) of powder is discharged from the outlet (148) when the movable lid (146) is in the open position.

Technical Field

Examples of the present disclosure relate generally to additive manufacturing systems and methods, and more particularly, to systems and methods of smoothing powder bed melting (additive manufacturing) components.

Background

Additive manufacturing systems and methods are used to manufacture a component (e.g., part or product) from a multi-layer material. For example, known additive manufacturing systems and methods form a part by adding material layer by layer. Additive manufacturing systems and methods may include or otherwise use three-dimensional (3D) modeling (e.g., computer-aided design or CAD) software, computer-controlled additive manufacturing equipment, and raw materials in powder or liquid form.

Additive manufacturing encompasses a wide variety of processes and incorporates a wide variety of technologies such as, for example, laser free form manufacturing (LFM), Laser Deposition (LD), Direct Metal Deposition (DMD), laser metal deposition, laser additive manufacturing, Laser Engineered Net Shaping (LENS), Stereolithography (SLA), Selective Laser Sintering (SLS), Fused Deposition Modeling (FDM), Multiple Jet Modeling (MJM), 3D printing, rapid prototyping, direct digital manufacturing, layered manufacturing, and additive manufacturing. In addition, various raw materials can be used in additive manufacturing to produce a product. Examples of such materials include plastic, metal, concrete, and glass.

One example of an additive manufacturing system is a laser additive manufacturing system. Laser additive manufacturing involves spraying or otherwise injecting a powder or liquid under controlled atmospheric conditions into a focused beam of high power laser or into associated portions (nexus) of multiple high power lasers to form a melt pool. The resulting deposit can then be used to build or repair articles for a wide variety of applications. The powder injected into the high power laser beam may comprise a variety of materials, such as metals, plastics, and/or the like.

Articles formed by additive manufacturing may require surface treatment to provide a more desirable product. One example of surface treatment includes smoothing or otherwise reducing the roughness of the product surface. Surfaces produced by known additive manufacturing systems and methods may have a rough surface finish, for example, approximately 600-_aOf the order of magnitude. Such a rough surface may have several adverse effects. For example, due to stresses typically associated with high surface roughnessIncreasingly, components with rough surface finishes have limited application in cyclic loading environments. Furthermore, rough surfaces may prevent the use of cost-effective non-destructive inspection systems, as rough surface treatments generate high levels of noise in such systems. When used with parts having relatively smooth surfaces, non-destructive inspection methods are widely recognized as cost-effective and accurate tools for identifying structural defects in these parts.

To improve the surface finish of components manufactured with additive manufacturing equipment, a separate post-processing step is typically performed at the machining location using conventional surface finishing equipment and techniques. However, due to the complexity of certain parts, post-processing of the surface can be cumbersome, expensive, and time consuming. In addition, conventional post-treatment surface finishing methods may be ineffective at reducing the surface roughness of the interior surfaces of some complex parts, resulting in products with less than desirable properties.

Certain additive manufacturing methods include forming a part having a powder bed of a material, such as metal, plastic, and/or the like. Typically, the parts are formed within a powder bed. Therefore, certain known smoothing systems and methods cannot be used because the surrounding material of the powder bed blocks the operating area of the surface treatment device. That is, the smoothing laser cannot emit energy onto the portion to be smoothed because a portion of the part is embedded or otherwise covered by the powder bed.

Disclosure of Invention

There is a need for an additive manufacturing system and method that allows for effective smoothing of portions of a component. Further, there is a need for an additive manufacturing system and method configured to expose at least a portion of a component to be smoothed.

In view of these needs, certain examples of the present disclosure provide an additive manufacturing system comprising: a powder bed; an additive manufacturing head configured to emit first energy into the powder bed to form at least one layer of a part; a part exposure mechanism configured to operate such that the part is in a first position at a first time within the powder bed and in a second position at a second time where a portion of the part is exposed to an exterior of the powder bed; and a surface smoothing head configured to emit a second energy onto the portion of the component to smooth the portion of the component in the second position.

In at least one example, the container defines a forming chamber. The part exposure mechanism may be on or in the container.

The additive manufacturing head may be fixed in position. Optionally, the additive manufacturing head may be movable. In at least one example, the additive manufacturing head is configured to emit the first energy as one or more laser beams.

The surface smoothing head may be fixed in position. Optionally, the surface smoothing head may be movable. In at least one example, the surface smoothing head is configured to emit the second energy as one or more laser beams.

The first energy and the second energy may be the same type of energy (such as a laser beam). Alternatively, the first energy and the second energy may be different types of energy.

The surface smoothing head may be coupled to the additive manufacturing head. In at least one example, the surface smoothing head may be movably coupled to the additive manufacturing head.

A molding control unit may be in communication with the additive manufacturing head, the part exposure mechanism, and the surface smoothing head. The molding control unit may be configured to control the additive manufacturing head, the part exposure mechanism, and the surface smoothing head.

In at least one example, the part exposure mechanism includes an actuation assembly configured to move the component upward into the second position such that the portion of the component extends upward beyond a top surface of the powder bed. The actuation assembly may include a shaping bed that supports the component, and an actuator operably coupled to the shaping bed. The actuation assembly may also include a motor operably coupled to the actuator.

In at least one example, the part exposure mechanism includes an ejection assembly configured to selectively move between a closed position and an open position in which at least a first portion of powder is ejected by the ejection assembly to expose the portion of the component in the second position. The discharge assembly may include a movable cover proximate an outlet formed through a receptacle holding the powder bed. The movable cover closes the outlet in the closed position and moves away from the outlet in the open position to open the outlet. At least some of the powder bed is discharged from the outlet when the movable cover is in the open position.

Certain examples of the present disclosure provide an additive manufacturing method, comprising: emitting a first energy into the powder bed from the additive manufacturing head to form at least one layer of the part; operating a part exposure mechanism such that the part is in a first position at a first time within the powder bed and in a second position at a second time in which a portion of the part is exposed to the exterior of the powder bed; and in the second position, injecting a second energy from the surface smoothing hair onto the portion of the component to smooth the portion of the component.

Drawings

Fig. 1 shows a schematic view of an additive manufacturing system according to an example of the present disclosure.

Fig. 2 shows a schematic view of a part exposure mechanism according to an example of the present disclosure.

Fig. 3 shows a schematic view of a part exposure mechanism according to an example of the present disclosure.

Fig. 4 shows a schematic diagram of an additive manufacturing system in a layer forming state, according to an example of the present disclosure.

Fig. 5 shows a schematic of an additive manufacturing system in a component smooth state according to an example of the present disclosure.

Fig. 6 shows a schematic diagram of an additive manufacturing system in a layer forming state, according to an example of the present disclosure.

Fig. 7 shows a schematic of an additive manufacturing system in a component smooth state according to an example of the present disclosure.

Fig. 8 shows a schematic view of an additive manufacturing head secured to a structure according to an example of the present disclosure.

Fig. 9 shows a schematic view of an additive manufacturing head secured to a mounting assembly according to an example of the present disclosure.

Fig. 10 shows a schematic view of an additive manufacturing head secured to a rail according to an example of the present disclosure.

Fig. 11 shows a schematic view of an additive manufacturing head secured to an articulated arm according to an example of the present disclosure.

Fig. 12 shows a schematic view of a surface treating head secured to a structure according to an example of the present disclosure.

Fig. 13 shows a schematic view of a surface treating head secured to a mounting assembly according to an example of the present disclosure.

Fig. 14 shows a schematic view of a surface treating head secured to a rail according to an example of the present disclosure.

Fig. 15 shows a schematic view of a surface treatment head secured to an articulated arm according to an example of the present disclosure.

Fig. 16 shows a schematic view of a surface treatment head coupled to an additive manufacturing head according to an example of the present disclosure.

Fig. 17 shows a flow diagram of an additive manufacturing method according to an example of the present disclosure.

Detailed Description

The foregoing summary, as well as the following detailed description of certain examples, will be better understood when read in conjunction with the appended drawings. As used herein, an element or step in the singular and proceeded with the word "a" or "an" should be understood as not necessarily excluding plural elements or steps. Furthermore, references to "one example" are not intended to be interpreted as excluding the existence of additional examples that also incorporate the recited features. Furthermore, unless explicitly stated to the contrary, examples of an element or elements that "comprise" or "have" a particular condition may include additional elements that do not have that condition.

Certain examples of the present disclosure provide an additive manufacturing system and method that includes a part exposure mechanism configured to expose a portion of a component formed within a powder bed through additive manufacturing. In at least one example, the part exposure mechanism includes an actuation assembly that moves at least a portion of the part out of the powder bed after the additive manufacturing head forms at least one layer of the part. In at least one other example, the part exposure mechanism includes an ejection assembly configured to eject at least a portion of the powder bed out of the forming chamber, thereby exposing at least a portion of the part. When the portion(s) of the component are exposed above the surface of the powder bed, the surface treatment head is operated to smooth the portion(s), for example by melting the rough surface of the portion(s).

Certain examples of the present disclosure provide an additive manufacturing system that includes an additive manufacturing head (such as an apparatus for selectively laser sintering new material layers on existing material layers), and a surface treatment head that may be coupled to the additive manufacturing head for selective laser sintering. The surface treatment device includes a laser emitting device configured to emit a laser beam that smoothes an adjacent surface of at least one of the new material layer and the existing material layer.

Certain examples of the present disclosure provide a method of additively manufacturing a component. The method includes melting a first layer of powder to produce a build portion and a metal powder, separating the build portion from an unused powder, emitting a laser beam (e.g., energy emitted from a laser emitting device) to smooth the build portion to produce a smoothed build portion, positioning the smoothed build portion within the unused powder, and sintering a second layer of metal powder onto the smoothed build portion.

Fig. 1 shows a schematic diagram of an additive manufacturing system 100 according to an example of the present disclosure. Additive manufacturing system 100 includes a container 102, container 102 including a base 104 and a wall 106 upstanding from base 104. The base 104 and the wall 106 define a forming chamber 108. The forming chamber 108 holds a powder bed 110, such as a powder bed 110 formed of metal, polymer, or other such material.

The part exposure mechanism 112 is positioned on the container 102 and/or within the container 102, such as within the forming chamber 108. The part exposure mechanism 112 provides a powder bed management system configured to expose at least a portion of the component 114 during an additive manufacturing process that forms one or more layers of the component 114.

The additive manufacturing head 116 is fixed in position or movable relative to the forming chamber 108. The additive manufacturing head 116 includes an energy emitter 118. In at least one example, the additive manufacturing head 116 is a laser scanner that emits one or more laser beams through the energy emitter 118, and the energy emitter 118 may be a laser output, an array, and/or the like. Alternatively, the additive manufacturing head 116 may be an electron beam scanner that emits one or more electron beams through the energy emitter 118, which may be an electron beam output, array, and/or the like. As another example, the additive manufacturing head 116 may be an arc scanner that emits arc energy through the energy emitter 118, which may be an arc output, an array, and/or the like. An example of an additive manufacturing head is disclosed in U.S. patent No.9.751,260 entitled "additive manufacturing Systems, apparatus, and Methods" (the "260 patent"). The 260 patent is hereby incorporated by reference in its entirety.

Additive manufacturing head 116 is configured to emit energy (e.g., one or more laser beams) into powder bed 110 to form a layer of component 114. For example, the additive manufacturing head 116 is configured to selectively laser sinter a material layer of the powder bed 110 onto an existing material layer to form the component 114.

The surface smoothing head 120 is fixed in position or movable relative to the forming chamber 108. The surface smoothing head 120 provides a smoothing device (smoothing device) configured to smooth portions of the component 114 after one or more layers of the component 114 are formed by operation of the additive manufacturing head 116. The surface smoothing head 120 includes an energy emitter 122. The surface smoothing head 120 may be configured to emit the same type of energy as the additive manufacturing head 116. For example, the additive manufacturing head 116 may be configured to emit a first energy into the powder bed 110 to form a layer of the part 114, while the surface smoothing head 120 is configured to emit a second energy onto exposed portions of the part 114 to smooth the exposed portions. The first energy and the second energy may be the same type of energy. In at least one other example, the first energy and the second energy may be different types of energy. For example, the first energy may be a laser beam and the second energy may be an electron beam.

In at least one example, the surface smoothing head 120 is a laser emitter that emits one or more laser beams via an energy emitter 122. Alternatively, the surface smoothing head 120 may be an electron beam scanner that emits one or more electron beams through the energy emitter 122. As another example, the surface smoothing head 120 may be configured to emit arc energy through the energy emitter 122. In at least one example, the surface smoothing head 120 can be the same as or similar to the surface treatment apparatus described in the' 260 patent.

Additive manufacturing head 116 may be coupled to surface smoothing head 120. For example, the surface smoothing head 120 may be movably coupled to the additive manufacturing head 116, such as by an articulated arm(s), carriage, gantry, rail, bracket, and/or the like. In at least one other example, the surface smoothing head 120 is not directly coupled to the additive manufacturing head 116.

In at least one example, additive manufacturing system 100 includes a forming control unit 124, and forming control unit 124 may be configured to control (e.g., operate) additive manufacturing system 100. The molding control unit 124 may be in communication with the part exposure mechanism 112, the additive manufacturing head 116, and the surface smoothing head 120, such as through one or more wired or wireless connections. The molding control unit 124 may be configured to operate the additive manufacturing system 100 through preprogrammed instructions stored in memory.

In operation, the additive manufacturing head 116 emits energy (e.g., one or more laser beams) into the powder bed 110 to form the layer 128 of the part 114. For example, the additive manufacturing head 116 selectively laser sinters a layer 128 from the material within the powder bed 110 onto an existing layer 130 of the component 114. The forming control unit 124 may control the additive manufacturing head 116 during the forming process.

After the layer 128 of the part 114 has been formed by the additive manufacturing head 116 emitting energy into the powder bed 110, the part exposure mechanism 112 is operated to expose at least a portion 132 of the part 114 out of the powder bed 110. Portion 132 may be an edge of member 114. Portion 132 may be one half or more of component 114. In at least one other example, the portion 132 may be an integral part of the component. In at least one example, the forming control unit 124 operates the part exposure mechanism 112 to expose the portion(s) 132 of the part 114 out of the powder bed 110. The portion(s) 132 may be the layer 128 (or at least a portion thereof) previously formed by the additive manufacturing head 116 emitting energy into the powder bed 110.

After the portion(s) 132 are exposed outside of the powder bed 110, the surface smoothing head 120 may be operated to melt rough surface portions of the portion(s) 132, which may include portions of the layer 128, the existing layer 130, and/or various other portions of the component 114. For example, the shaping control unit 124 may control operation of the surface smoothing head 120 to emit energy (e.g., a laser beam) to smooth the portion(s) 132 outside of the powder bed 110. After the portion(s) 132 are smoothed by the surface smoothing head 120, the part exposure mechanism 112 is operated to move the part 114 back into the powder bed 110 so that the part 114 is submerged or otherwise covered therein. In at least one example, additional material may be added to the powder bed 110 to immerse the component 114 therein. When the part 114 is submerged within the powder bed 110 or otherwise covered by the powder bed 110, the process may be repeated such that the additive manufacturing head 116 emits energy into the powder bed 110 to form another layer on the layer 128, followed by operation of the part exposure mechanism 112 to expose at least a portion of the part 114 smoothed by the surface smoothing head 120. This process continues to repeat until all layers of the component 114 are formed and all portions to be smoothed by the surface smoothing head 120 are smoothed.

As described, examples of the present disclosure provide an additive manufacturing system 100, comprising: a powder bed 110; an additive manufacturing head 116 configured to emit first energy (e.g., one or more laser beams) into the powder bed 110 to form at least one layer 128 of the component 114; a part exposure mechanism 112 configured to operate such that the part 114 is in a first position (e.g., a covered or submerged position) within the powder bed 110 at a first time, and in a second position (e.g., after the first time) at which a portion 132 of the part 114 is exposed to an exterior of the powder bed 110; a surface smoothing head 120 configured to emit a second energy (e.g., one or more laser beams) onto the portion 132 of the component 114 in a second position to smooth the portion 132 of the component 114.

In at least one example, the part exposure mechanism 112 is or includes an actuation assembly that moves the member 114 upward within the forming chamber 108 such that the portion(s) 132 are exposed above the top surface 134 of the powder bed 110. In at least one other example, the part exposure mechanism 112 is or includes an evacuation assembly configured to be selectively closed and opened. In the open position, a portion of the powder bed 110 is discharged from the forming chamber 108 until the portion 132 is exposed above the top surface 134.

As used herein, the terms "control unit," "central processing unit," "CPU," "computer," and the like may include any processor-based or microprocessor-based system comprising: systems using microcontrollers, Reduced Instruction Set Computers (RISC), Application Specific Integrated Circuits (ASIC), logic circuits, and any other circuit or processor including hardware, software, or a combination thereof, capable of executing the functions described herein. These are exemplary only, and thus are not intended to limit the definition and/or meaning of these terms in any way. For example, the forming control unit 124 may be or include one or more processors configured to control the operation of the additive manufacturing system 100, as described herein.

The molding control unit 124 is configured to execute a set of instructions stored in one or more data storage units or elements (e.g., one or more memories) in order to process the data. For example, the molding control unit 124 may include or be coupled to one or more memories. The data storage unit may also store data or other information as desired or needed. The data storage elements may be in the form of information sources or physical memory elements within the processing machine.

The set of instructions may include various commands that instruct the forming control unit 124 as a processing machine to perform specific operations, such as the methods and processes of the various examples of the subject matter described herein. The set of instructions may be in the form of a software program. The software may be in various forms, such as system software or application software. Further, the software may be in the form of a collection of separate programs, a subset of programs within a larger program, or a portion of a program. The software may also include modular programming in the form of object-oriented programming. The processing of input data by a processing machine may be in response to a user command, or in response to the results of a previous process, or in response to a request made by another processing machine.

The illustrations exemplified herein may show one or more control or processing units, such as the forming control unit 124. It should be understood that the processing or control unit may represent circuitry, or portions thereof, which may be implemented as hardware having associated instructions (e.g., software stored on a tangible and non-transitory computer readable storage medium, such as a computer hard drive, ROM, RAM, etc.) that perform the operations described herein. The hardware may include hardwired state machine circuitry to perform the functions described herein. Alternatively, the hardware may comprise electronic circuitry that includes and/or is coupled to one or more logic-based devices, such as microprocessors, processors, controllers, and the like. Alternatively, the profiling control unit 124 may represent processing circuitry, such as one or more of a Field Programmable Gate Array (FPGA), an Application Specific Integrated Circuit (ASIC), microprocessor(s), and/or the like. The circuitry in various examples may be configured to execute one or more algorithms to perform the functions described herein. One or more algorithms may include aspects of the examples disclosed herein, whether or not explicitly identified in a flowchart or a method.

As used herein, the terms "software" and "firmware" are interchangeable, and include any computer program stored in a data storage unit (e.g., one or more memories) for execution by a computer, including RAM memory, ROM memory, EPROM memory, EEPROM memory, and non-volatile RAM (nvram) memory. The above data storage unit types are exemplary only, and are thus not limiting as to the types of memory usable for storage of a computer program.

Fig. 2 shows a schematic view of a part exposure mechanism 112 according to an example of the present disclosure. In this example, the part exposure mechanism 112 is an actuation assembly 135, the actuation assembly 135 including a forming bed 136 and an actuator 138 operably coupled to the forming bed 136. A motor 140 is operably coupled to the actuator 138.

Referring to fig. 1 and 2, the part 114 is supported on the top surface 142 of the forming bed 136. The actuator 138 may be or include one or more electric, pneumatic, hydraulic, and/or the like pistons, cams, lift brackets, and/or the like that are moved by a motor 140. The motor 140 is activated to move the actuator 138 and selectively raise and lower the forming bed 136, and thus the component 114, up and down relative to the powder bed 110. Alternatively, the actuator 138 may include an integral motor or other form of powered actuation rather than being coupled to a separate and distinct motor. The molding control unit 124 may be in communication with the motor 140, such as through one or more wired or wireless connections, to control operation of the part exposure mechanism 112. In at least one other example, the actuation assembly may include a vibration device or the like configured to shake the powder bed material off the member 114.

Fig. 3 shows a schematic view of a part exposure mechanism 112 according to an example of the present disclosure. In this example, the part exposure mechanism 112 is a drain assembly 144 coupled to a portion of the container 102. For example, the drain assembly 144 may be secured to the base 104 of the container 102. In at least one other example, the discharge assembly 144 can be secured to the wall 106 of the container 102 (shown in fig. 1) below the top surface 134 of the powder bed 110.

The drain assembly 144 includes a removable cap 146 proximate an outlet 148 (e.g., an opening) formed through the container 102. The cover 146 is movably coupled to an actuator 150 (e.g., a movable hinge, post, or the like). In the closed position, the cover 146 closes the outlet 148. For example, in the closed position, the cover 146 may be positioned below, above, or within the outlet 148 to prevent material from being discharged from the outlet 148. In the open position, the actuator 150 moves the cover 146 away from the outlet 148, thereby allowing material to be discharged from the outlet 148. The form control unit 124 may be in communication with the actuator 150, such as through one or more wired or wireless connections, to control operation of the part exposure mechanism 112.

Fig. 4 shows a schematic diagram of an additive manufacturing system 100 in a layer forming state according to an example of the present disclosure. As shown, the part 114 is supported on a forming bed 136 (e.g., a plate) within the forming chamber 108. In the layer formation state, the part exposure mechanism 112 is in a first position in which the actuator 138 is retracted. In the layer forming state, the part 114 is submerged within the powder bed 110 or otherwise covered by the powder bed 110. No portion of the feature 114 is exposed above the top surface 134 during the layer formation stage.

During the layer forming state, the additive manufacturing head 116 emits energy 151 (e.g., one or more laser beams) into the powder bed 110 to form a layer of the component 114, as described herein. During the layer formation state, the surface smoothing head 120 is located outside the energy emitting envelope 152 of the additive manufacturing head 116. After the energy 151 is emitted into the powder bed 110 by the additive manufacturing head 116 to form the desired layer of the part 114, the part exposure mechanism 112 is operated to move the portion 132 of the part 114 over the top surface 134 of the powder bed 110.

Fig. 5 shows a schematic of an additive manufacturing system 100 in a component smoothing state according to an example of the present disclosure. As shown, in the part smoothing state, the part exposure mechanism 112 is in a second position in which the actuator 138 is extended to move the part 114 upward through the powder bed 110. In the part smoothing state, the additive manufacturing head 116 is deactivated and the actuator 138 is moved to push the portion(s) 132 above the top surface 134 of the powder bed 110. As such, the surface smoothing head 120 may then be moved to a desired position to emit focused energy 154 (e.g., a focused laser beam) onto the portion(s) 132 of the component 114 to melt and thereby smooth the portion(s) 132. As the part exposure mechanism 112 moves the part 114 upward within the forming chamber 108, excess powder 156 may overflow the forming chamber 108. Excess powder 156 may be deposited back into the forming chamber 108.

Fig. 6 shows a schematic of an additive manufacturing system 100 in a layer forming state according to an example of the present disclosure. In the layer forming state, the discharge assembly 144 is in a first position, e.g., a closed position, to ensure that the material within the powder bed 110 remains in the forming chamber.

Fig. 7 shows a schematic of an additive manufacturing system 100 in a component smoothing state according to an example of the present disclosure. In the part smoothing condition, the discharge assembly 144 moves to a second position, e.g., an open position, allowing the unused portion 160 of the powder bed 110 to discharge out of the forming chamber 108. When the unused portion 160 exits the forming chamber 108, the portion(s) 132 of the member 114 are exposed above the top surface 134 of the powder bed 110 within the forming chamber 108. Portion(s) 132 may then be smoothed by surface smoothing head 120, as described herein.

Alternatively, the examples shown in fig. 4-7 may be combined into a single example. For example, the additive manufacturing system 100 may include an actuation system that may include the actuator 138 shown in fig. 4 and 5, and the exhaust assembly 144 shown in fig. 6 and 7.

Fig. 8 shows a schematic view of an additive manufacturing head 116 secured to a structure 170 according to an example of the present disclosure. Referring to fig. 1 and 8, the additive manufacturing head 116 may be located in a fixed position above the powder bed 110. For example, the additive manufacturing head 116 may be securely mounted to the structure 170 (e.g., via fasteners, one or more intermediate structures, adhesives, and/or the like). The structure 170 may be a wall, ceiling, or the like.

Fig. 9 shows a schematic view of an additive manufacturing head 116 secured to a mounting assembly 172 according to an example of the present disclosure. The mounting assembly 172 includes a base 174 and a mounting arm 176 extending therefrom. The base 174 may be supported on a floor 178. The additive manufacturing head 116 is secured to the distal end 180 of the mounting arm 176. The mounting assembly 172 may be configured to secure the additive manufacturing head 116 above the powder bed 110 (shown in fig. 1). Optionally, the mounting assembly 172 may be configured to movably position the additive manufacturing head 116.

Fig. 10 shows a schematic view of an additive manufacturing head 116 secured to a rail 182 according to an example of the present disclosure. The track 182 may be secured to a wall, ceiling, floor, and/or the like. The track 182 includes a rail 184, the rail 184 holding a movable portion of the additive manufacturing head 116. For example, the additive manufacturing head 116 may include rollers held within the rails 184. In this manner, the additive manufacturing head 116 may move relative to the powder bed 110 (shown in fig. 1). The track 182 may include more or fewer rails than shown. Additive manufacturing head 116 may be movably coupled to a structure (e.g., a wall, floor, ceiling, or the like) by other interfaces (e.g., hinged or telescoping members, wheel assemblies, and/or the like).

Fig. 11 shows a schematic view of an additive manufacturing head 116 secured to an articulated arm 188 according to an example of the present disclosure. The articulated arm 188 includes one or more movable segments 190 that allow the additive manufacturing head 116 to move through various degrees of freedom. The articulated arm 188 may include more or fewer movable segments 190 than shown.

Fig. 12 shows a schematic view of a surface smoothing head 120 secured to a structure 192 according to an example of the present disclosure. Referring to fig. 1 and 12, the surface smoothing head 120 may be located in a fixed position above the powder bed 110. For example, the surface smoothing head 120 may be securely mounted to the structure 192 (e.g., via fasteners, one or more intermediate structures, adhesives, and/or the like). The structure 192 may be a wall, ceiling, or the like.

Fig. 13 illustrates a schematic view of the surface smoothing head 120 secured to the mounting assembly 194 in accordance with an example of the present disclosure. The mounting assembly 194 includes a base 196 and a mounting arm 198 extending therefrom. The base 196 may be supported on a floor 199. The surface smoothing head 120 is secured to the distal end 200 of the mounting arm 198. The mounting assembly 194 may be configured to secure the surface smoothing head 120 above the powder bed 110 (shown in fig. 1). Optionally, the mounting assembly 194 may be configured to movably position the surface smoothing head 120.

Fig. 14 shows a schematic view of the surface smoothing head 120 secured to the rail 202 according to an example of the present disclosure. The track 202 may be secured to a wall, ceiling, floor, and/or the like. The track 202 includes a guide rail 204, the guide rail 204 holding a movable portion of the surface smoothing head 120. For example, the surface smoothing head 120 may include rollers held within the guide rails 204. In this manner, the surface smoothing head 120 may be moved relative to the powder bed 110 (as shown in FIG. 1). The track 202 may include more or fewer rails than shown. The surface smoothing head 120 may be movably coupled to a structure (e.g., a wall, floor, ceiling, or the like) by other interfaces (e.g., hinged or telescoping members, wheel assemblies, and/or the like).

Fig. 15 shows a schematic view of the surface smoothing head 120 secured to the articulating arm 206 according to an example of the present disclosure. The articulated arm 206 includes one or more movable segments 208 that allow the surface smoothing head 120 to move through various degrees of freedom. The articulated arm 206 may include more or fewer movable segments 208 than shown.

Fig. 16 shows a schematic view of a surface smoothing head 120 coupled to an additive manufacturing head 116, according to an example of the present disclosure. Mounting coupler 210 connects surface smoothing head 120 to additive manufacturing head 116. For example, mounting coupler 210 may movably couple surface smoothing head 120 to additive manufacturing head 116, such as by articulating arm segments, movable carriages, rails, and/or the like. In at least one other example, the surface smoothing head 120 may be coupled to the additive manufacturing head 116 in a fixed relationship.

Fig. 17 shows a flow diagram of an additive manufacturing method according to an example of the present disclosure. Referring to fig. 1 and 17, the forming control unit 124 may be programmed to operate in accordance with the methods shown and described herein.

At 300, energy (e.g., one or more laser beams) is emitted from the additive manufacturing head 116 into the powder bed 110 to form the layer 128 of the component 114. At 302, it is determined whether layer 128 has been completely formed. If not, the process returns to 300. The process may continue to cycle between 300 and 302 until one or more layers have been formed to a desired depth, height, etc. However, if the layer 128 has been completely formed at 302, the method proceeds to 304, at 304, the additive manufacturing head 116 is deactivated.

At 306, the part exposure mechanism 112 is operated to expose at least a portion 132 of the component 114 to be smoothed. At 308, it is determined whether the portion(s) 132 are exposed above the top surface 134 of the powder bed 110. If not, the method returns to 306, at 306, the part exposure mechanism continues to be operated to expose portion(s) 132.

However, if the portion(s) 132 are exposed above the top surface 134 of the powder bed 110 at 308, the method proceeds to 310 where energy, such as a focused laser beam, is emitted from the surface smoothing head 120 onto the portion(s) 132 to melt and smooth the portion(s) 132 at 310. At 312, it is determined whether the portion(s) 132 is a desired smoothness. If not, the method returns to 310, where energy continues to be transmitted from the surface smoothing head 120 onto the portion(s) 132 at 310.

However, if the portion(s) 132 is a desired smoothness at 312, the method proceeds to 314 where a determination is made as to whether the part 114 is fully formed at 314. If the part 114 is fully formed, the part 114 is removed from the forming chamber 108 and the method ends at 315. However, if the part 114 is not fully formed at 314, the method proceeds to 316 where the part exposure mechanism 112 is engaged to submerge the part 114 back into the powder bed 110. The method then returns to 300.

As described herein, certain embodiments of the present disclosure provide an additive manufacturing system comprising: a container defining a forming chamber holding a powder bed (which includes powder); an additive manufacturing head configured to emit first energy into the powder bed to form at least one layer of a part; and a part exposure mechanism on or in the container. The part exposure mechanism is configured to operate such that the component is in a first position at a first time within the powder bed and in a second position at a second time where a portion of the component is exposed to an exterior of the powder bed. The surface smoothing head is configured to emit a second energy onto the portion of the component in the second position to smooth the portion of the component. A molding control unit is in communication with the additive manufacturing head, the part exposure mechanism, and the surface smoothing head. The molding control unit is configured to control (e.g., operate) the additive manufacturing head, the part exposure mechanism, and the surface smoothing head. In at least one example, the surface smoothing head is coupled to the additive manufacturing head.

The part exposure mechanism may include an actuation assembly configured to move the member upward into the second position such that the portion of the member extends upward beyond a top surface of the powder bed. The actuation assembly may include a shaping bed that supports the component, and an actuator operably coupled to the shaping bed.

The parts exposure mechanism includes an ejection assembly configured to selectively move between a closed position and an open position. At least a first portion of powder is expelled through the expelling assembly in the open position to expose the portion of the component in the second position. The discharge assembly may include a movable cover proximate an outlet formed through a receptacle holding the powder bed. The movable cover closes the outlet in the closed position and moves away from the outlet in the open position to open the outlet. At least a first portion of the powder is discharged from the outlet when the movable lid is in the open position.

As described herein, examples of the present disclosure provide additive manufacturing systems and methods that allow for effective smoothing of portions of a component. Further, the additive manufacturing system and method are configured to expose at least a formed portion of the component to be smoothed.

Although examples of the present disclosure may be described using various spatial and directional terms, such as top, bottom, lower, mid, lateral, horizontal, vertical, front, and the like, it is understood that these terms are used only with respect to the orientations shown in the figures. The orientation may be reversed, rotated or otherwise changed such that the upper portion is the lower portion and vice versa, horizontal becomes vertical, and so on.

As used herein, a structure, limitation, or element that is "configured to" perform a task or operation is formed, constructed, or adjusted on a particular structure in a manner that corresponds to the task or operation. For the purposes of clarity and avoidance of doubt, an object that can only be modified to perform a task or operation is not "configured to" perform the task or operation as used herein.

It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described examples (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the various examples of the disclosure without departing from the scope thereof. While the dimensions and types of materials described herein are intended to define the parameters of the various examples of the disclosure, these examples are by no means limiting and are exemplary examples. Many other examples will be apparent to those of skill in the art upon reading the above description. The scope of various examples of the disclosure should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms "including" and "in which" are used as the plain-term equivalents of the respective terms "comprising" and "wherein". Furthermore, the terms "first," "second," and "third," etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Furthermore, the limitations of the appended claims are not written in a device-plus-function format, and are not intended to be interpreted based on 35 u.s.c § 112(f), unless and until such claim limitations explicitly use the phrase "means for … …" followed by a functional statement without further structural statement.

Further, the present disclosure includes examples according to the following clauses:

clause 1. an additive manufacturing system (100), comprising:

a powder bed (110, 136);

an additive manufacturing head (116) configured to emit first energy (151, 154) into the powder bed (110, 136) to form at least one layer (128, 130) of a component (114);

a part exposure mechanism (112) configured to operate such that the component (114) is in a first position at a first time within the powder bed (110, 136) and in a second position at a second time in which a portion (132) of the component (114) is exposed to an exterior of the powder bed (110, 136); and

a surface smoothing head (120) configured to emit second energy (151, 154) onto the portion (132) of the component (114) in the second position to smooth the portion (132) of the component (114).

Clause 2. the additive manufacturing system (100) of clause 1, further comprising a container (102) defining a forming chamber (108).

Clause 3. the additive manufacturing system (100) of clause 2, wherein the part exposure mechanism (112) is on or within the container (102).

Clause 4. the additive manufacturing system (100) of any of clauses 1-3, wherein the additive manufacturing head (116) is one of: fixed in place or movable.

Clause 5. the additive manufacturing system (100) of any of clauses 1-4, wherein the additive manufacturing head (116) is configured to emit the first energy (151, 154) as one or more laser beams.

Clause 6. the additive manufacturing system (100) of any of clauses 1-5, wherein the surface smoothing head (120) is one of: fixed in place or movable.

Clause 7. the additive manufacturing system (100) according to any one of clauses 1-6, wherein the surface smoothing head (120) is configured to emit the second energy (151, 154) as one or more laser beams.

Clause 8. the additive manufacturing system (100) according to any one of clauses 1-7, wherein the first energy (151, 154) and the second energy (151, 154) are the same type of energy (151, 154), or wherein the first energy (151, 154) and the second energy (151, 154) are different types of energy (151, 154).

Clause 9. the additive manufacturing system (100) of any of clauses 1-8, wherein the surface smoothing head (120) is coupled to the additive manufacturing head (116).

Clause 10. the additive manufacturing system (100) of clause 9, wherein the surface smoothing head (120) is movably coupled to the additive manufacturing head (116).

Clause 11. the additive manufacturing system (100) of any of clauses 1-10, further comprising a molding control unit (124) in communication with the additive manufacturing head (116), the part exposure mechanism (112), and the surface smoothing head (120), wherein the molding control unit (124) is configured to operate the additive manufacturing head (116), the part exposure mechanism (112), and the surface smoothing head (120).

Clause 12. the additive manufacturing system (100) according to any of clauses 1-11, wherein the part exposure mechanism (112) comprises an actuation assembly (135), the actuation assembly (135) configured to move the part (114) upward into the second position such that the portion (132) of the part (114) extends upward beyond a top surface (134, 142) of the powder bed (110, 136).

Clause 13. the additive manufacturing system (100) of clause 12, wherein the actuation assembly (135) comprises a forming bed (136) supporting the component (114), and an actuator (138, 150) operably coupled to the forming bed (136).

Clause 14. the additive manufacturing system (100) of any of clauses 1-13, wherein the part exposure mechanism (112) comprises an ejection assembly (144) configured to be selectively moved between a closed position and an open position, wherein at least a first portion (132) of powder is ejected through the ejection assembly (144) in the open position to expose the portion (132) of the component (114) in the second position.

Clause 15. the additive manufacturing system (100) of clause 14, wherein the discharge assembly (144) comprises a movable cover (146) (146), the movable cover (146) proximate to an outlet (148) formed through a container (102) holding the powder bed (110, 136), wherein the movable cover (146) is configured to close the outlet (148) in the closed position and to move away from the outlet (148) to open the outlet (148) in the open position, and wherein at least some of the powder bed (110) (136) is discharged from the outlet (148) when the movable cover (146) is in the open position.

Clause 16. a method of additive manufacturing, comprising:

emitting first energy (151, 154) from an additive manufacturing head (116) into a powder bed (110) (136) to form at least one layer (128, 130) of a part (114);

operating a part exposure mechanism (112) such that the part (114) is in a first position at a first time within the powder bed (110, 136) and in a second position at a second time in which a portion (132) of the part (114) is exposed to the exterior of the powder bed (110, 136); and is

Emitting second energy (151, 154) from a surface smoothing head (120) onto the portion (132) of the component (114) at the second location to smooth the portion (132) of the component (114).

Clause 17. the additive manufacturing method of clause 16, wherein the operating comprises using an actuating assembly (135) that moves the component (114) upward into the second position such that the portion (132) of the component (114) extends upward beyond a top surface (134, 142) of the powder bed (110, 136).

Clause 18. the additive manufacturing method of clause 16 or 17, wherein the operating further comprises supporting the component (114) on a forming bed (136), the forming bed (136) operably coupled to an actuator (138, 150).

Clause 19. the additive manufacturing method of any one of clauses 16-18, wherein the operating comprises selectively moving a discharge assembly (144) between a closed position and an open position, wherein at least a first portion (132) of the powder bed (110, 136) is discharged through the discharge assembly (144) in the open position to expose the portion (132) of the component (114) in the second position.

Clause 20. the additive manufacturing method of clause 19, wherein the operations further comprise:

closing an outlet (148) through a receptacle (102) with a movable lid (146) in the closed position, the receptacle (102) holding the powder bed (110) (136); and

moving the movable lid (146) away from the outlet (148) in the open position to open the outlet (148), wherein at least a first portion (132) of powder is discharged from the outlet (148) when the movable lid is in the open position.

This written description uses examples to disclose various examples of the disclosure, including the best mode, and also to enable any person skilled in the art to practice the various examples of the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the various examples of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if the examples have structural elements that do not differ from the literal language of the claims, or if the examples include equivalent structural elements with insubstantial differences from the literal languages of the claims.