阅读说明：本技术 用于用粉末材料来增材制造物体的设备和方法 (Apparatus and method for additive manufacturing of objects with powder material ) 是由 P·J·克罗瑟斯 P·L·弗里曼 于 2020-09-22 设计创作，主要内容包括：本发明涉及一种用于用粉末材料来增材制造物体的设备和方法,该增材制造设备(100)包括支撑件(102)和粉末材料源(106)。增材制造设备(100)还包括粉末供应臂(108),该粉末供应臂包括具有与粉末材料源(106)连通的内部容积(124)的中空主体(122)、中空主体(122)中的粉末沉积开口(126)以及联接到中空主体(122)并沿着粉末沉积开口(126)延伸的粉末分配叶片(128)。增材制造设备(100)还包括能量源(110)、能量供应臂(112)以及联接到能量供应臂(112)的能量发射器(114)。增材制造设备(100)还包括旋转驱动器(116),该旋转驱动器(116)被构造成使粉末供应臂(108)和能量供应臂(112)围绕穿过支撑件(102)并且与粉末供应臂中心轴线A2和能量供应臂中心轴线A3相交的竖直轴线A1旋转。(The invention relates to an apparatus and a method for additive manufacturing an object with a powder material, the additive manufacturing apparatus (100) comprising a support (102) and a source (106) of powder material. The additive manufacturing apparatus (100) further includes a powder supply arm (108) including a hollow body (122) having an internal volume (124) in communication with the powder material source (106), a powder deposition opening (126) in the hollow body (122), and a powder distribution blade (128) coupled to the hollow body (122) and extending along the powder deposition opening (126). The additive manufacturing apparatus (100) further comprises an energy source (110), an energy supply arm (112), and an energy emitter (114) coupled to the energy supply arm (112). The additive manufacturing apparatus (100) further comprises a rotary drive (116), the rotary drive (116) being configured to rotate the powder supply arm (108) and the energy supply arm (112) about a vertical axis a1 passing through the support (102) and intersecting the powder supply arm central axis a2 and the energy supply arm central axis A3.)

1. An additive manufacturing apparatus (100), the additive manufacturing apparatus (100) comprising:

a support (102);

a source of powdered material (106);

a powder supply arm (108), the powder supply arm (108) having a powder supply arm central axis (A2) and comprising:

a hollow body (122), the hollow body (122) having an interior volume (124) in communication with the powder material source (106) such that powder material (202) can be transferred from the powder material source (106) to the interior volume (124);

a powder deposition opening (126) in the hollow body (122), and wherein the powder deposition opening (126) has a width (W) and is in communication with the internal volume (124) of the hollow body (122) such that the powder material (202) can be transferred out of the internal volume (124) through the powder deposition opening (126); and

a powder distribution blade (128), the powder distribution blade (128) coupled to the hollow body (122) and extending along the powder deposition opening (126);

an energy source (110);

an energy supply arm (112), the energy supply arm (112) having an energy supply arm central axis (A3);

an energy emitter (114), the energy emitter (114) coupled to the energy supply arm (112), and wherein the energy emitter (114) is configured to one of electrically and optically communicate with the energy source (110); and

a rotary drive (116), the rotary drive (116) being configured to rotate the powder supply arm (108) and the energy supply arm (112) about a vertical axis (A1) passing through the support (102) and intersecting the powder supply arm central axis (A2) and the energy supply arm central axis (A3).

2. The additive manufacturing apparatus (100) of claim 1, the additive manufacturing apparatus (100) further comprising a shaft (104) coupled to the support (102), and wherein the powder supply arm (108) and the energy supply arm (112) are coupled to the shaft (104).

3. The additive manufacturing apparatus (100) of claim 2, wherein:

the powder supply arm (108) and the energy supply arm (112) are fixed to the shaft (104) such that the powder supply arm (108) and the energy supply arm (112) are not rotatable and not translatable relative to the shaft (104); and is

The rotation drive (116) is configured to rotate the shaft (104) relative to the support (102) about the vertical axis (A1).

4. The additive manufacturing apparatus (100) according to claim 2, wherein the rotary drive (116) is configured to rotate the powder supply arm (108) and the energy supply arm (112) relative to the shaft (104) about the vertical axis (a 1).

5. The additive manufacturing apparatus (100) according to any one of claims 1 to 4, wherein the powder supply arm (108) further comprises:

a conveyor screw (140), the conveyor screw (140) located within the interior volume (124) of the hollow body (122) and extending along the powder deposition opening (126); and

a motor (138), the motor (138) configured to rotate the conveyor screw (140).

6. The additive manufacturing apparatus (100) according to any one of claims 1 to 5, wherein:

the powder supply arm (108) further comprises a door (144) coupled to the hollow body (122); and is

The door (144) is movable relative to the hollow body (122) to at least partially open or close the powder deposition opening (126).

7. The additive manufacturing apparatus (100) according to any one of claims 1 to 6, wherein:

the source of powder material (106) includes a hopper (148);

the powder supply arm (108) further comprising a powder supply opening (132) formed in the hollow body (122);

the powder supply opening (132) being in communication with the internal volume (124) of the hollow body (122); and is

The hopper (148) is in communication with the powder supply opening (132) such that the powder material (202) can be transferred from the hopper (148) to the internal volume (124) through the powder supply opening (132).

8. The additive manufacturing apparatus (100) of claim 7, wherein:

the powder material source (106) further comprising a tubular chamber (150), the tubular chamber (150) being coupled to the powder supply arm (108) and the energy supply arm (112);

the hopper (148) being in communication with the tubular chamber (150) such that the powder material (202) can be transferred from the hopper (148) to the tubular chamber (150);

the tubular chamber (150) being in communication with the powder supply opening (132) such that the powder material (202) can be transferred from the tubular chamber (150) to the interior volume (124) of the hollow body (122) through the powder supply opening (132); and is

The rotary drive (116) is configured to rotate the tubular chamber (150) together with the powder supply arm (108) and the energy supply arm (112) about the vertical axis (A1).

9. A method (1000) for additive manufacturing an object (200) with a powder material (202), the method (1000) comprising the steps of:

discharging the powder material (202) from a powder deposition opening (126) in a hollow body (122) of a powder supply arm (108) while rotating the powder supply arm (108) and an energy supply arm (112) about a vertical axis (A1);

while rotating the powder supply arm (108) and the energy supply arm (112) about the vertical axis (A1), dispensing the powder material (202) within a powder bed volume (204) using a powder dispensing blade (128) coupled to the hollow body (122) and extending along the powder deposition opening (126); and

consolidating at least a portion of the powder material (202) in the powder bed volume (204) using an energy emitter (114) coupled to the energy supply arm (112) while rotating the powder supply arm (108) and the energy supply arm (112) about the vertical axis (A1).

10. The method (1000) of claim 9, further comprising the step of rotating the powder supply arm (108) and the energy supply arm (112) about the vertical axis (a1) at a constant speed.

Technical Field

Disclosed herein are additive manufacturing apparatuses and methods for additive manufacturing an object with a powder material.

Background

Conventional powder bed additive manufacturing devices utilize various processing techniques to deposit, distribute, and consolidate powder materials. For example, powder material is typically dispensed in a powder bed using a dispense arm that moves linearly relative to the powder bed. After dispensing the powder material, a portion of the powder material is consolidated using an appropriate type of energy emitter that moves separately from the dispense arm to form a layer of the additive manufactured object. However, such additive manufacturing devices have limited processing speeds and require complex control systems.

Disclosure of Invention

Accordingly, an apparatus and method that addresses at least the above concerns would find utility.

The following is a non-exhaustive list of embodiments of the subject matter disclosed herein that may or may not be claimed.

An additive manufacturing apparatus is disclosed herein that includes a support and a source of powder material. The additive manufacturing apparatus further comprises a powder supply arm having a powder supply arm central axis a 2. The powder supply arm includes a hollow body having an interior volume in communication with a source of powder material such that powder material can be transferred from the source of powder material to the interior volume. The powder supply arm further comprises a powder deposition opening in the hollow body. The powder deposition opening has a width W and is in communication with the interior volume of the hollow body such that powder material can be transferred out of the interior volume through the powder deposition opening. The powder supply arm further includes a powder distribution blade coupled to the hollow body and extending along the powder deposition opening. The additive manufacturing apparatus further comprises an energy source and an energy supply arm having an energy supply arm central axis a 3. The additive manufacturing apparatus also includes an energy emitter coupled to the energy supply arm. The energy emitter is configured to be in one of electrical and optical communication with an energy source. The additive manufacturing apparatus additionally comprises a rotary drive configured to rotate the powder supply arm and the energy supply arm about a vertical axis a1 passing through the support and intersecting the powder supply arm central axis a2 and the energy supply arm central axis A3.

The additive manufacturing apparatus enables substantially continuous (e.g., uninterrupted) deposition, dispensing and consolidation of powder material as the powder supply arm and energy supply arm rotate about the vertical axis a1, which improves the processing speed of the additive manufacturing operation by eliminating the need for back-and-forth motion and thus eliminating corresponding acceleration and deceleration of the part during deposition, dispensing and consolidation of the powder material.

Also disclosed herein is a method for additive manufacturing an object with a powder material. The method includes discharging powder material from a powder deposition opening in a hollow body of the powder supply arm while rotating the powder supply arm and the energy supply arm about a vertical axis a 1. The method further includes dispensing powder material within the powder bed volume using a powder dispensing blade coupled to the hollow body and extending along the powder deposition opening while rotating the powder supply arm and the energy supply arm about the vertical axis a 1. The method further includes consolidating at least a portion of the powder material in the powder bed volume using an energy emitter coupled to the energy supply arm while rotating the powder supply arm and the energy supply arm about the vertical axis a 1.

The method enables substantially continuous (e.g., uninterrupted) deposition, dispensing and consolidation of the powder material as the powder supply arm and energy supply arm rotate about the vertical axis a1, which improves the processing speed of additive manufacturing by eliminating the need for back-and-forth motion and thus eliminating corresponding acceleration and deceleration of the part during deposition, dispensing and consolidation of the powder material.

Also disclosed herein are the following illustrative, non-exhaustive list of embodiments that may or may not be claimed:

1. an additive manufacturing apparatus 100, the additive manufacturing apparatus 100 comprising:

a support 102;

a source of powdered material 106;

a powder supply arm 108, the powder supply arm 108 having a powder supply arm central axis A2 and comprising:

a hollow body 122 having an interior volume 124 in communication with the powder material source 106 such that powder material 202 can be transferred from the powder material source 106 to the interior volume 124;

a powder deposition opening 126 in the hollow body 122, and wherein the powder deposition opening 126 has a width W and is in communication with the interior volume 124 of the hollow body 122 such that the powder material 202 can be transferred out of the interior volume 124 through the powder deposition opening 126; and

a powder distribution blade 128, the powder distribution blade 128 coupled to the hollow body 122 and extending along the powder deposition opening 126;

an energy source 110;

an energy supply arm 112, said energy supply arm 112 having an energy supply arm central axis a 3;

an energy emitter 114, the energy emitter 114 coupled to the energy supply arm 112, and wherein the energy emitter 114 is configured to one of electrically and optically communicate with the energy source 110; and

a rotary drive 116, the rotary drive 116 configured to rotate the powder supply arm 108 and the energy supply arm 112 about a vertical axis A1 passing through the support 102 and intersecting the powder supply arm central axis A2 and the energy supply arm central axis A3.

2. The additive manufacturing apparatus 100 of embodiment 1, wherein the rotary drive 116 is configured to rotate the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 at a constant speed.

3. The additive manufacturing apparatus 100 of embodiment 1 or 2, the additive manufacturing apparatus 100 further comprising a shaft 104 coupled to the support 102, and wherein the powder supply arm 108 and the energy supply arm 112 are coupled to the shaft 104.

4. The additive manufacturing apparatus 100 of embodiment 3, wherein:

the powder supply arm 108 and the energy supply arm 112 are fixed to the shaft 104 such that the powder supply arm 108 and the energy supply arm 112 are not rotatable and not translatable relative to the shaft 104; and is

The rotation drive 116 is configured to rotate the shaft 104 relative to the support 102 about the vertical axis a 1.

5. The additive manufacturing apparatus 100 of embodiment 3, wherein the rotary drive 116 is configured to rotate the powder supply arm 108 and the energy supply arm 112 relative to the shaft 104 about the vertical axis a 1.

6. The additive manufacturing apparatus 100 according to any one of embodiments 1 to 5, wherein the powder supply arm 108 further comprises:

a conveyor screw 140, the conveyor screw 140 being located within the interior volume 124 of the hollow body 122 and extending along the powder deposition opening 126; and

a motor 138, the motor 138 configured to rotate the conveyor screw 140.

7. The additive manufacturing apparatus 100 according to any one of embodiments 1 to 6, wherein the width W of the powder deposition opening 126 is constant along the powder supply arm central axis A2.

8. The additive manufacturing apparatus 100 according to any one of embodiments 1 to 6, wherein the width W of the powder deposition opening 126 increases in a direction along the powder supply arm central axis A2 and away from the vertical axis A1.

9. The additive manufacturing apparatus 100 according to any one of embodiments 1 to 8, wherein the powder deposition opening 126 is continuous and extends along the powder supply arm central axis a 2.

10. The additive manufacturing apparatus 100 according to any one of embodiments 1 to 8, wherein the powder deposition openings 126 are a plurality of holes 142 extending along the powder supply arm central axis a 2.

11. The additive manufacturing apparatus 100 of any one of embodiments 1 to 10, wherein:

the powder supply arm 108 further includes a door 144 coupled to the hollow body 122; and is

The door 144 is movable relative to the hollow body 122 to at least partially open or close the powder deposition opening 126.

12. The additive manufacturing apparatus 100 of embodiment 11, wherein a width W of at least a portion of the powder deposition opening 126 increases along the powder supply arm central axis a2 of the powder supply arm 108 in a direction away from the vertical axis a1 when the door 144 is positioned relative to the hollow body 122 of the powder supply arm 108 such that the powder deposition opening 126 is partially open.

13. The additive manufacturing apparatus 100 according to embodiment 11 or 12, wherein a width W of the powder deposition opening 126 is constant along the powder supply arm central axis a2 when the door 144 is positioned relative to the hollow body 122 of the powder supply arm 108 such that the powder deposition opening 126 is fully open.

14. The additive manufacturing apparatus 100 of any one of embodiments 1 to 13, wherein:

the powder deposition opening 126 has an opening length L1;

the powder distribution blade 128 has a blade length L2; and

the vane length L2 is equal to or greater than the opening length L1.

15. The additive manufacturing apparatus 100 of any one of embodiments 1 to 14, wherein:

the powder supply arm 108 has a powder supply arm proximal end 134 and a powder supply arm distal end 136 located opposite the powder supply arm proximal end 134 along the powder supply arm central axis a 2;

the energy supply arm 112 has an energy supply arm proximal end 154 and an energy supply arm distal end 156 positioned opposite the energy supply arm proximal end 154 along the energy supply arm central axis a 3; and

the powder supply arm central axis a2 and the energy supply arm central axis A3 are inclined to each other when viewed along the vertical axis a 1.

16. The additive manufacturing apparatus 100 of any one of embodiments 1 to 14, wherein:

the powder supply arm 108 has a powder supply arm proximal end 134 and a powder supply arm distal end 136 located opposite the powder supply arm proximal end 134 along the powder supply arm central axis a 2;

the energy supply arm 112 has an energy supply arm proximal end 154 and an energy supply arm distal end 156 positioned opposite the energy supply arm proximal end 154 along the energy supply arm central axis a 3; and

the powder supply arm central axis a2 and the energy supply arm central axis A3 are orthogonal to each other when viewed along the vertical axis a 1.

17. The additive manufacturing apparatus 100 of any one of embodiments 1 to 14, wherein:

the powder supply arm 108 has a powder supply arm proximal end 134 and a powder supply arm distal end 136 located opposite the powder supply arm proximal end 134 along the powder supply arm central axis a 2;

the energy supply arm 112 has an energy supply arm proximal end 154 and an energy supply arm distal end 156 positioned opposite the energy supply arm proximal end 154 along the energy supply arm central axis a 3; and

when viewed along the vertical axis a1, the powder supply arm central axis a2 and the energy supply arm central axis A3 are collinear with each other, and the powder supply arm 108 and the energy supply arm 112 extend in opposite directions away from the vertical axis a 1.

18. The additive manufacturing apparatus 100 of any one of embodiments 1 to 17, wherein:

the powder distribution blade 128 has a blade central axis a 4; and is

The vane central axis a4 is oblique to the powder supply arm central axis a2 when viewed along the vertical axis a 1.

19. The additive manufacturing apparatus 100 of any one of embodiments 1 to 18, wherein:

the powder supply arm 108 has a powder supply arm proximal end 134 and a powder supply arm distal end 136 positioned opposite the powder supply arm proximal end 134; and is

The powder supply arm 108 further includes a powder barrier 146, the powder barrier 146 being coupled to the powder distribution blade 128 proximate the powder supply arm proximal end 134 and extending between the powder deposition opening 126 and the vertical axis a 1.

20. The additive manufacturing apparatus 100 of any one of embodiments 1 to 19, wherein:

the source of powder material 106 includes a hopper 148;

the powder supply arm 108 further includes a powder supply opening 132 formed in the hollow body 122;

the powder supply opening 132 communicates with the interior volume 124 of the hollow body 122; and is

The hopper 148 is in communication with the powder supply opening 132 such that the powder material 202 can be transferred from the hopper 148 to the internal volume 124 through the powder supply opening 132.

21. The additive manufacturing apparatus 100 of embodiment 20, wherein the hopper 148 is mounted on the powder supply arm 108.

22. The additive manufacturing apparatus 100 of embodiment 20, wherein:

the source of powder material 106 further comprises a tubular chamber 150, the tubular chamber 150 being coupled to the powder supply arm 108 and the energy supply arm 112;

the hopper 148 is in communication with the tubular chamber 150 such that the powder material 202 can be transferred from the hopper 148 to the tubular chamber 150;

the tubular chamber 150 is in communication with the powder supply opening 132 such that the powder material 202 can be transferred from the tubular chamber 150 to the interior volume 124 of the hollow body 122 through the powder supply opening 132; and is

The rotary drive 116 is configured to rotate the tubular chamber 150 together with the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1.

23. The additive manufacturing apparatus 100 of any one of embodiments 1 to 22, wherein:

the energy supply arm 112 has an energy supply arm proximal end 154 and an energy supply arm distal end 156 located opposite the energy supply arm proximal end 154; and is

A plurality of the energy emitters 114 are positioned in a linear array 172 extending along the energy supply arm central axis a3 between the energy supply arm proximal end 154 and the energy supply arm distal end 156.

24. The additive manufacturing apparatus 100 of embodiment 23, wherein:

a second plurality of the energy emitters 114 are arranged in a second linear array 178 extending along the energy supply arm central axis a3 between the energy supply arm proximal end 154 and the energy supply arm distal end 156; and is

The second linear array 178 of the energy emitters 114 is offset along the energy delivery arm central axis a3 relative to the linear array 172 of the energy emitters 114.

25. The additive manufacturing apparatus 100 of embodiment 24, wherein:

a third plurality of the energy emitters 114 is arranged in a third linear array 232 extending along the energy-supply-arm central axis a3 between the energy-supply-arm proximal end 154 and the energy-supply-arm distal end 156; and is

The third linear array 232 of the energy emitters 114 is offset along the energy supply arm central axis A3 with respect to at least one of the linear array 172 of the energy emitters 114 and the second linear array 178 of the energy emitters 114.

26. The additive manufacturing apparatus 100 of any one of embodiments 1 to 25, wherein:

the energy emitters 114 are arranged in groups 184, each group containing a plurality of the energy emitters 114; and is

The groups 184 are arranged along a circular path 230, the circular path 230 encircling the vertical axis a1 and centered about the vertical axis a 1.

27. The additive manufacturing apparatus 100 of embodiment 26, wherein:

each of the groups 184 of the energy emitters 114 is arranged along a corresponding one of the circular paths 230 and comprises:

a preheat emitter 186, the preheat emitter 186 configured to heat a portion of the powdered material 202 to a first temperature; and

a melt emitter 188, the melt emitter 188 configured to heat the portion of the powdered material 202 to a second temperature that is higher than the first temperature.

28. The additive manufacturing apparatus 100 of embodiment 27, wherein:

each of the group 184 of the energy emitters 114 further includes a post-heat emitter 192 configured to heat the portion of the powdered material 202 to a third temperature that is lower than the second temperature; and is

The melting emitter 188 is located between the pre-heat emitter 186 and the post-heat emitter 192.

29. The additive manufacturing apparatus 100 according to any one of embodiments 1 to 8 and 14 to 28, wherein the powder supply arm 108 is curved in a viewing plane perpendicular to the vertical axis a 1.

30. The additive manufacturing apparatus 100 of any one of embodiments 1 to 29, the additive manufacturing apparatus 100 further comprising:

a first energy transmission line 166, the first energy transmission line 166 configured to one of electrically and optically communicate with the energy source 110;

a rotational energy connector 170, the rotational energy connector 170 configured to one of electrically and optically communicate with the first energy transmission line 166; and

a second energy transmission line 168, the second energy transmission line 168 configured to one of electrically and optically communicate with the rotational energy connector 170.

31. The additive manufacturing apparatus 100 of embodiment 30, wherein each of the energy emitters 114 comprises a laser emitting diode 160 configured to be in electrical communication with the second energy transmission line 168 and the energy source 110.

32. The additive manufacturing apparatus 100 of embodiment 30, wherein each of the energy emitters 114 comprises an optical output 162 configured to be in optical communication with the second energy transmission line 168 and the energy source 110.

33. The additive manufacturing apparatus 100 of any one of embodiments 1 to 32, the additive manufacturing apparatus 100 further comprising:

a build platform 206; and

a slot 208, the slot 208 surrounding the build platform 206.

34. The additive manufacturing apparatus 100 of embodiment 33, wherein the build platform 206 is movable along the vertical axis a1 relative to the powder supply arm 108 and the energy supply arm 112.

35. The additive manufacturing apparatus 100 of embodiments 33 or 34, wherein the build platform 206 is movable relative to the trough 208 along the vertical axis a 1.

36. The additive manufacturing apparatus 100 of embodiment 33, the additive manufacturing apparatus 100 further comprising a powder recovery device 210 in communication with the tank 208 and the powder material source 106 such that the powder material 202 can be transferred from the tank 208 to the powder material source 106.

37. The additive manufacturing apparatus 100 of any one of embodiments 1 to 36, the additive manufacturing apparatus 100 further comprising:

a second powder supply arm 196, the second powder supply arm 196 comprising:

a second hollow body 214, the second hollow body 214 having a second interior volume 216 in communication with a second powder material source 236 such that the powder material 202 may be transferred from the powder material source 106 to the second interior volume 216;

a second powder deposition opening 218, the second powder deposition opening 218 formed in the second hollow body 214, and wherein the second powder deposition opening 218 is in communication with the second interior volume 216 of the second hollow body 214 such that the powder material 202 may be transferred out of the second interior volume 216 through the second powder deposition opening 218; and

a second powder distribution blade 220, the second powder distribution blade 220 coupled to the second hollow body 214 and extending along the second powder deposition opening 218;

a second energy supply arm 198; and

a second energy emitter 222, the second energy emitter 222 coupled to the second energy supply arm 198; and is

Wherein:

the second energy emitter 222 is in one of electrical or optical communication with the energy source 110; and

the rotary drive 116 is also configured to rotate the second powder supply arm 196 and the second energy supply arm 198 about the vertical axis a 1.

38. The additive manufacturing apparatus 100 of any one of embodiments 1 to 36, the additive manufacturing apparatus 100 further comprising:

a second energy supply arm 198;

a second energy emitter 222, the second energy emitter 222 coupled to the second energy supply arm 198, and wherein the second energy emitter 222 is one of in electrical or optical communication with the energy source 110;

a third energy supply arm 212; and

a third energy emitter 224, the third energy emitter 224 coupled to the third energy supply arm 212; and is

Wherein:

the third energy emitter 224 is in one of electrical and optical communication with the energy source 110; and is

The rotational drive 116 is also configured to rotate the second energy supply arm 198 and the third energy supply arm 212 about the vertical axis a 1.

39. A method 1000 for additive manufacturing an object 200 from a powder material 202, the method 1000 comprising the steps of:

discharging the powder material 202 from the powder deposition opening 126 in the hollow body 122 of the powder supply arm 108 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1;

while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1, dispensing the powder material 202 within a powder bed volume 204 using a powder dispensing blade 128 coupled to the hollow body 122 and extending along the powder deposition opening 126; and

consolidating at least a portion of the powder material 202 in the powder bed volume 204 using an energy emitter 114 coupled to the energy supply arm 112 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1.

40. The method 1000 of embodiment 39, further comprising the step of rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis A1 at a constant speed.

41. The method 1000 of embodiment 40, wherein:

the powder supply arm 108 and the energy supply arm 112 are coupled to a shaft 104, which is coupled to a support 102; and is

The step of rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 includes rotating the shaft 104 about the vertical axis a 1.

42. The method 1000 of embodiment 40, wherein:

the powder supply arm 108 and the energy supply arm 112 are coupled to a shaft 104, which is coupled to a support 102; and is

The step of rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 includes rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 relative to the shaft 104.

43. The method 1000 of any of embodiments 39 to 42, further comprising transferring the powder material 202 from a powder material source 106 to the interior volume 124 of the hollow body 122 of the powder supply arm 108.

44. The method 1000 of embodiment 43, further comprising conveying the powder material 202 through the interior volume 124 of the hollow body 122 in a direction away from the vertical axis A1 and perpendicular to the vertical axis A1.

45. The method 1000 of embodiment 43 or 44, further comprising at least partially opening or closing the powder deposition opening 126.

46. The method 1000 according to any of embodiments 43-45, wherein the step of discharging the powder material 202 from the powder deposition opening 126 in the hollow body 122 of the powder supply arm 108 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis A1 comprises discharging a greater amount of the powder material 202 from the powder deposition opening 126 at a first location along the powder deposition opening 126 than at a second location along the powder deposition opening 126 that is closer to the vertical axis A1 than the first location.

47. The method 1000 according to any one of embodiments 43 to 46, wherein the step of dispensing the powder material 202 within the powder bed volume 204 using the powder dispensing blade 128 coupled to the hollow body 122 and extending along the powder deposition opening 126 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis A1 comprises moving a portion of the powder material 202 in a direction away from the vertical axis A1.

48. The method 1000 of embodiment 47, further comprising collecting excess powder material 202 in a trough 208 that is moved beyond a peripheral boundary of the powder bed volume 204 by the powder distribution blade 128.

49. The method 1000 of embodiment 48, further comprising transferring the excess powdered material 202 from the trough 208 to the powdered material source 106.

50. The method 1000 of any of embodiments 43-49, further comprising, while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis A1, preventing at least some of the powder material 202 from moving in a direction toward the vertical axis A1.

51. The method 1000 of any of embodiments 39-50, wherein:

the energy emitter 114 is in one of electrical and optical communication with the energy source 110; and is

Consolidating at least the portion of the powder material 202 in the powder bed volume 204 using the energy emitter 114 coupled to the energy supply arm 112 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 includes heating at least the portion of the powder material 202.

52. The method 1000 according to any one of embodiments 39 to 51, wherein the step of consolidating at least the portion of the powder material 202 in the powder bed volume 204 using the energy emitter 114 coupled to the energy supply arm 112 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis A1 comprises at least partially overlapping energy beams 228 emitted from the energy emitter 114.

53. The method 1000 of any of embodiments 39-52, wherein:

the energy emitters 114 include preheat emitters 186 and melt emitters 188 arranged along a circular path 230, the circular path 230 encircling the vertical axis A1 and centered about the vertical axis A1; and is

Consolidating at least the portion of the powder material 202 in the powder bed volume 204 using the energy emitter 114 coupled to the energy supply arm 112 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 comprises:

preheating at least the portion of the powder material 202 to a first temperature using the preheat launcher 186; and

after preheating at least the portion of the powder material 202 using the preheat emitter 186, heating at least the portion of the powder material 202 to a second temperature greater than the first temperature using the melt emitter 188.

54. The method 1000 of embodiment 53, wherein:

the energy emitter 114 further includes a post-heat emitter 192 disposed along the circular path 230 between the preheat emitter 186 and the post-heat emitter 192; and is

Consolidating at least the portion of the powder material 202 in the powder bed volume 204 using the energy emitter 114 coupled to the energy supply arm 112 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 further comprises post-heating at least the portion of the powder material 202 to a third temperature less than the second temperature using the post-heating emitter 192 after heating at least the portion of the powder material 202 using the melting emitter 188.

55. The method 1000 of any of embodiments 39-54, further comprising:

supporting the powder bed volume 204 on a build platform 206; and is

Moving the build platform 206 away from the powder supply arm 108 and the energy supply arm 112 along the vertical axis a1 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1.

Drawings

Reference will now be made to the drawings, which are not necessarily drawn to scale, and wherein like reference numerals refer to the same or similar parts throughout the several views. In the drawings:

fig. 1A and 1B are collectively a block diagram of an additive manufacturing apparatus according to one or more embodiments of the subject matter disclosed herein;

fig. 2 is a schematic front cross-sectional view of the additive manufacturing apparatus of fig. 1A and 1B in accordance with one or more embodiments of the subject matter disclosed herein;

fig. 3 is a schematic front cross-sectional view of the additive manufacturing apparatus of fig. 1A and 1B in accordance with one or more embodiments of the subject matter disclosed herein;

fig. 4 is a schematic front cross-sectional view of the additive manufacturing apparatus of fig. 1A and 1B in accordance with one or more embodiments of the subject matter disclosed herein;

fig. 5 is a schematic top plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 6 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 7 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 8 is a schematic top plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 9 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 10 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 11 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 12 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 13 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 14 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 15 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 16 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 17 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 18 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 19 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 20 is a schematic bottom plan view of a portion of an energy supply arm of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 21 is a schematic bottom plan view of a portion of an energy supply arm of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 22 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 23 is a schematic bottom plan view of a portion of an energy supply arm of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 24 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 25 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 26 is a schematic front cross-sectional view of the additive manufacturing apparatus of fig. 1A and 1B in accordance with one or more embodiments of the subject matter disclosed herein;

fig. 27 is a schematic front cross-sectional view of the additive manufacturing apparatus of fig. 1A and 1B in accordance with one or more embodiments of the subject matter disclosed herein;

fig. 28 is a schematic front cross-sectional view of the additive manufacturing apparatus of fig. 1A and 1B in accordance with one or more embodiments of the subject matter disclosed herein;

fig. 29 is a schematic elevation view of a portion of an energy supply arm of the additive manufacturing apparatus of fig. 1A and 1B during consolidation of a powder material, according to one or more embodiments of the subject matter disclosed herein;

fig. 30 is a schematic top plan environmental view of a portion of a powder material consolidated to form a portion of an object using the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 31 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B in accordance with one or more embodiments of the subject matter disclosed herein;

fig. 32 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 33 is a schematic bottom plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B in accordance with one or more embodiments of the subject matter disclosed herein;

fig. 34 is a schematic top plan view of a subassembly of the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein;

fig. 35 is a block diagram of a method of additive manufacturing an object using the powder material for the additive manufacturing apparatus of fig. 1A and 1B, according to one or more embodiments of the subject matter disclosed herein, the method according to one or more embodiments of the subject matter disclosed herein;

FIG. 36 is a block diagram of an aircraft production and service method; and

FIG. 37 is a schematic view of an aircraft.

Detailed Description

In fig. 1A and 1B, with reference to the above, the solid lines connecting the various elements and/or components (if any) may represent mechanical, electrical, fluidic, optical, electromagnetic and other couplings and/or combinations thereof. As used herein, "coupled" means directly and indirectly associated. For example, component a may be directly associated with component B, or may be indirectly associated therewith, e.g., via another component C. It should be understood that not necessarily all relationships between the various disclosed elements are shown. Thus, couplings other than those depicted in block diagrams may also exist. Dashed lines connecting blocks designating various elements and/or components, if any, represent couplings similar in function and purpose to those represented by solid lines; however, the coupling represented by the dashed lines may be selectively provided or may relate to alternative embodiments of the subject matter disclosed herein. Also, elements and/or components shown in phantom, if any, indicate alternative embodiments of the subject matter disclosed herein. One or more elements shown in solid and/or dashed lines may be omitted from a particular embodiment without departing from the scope of the subject matter disclosed herein. Environmental elements, if any, are indicated by dashed lines. Virtual (phantom) elements may also be shown for clarity. Those skilled in the art will appreciate that some of the features shown in fig. 1A and 1B may be combined in various ways without the need to include other features described in fig. 1A and 1B, other figures, and/or the appended disclosure, even if such a combination or combinations are not explicitly shown herein. Similarly, additional features not limited to the embodiments presented may be combined with some or all of the features shown and described herein.

In fig. 35 and 36, referring to the above, the blocks may represent operations and/or portions thereof, and the lines connecting the various blocks do not imply any particular order or dependency of the operations or portions thereof. Blocks represented by dashed lines represent alternate operations and/or portions thereof. The dashed lines connecting the various blocks represent alternative dependencies of the operations or portions thereof, if any. It will be understood that not necessarily all dependencies between the various disclosed operations are represented. Fig. 35 and 36, as well as the accompanying disclosure describing the operations of the methods set forth herein, should not be construed as necessarily determining the order in which the operations are to be performed. Rather, although an illustrative order is indicated, it should be understood that the order of the operations may be modified as appropriate. Thus, certain operations may be performed in a different order or concurrently. In addition, those skilled in the art will appreciate that not all of the operations described need be performed.

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the disclosed concepts, which may be practiced without some or all of these details. In other instances, details of well-known devices and/or processes have been omitted to avoid unnecessarily obscuring the present disclosure. While some concepts will be described in conjunction with specific embodiments, it will be understood that these embodiments are not intended to be limiting.

Unless otherwise indicated, the terms "first," "second," and the like are used herein merely as labels, and are not intended to impose order, position, or hierarchical requirements on the items to which they refer. Furthermore, for example, reference to "a second" item does not require or exclude the presence of, for example, "a first" or lower numbered item and/or, for example, "a third" or higher numbered item.

Reference herein to "one or more embodiments" means that one or more features, structures, or characteristics described in connection with the embodiments are included in at least an implementation. The phrase "one or more embodiments" in various places in the specification may or may not refer to the same embodiments.

As used herein, a system, device, structure, article, element, component, or hardware that is "configured to" perform a specified function is actually capable of performing the specified function without any alteration, and does not merely have the potential to perform the specified function after further modification. In other words, a system, device, structure, article, element, component, or hardware that is "configured to" perform a specified function is specifically selected, created, implemented, utilized, programmed, and/or designed for the purpose of performing the specified function. As used herein, "configured to" refers to an existing characteristic of a system, apparatus, structure, article, element, component, or hardware that enables the system, apparatus, structure, article, element, component, or hardware to perform a specified function without further modification. For purposes of this disclosure, a system, device, structure, article, element, component, or hardware described as "configured to" perform a particular function may additionally or alternatively be described as "adapted to" and/or "operable to" perform that function.

The following provides illustrative, non-exhaustive embodiments of the subject matter disclosed herein that may or may not be claimed.

Referring to fig. 1A and 1B generally, and in particular, for example, to fig. 2-34, which are for illustrative purposes only and not by way of limitation, an additive manufacturing apparatus 100 is disclosed. Additive manufacturing apparatus 100 includes a support 102 and a powder material source 106. Additive manufacturing apparatus 100 also includes a powder supply arm 108 having a powder supply arm central axis a 2. The powder supply arm 108 includes a hollow body 122 having an internal volume 124 in communication with the powder material source 106 such that the powder material 202 may be transferred from the powder material source 106 to the internal volume 124. The powder supply arm 108 also includes a powder deposition opening 126 in the hollow body 122. The powder deposition opening 126 has a width W and is in communication with the internal volume 124 of the hollow body 122 such that the powder material 202 may be transferred out of the internal volume 124 through the powder deposition opening 126. The powder supply arm 108 also includes a powder distribution blade 128 coupled to the hollow body 122 and extending along the powder deposition opening 126. Additive manufacturing apparatus 100 also includes an energy source 110 and an energy supply arm 112 having an energy supply arm central axis a 3. The additive manufacturing apparatus 100 additionally includes an energy emitter 114 coupled to the energy supply arm 112. The energy emitter 114 is configured to be one of in electrical communication or optical communication with the energy source 110. Additive manufacturing apparatus 100 also includes a rotary drive 116, which rotary drive 116 is configured to rotate powder supply arm 108 and energy supply arm 112 about a vertical axis a1 that passes through support 102 and intersects powder supply arm central axis a2 and energy supply arm central axis A3. The previous section of this paragraph depicts features of embodiment one of the subject matter disclosed herein.

Additive manufacturing apparatus 100 enables substantially continuous (e.g., uninterrupted) deposition, distribution, and consolidation of at least a portion of powder material 202 as powder supply arm 108 and energy supply arm 112 rotate about vertical axis a1, which improves the processing speed of additive manufacturing operations by eliminating changes in direction (e.g., the need for linear, back-and-forth motion) and thus eliminating corresponding acceleration and deceleration of operational components of additive manufacturing apparatus 100 during deposition, distribution, and consolidation of powder material 202.

Additive manufacturing apparatus 100 is configured to advantageously facilitate a reduction in time and energy associated with additive manufacturing of object 200 from powder material 202, which in turn increases the overall efficiency of additive manufacturing apparatus 100. The additive manufacturing apparatus 100 is also configured to advantageously facilitate automated deposition, dispensing, and consolidation of the powder material 202 to form the object 200.

Object 200 is any three-dimensional object manufactured using additive manufacturing apparatus 100 and according to method 1000, the object 200 being built from a Computer Aided Design (CAD) model by continuously adding material layer-by-layer. In one or more embodiments, object 200 is any of the structures, components, parts, assemblies, and subassemblies of an aircraft (e.g., aircraft 1102 of fig. 37).

The powder material 202 is any of various types of suitable additive manufacturing powders. In one or more embodiments, the powder material 202 is a metal powder or metal alloy powder including, but not limited to, cobalt, copper, inconel, nickel, precious metals (e.g., gold, silver, platinum), stainless steel, tantalum, titanium, tool steel, tungsten, and combinations thereof. In one or more embodiments, the powder material 202 is a thermoplastic powder or other polymer-based powder, including, but not limited to, acetal, acrylic, Acrylonitrile Butadiene Styrene (ABS), Acrylonitrile Styrene Acrylate (ASA), High Impact Polystyrene (HIPS), nylon, Polycarbonate (PC), Polyetheretherketone (PEEK), polyethylene terephthalate (PET), polytrimethylene terephthalate (PETT), polyethylene terephthalate glycol modifier (PETG), polylactic acid (PLA), polypropylene (PP), polyvinyl alcohol (PVA), thermoplastic elastomers (TPE), polyetherimide, and combinations thereof.

Support 102 is any suitable support structure, and support 102 is configured to hold powder supply arm 108 and energy supply arm 112, and is configured to allow powder supply arm 108 and energy supply arm 112 to rotate about vertical axis a 1. In one or more embodiments, the support 102 is an overhead support structure configured to hold the powder supply arm 108 and the energy supply arm 112 in a horizontal orientation, such as above the powder bed volume 204 (fig. 26-28). In one or more embodiments, the support 102 comprises or takes the form of an overhead gantry. In one or more embodiments, the support 102 comprises or takes the form of an elevated platform.

As used herein, relative terms, such as horizontal, vertical, parallel, vertical, and the like, include the case where the item is exactly the condition and the case where the item is approximately the condition. As used herein, the term "approximately" refers to conditions that are close, but not precisely close, yet perform a desired function or achieve a desired result, e.g., conditions within an acceptable predetermined tolerance or accuracy. For example, the term "approximately" refers to conditions within 10% of the stated conditions. However, the term "approximately" does not exclude conditions that are exactly the stated conditions.

In one or more embodiments, the powdered material source 106 includes any suitable container configured to store a quantity of powdered material 202 for use in an additive manufacturing process. The powder material 202 may be fresh powder material or recycled powder material. The powder material source 106 is also configured to transfer the powder material 202 to the powder supply arm 108. In one or more embodiments, the powder material source 106 includes a powder transfer mechanism in communication with the interior volume 124 of the hollow body 122 of the powder supply arm 108 and configured to transport or otherwise feed the powder material 202 to the interior volume 124 of the hollow body 122.

In one or more embodiments, the powder deposition opening 126 extends along the powder supply arm central axis a 2. The powder deposition opening 126 is configured to discharge the powder material 202 such that, as the powder supply arm 108 rotates about the vertical axis a1, the powder material 202 is deposited from the interior volume 124 of the hollow body 122 to the powder bed volume 204 (fig. 1A) through the powder deposition opening 126. The powder deposition opening 126 has any of a variety of shapes as viewed along the vertical axis a 1. The width W of the powder deposition opening 126 is of any suitable size. It will be appreciated that the shape and/or width W of the powder deposition opening 126 may depend on the type of powder material 202, the desired discharge rate for the powder material 202, the rotational speed of the powder supply arm 108, and the like.

The powder distribution blade 128 is configured to distribute the powder material 202 discharged from the powder deposition opening 126 such that the powder material 202 moves substantially uniformly throughout the powder bed volume 204 as the powder supply arm 108 rotates about the vertical axis a 1. The powder distribution blade 128 is also configured to smooth the powder material 202 for subsequent consolidation using the energy emitter 114. In one or more embodiments, the powder distribution blade 128 extends downward from the hollow body 122 and includes a smooth edge positioned opposite the hollow body 122.

The energy source 110 is configured to generate and/or supply energy to the energy emitter 114. In one or more embodiments, the energy source 110 is configured to supply electrical energy (e.g., power) to the energy emitter 114. In such embodiments, the energy source 110 includes or takes the form of any suitable generator or other power source. In one or more embodiments, the energy source 110 is configured to supply optical energy (e.g., laser light) to the energy emitter 114. In such embodiments, the energy source 110 includes or takes the form of any suitable laser.

The energy emitter 114 is configured to consolidate the powder material 202. As used herein, the terms "consolidating," "consolidating," and similar terms refer to heating a portion of the powder material 202 to fuse them together and form a solid. Each of the energy emitters 114 is configured to generate and/or emit an energy beam 228 (fig. 29 and 30) such that, as the energy supply arm 112 rotates about the vertical axis a1, the energy emitter 114 selectively consolidates a portion of the powder material 202 to form a portion of the object 200. In one or more embodiments, each of the energy emitters 114 is selectively controlled or actuated such that the energy beam 228 is emitted at a predetermined location or for a predetermined period of time during rotation of the energy supply arm 112 about the vertical axis a 1. In one or more embodiments, the energy beam 228 is in the form of a beam of optical energy (e.g., a laser beam) or electrical energy (e.g., an electron beam). In one or more embodiments, consolidating the powder material 202 includes completely melting a portion of the powder material 202 using the energy beam 228, such as by selective laser melting or electron beam melting. In such embodiments, each of the energy emitters 114 is configured to generate and/or emit a laser beam or an electron beam to consolidate the powder material 202. In one or more embodiments, consolidating the powder material 202 includes sintering the powder material using the energy beam 228, such as by selective laser sintering. In such embodiments, each of the energy emitters 114 is configured to emit a laser beam to consolidate the powder material 202.

The rotary drive 116 includes any suitable drive mechanism configured to rotate the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1. In one or more embodiments, the rotary drive 116 is configured to simultaneously rotate the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1. In one or more embodiments, the rotary drive 116 is configured to independently rotate the powder supply arm 108 and the energy supply arm 112 about a vertical axis a 1. As used herein, the terms "rotate," "rotating," "rotation," and similar terms refer to movement of a body about an axis and include states in which the axis extends through a center of mass of the body (e.g., spinning), states in which the axis extends through the body but not through the center of mass of the body (e.g., turning), and states in which the axis does not extend through the body (e.g., gyrating).

In one or more embodiments, the rotary drive 116 is configured to continuously rotate the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 relative to the support 102. The continuous rotation of the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 improves processing time and efficiency by eliminating the directional changes and corresponding acceleration and deceleration periods associated with conventional powder dispensing and consolidation techniques.

Referring to fig. 1A and 1B generally, and to fig. 2-4 in particular, for illustration purposes only and not by way of limitation, rotary drive 116 is configured to rotate powder supply arm 108 and energy supply arm 112 about vertical axis a1 at a constant speed. The foregoing section of this paragraph describes features of embodiment two of the subject matter disclosed herein, wherein embodiment two also includes embodiment one described above.

The continuous rotation of the powder supply arm 108 and the energy supply arm 112 at a constant speed (e.g., at a constant angular speed) further improves processing time and efficiency by eliminating accelerations and decelerations associated with speed changes. The rotation of the energy supply arm 112 and thus the energy emitter 114 at a constant speed also simplifies the command and control of the actuation of the energy emitter 114.

Rotation of the energy supply arm 112 enables the energy emitter 114 to be positioned using a polar coordinate system. For example, throughout rotation of energy supply arm 112 about vertical axis a1, the two-dimensional position of each of energy emitters 114 is determined by the distance from a reference point and the angle from a reference direction. Thus, with energy supply arm 112 rotating at a constant speed, the position of each of energy emitters 114 may be easily calculated and accurately predicted at any time during formation of object 200 (e.g., during an additive manufacturing process for forming object 200). In one or more embodiments, during rotation of the energy supply arm 112, one or more of the energy emitters 114 are selectively actuated after a predetermined time or for a predetermined period of time based on the position of the energy supply arm 112 to consolidate a portion of the powder material 202.

Referring to fig. 1A and 1B generally, and to fig. 27-30 in particular, for example, in one or more embodiments, additive manufacturing apparatus 100 includes a controller 238. In one or more embodiments, controller 238 includes or takes the form of a suitable computing device in communication with one or more operational components of additive manufacturing apparatus 100 and configured to control the one or more operational components and perform one or more computing or processing operations of an additive manufacturing process. In one or more embodiments, the controller 238 includes at least one processor configured to execute program instructions, such as software instructions loaded onto a memory (e.g., a non-transitory computer-readable storage medium).

In one or more embodiments, the controller 238 communicates with and controls at least a portion of the operating functions of the rotary drive 116. For example, the controller 238 is configured to control activation of the rotary drive 116 and to set the rotational speed of the powder supply arm 108 and the energy supply arm 112.

In one or more embodiments, the controller 238 communicates with and controls at least a portion of the operating functions of the powder material source 106. For example, the controller 238 is configured to control the feed rate of the powder material 202 from the powder material source 106 to the interior volume 124 of the hollow body 122 of the powder supply arm 108.

In one or more embodiments, controller 238 communicates with and controls at least a portion of the operating functions of energy source 110. For example, the controller 238 is configured to control activation of the energy source 110 and an operating parameter (e.g., electrical or optical output) of the energy source 110.

In one or more embodiments, the controller 238 communicates with and controls at least a portion of the operating functions of the energy emitter 114. In one or more embodiments, the controller 238 is configured to selectively actuate each of the energy emitters 114 such that the energy beam 228 consolidates a portion of the powder material 202 at a predetermined location in the powder bed volume 204 (fig. 29 and 30) during rotation of the energy supply arm 112. In one or more embodiments, the controller 238 is configured to adjust the power level of the energy emitter 114 during rotation of the energy supply arm 112.

It will be appreciated that during rotation of the energy supply arm 112 about the vertical axis a1, energy emitters 114 located further from the vertical axis a1 rotate faster about the vertical axis a1 than energy emitters 114 located closer to the vertical axis a 1. Generally, the rotational speed of the energy emitter 114 increases in proportion to the distance from the vertical axis a 1. Thus, during rotation of the energy supply arm 112, portions of the powder material 202 located farther from the vertical axis a1 receive energy or are heated for less period of time than portions of the powder material 202 located closer to the vertical axis a 1. Thus, in one or more embodiments, the first power level of the energy emitter 114 located farther from the vertical axis a1 is greater than the second power level of the energy emitter 114 located closer to the vertical axis a1, such that the first energy deposited to the portion of the powder material 202 located farther from the vertical axis a1 is greater than the second energy deposited to the portion of the powder material 202 located closer to the vertical axis a 1. Generally, the power level of the energy emitter 114 increases in proportion to the distance from the vertical axis a 1.

Referring to fig. 1A and 1B generally, and to fig. 2-5, 8, 11-19, 22, 26-28, 31, and 34, for example, in particular, for illustrative purposes only and not by way of limitation, additive manufacturing apparatus 100 also includes a shaft 104 coupled to support 102. The powder supply arm 108 and the energy supply arm 112 are coupled to the shaft 104. The foregoing section of this paragraph describes features of embodiment three of the subject matter disclosed herein, wherein embodiment three further includes either embodiment one or two above.

The shaft 104 structurally supports the powder supply arm 108 and the energy supply arm 112 while rotating about a vertical axis a 1.

The shaft 104 is any suitable structure capable of supporting the powder supply arm 108 and the energy supply arm 112 and configured to allow the powder supply arm 108 and the energy supply arm 112 to rotate about the vertical axis a 1. In one or more embodiments, the shaft 104 includes or takes the form of a relatively straight elongated body extending from the support 102. In one or more embodiments, each of the powder supply arm 108 and the energy supply arm 112 is coupled to an end of the shaft 104 opposite the support 102. In one or more embodiments, the vertical axis a1 passes through the shaft 104, such as through the center of mass of the shaft 104.

Referring to fig. 1A and 1B generally, and to fig. 2, 4, 27, and 28 in particular, for illustrative purposes only and not by way of limitation, the powder supply arm 108 and the energy supply arm 112 are fixed to the shaft 104 such that the powder supply arm 108 and the energy supply arm 112 cannot rotate and translate relative to the shaft 104. The rotation drive 116 is configured to rotate the shaft 104 relative to the support 102 about a vertical axis a 1. The foregoing section of this paragraph describes features of embodiment four of the subject matter disclosed herein, wherein embodiment four also includes embodiment three above.

Rotation of the shaft 104 relative to the support 102 rotates the powder supply arm 108 and the energy supply arm 112 about a vertical axis a 1.

In one or more embodiments, the shaft 104 is coupled to the support 102 and is rotatable relative to the support 102. In one or more embodiments, a bearing is located between support 102 and shaft 104 and is coupled to support 102 and shaft 104, which enables shaft 104 to rotate about vertical axis a1 relative to support 102. In one or more embodiments, the rotational drive 116 is coupled to a bearing. Activation of the rotary drive 116 rotates the shaft 104 relative to the support 102 about a vertical axis a 1.

Referring to fig. 1A and 1B generally, and to fig. 3, for illustration purposes only and not by way of limitation, and in particular to fig. 3, the rotary drive 116 is configured to rotate the powder supply arm 108 and the energy supply arm 112 about a vertical axis a1 relative to the shaft 104. The foregoing section of this paragraph describes features of embodiment five of the subject matter disclosed herein, wherein embodiment five further includes embodiment three above.

Rotation of the powder supply arm 108 and the energy supply arm 112 relative to the shaft 104 rotates the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1.

In one or more embodiments, the shaft 104 is coupled to the support 102 and is fixed relative to the support 102. Each of the powder supply arm 108 and the energy supply arm 112 is coupled to the shaft 104 and is rotatable relative to the shaft 104. In one or more embodiments, bearings are located between the shaft 104 and the powder supply arm 108 and the energy supply arm 112 and are coupled to the shaft 104 and the powder supply arm 108 and the energy supply arm 112, which enable the powder supply arm 108 and the energy supply arm 112 to rotate about the vertical axis a1 relative to the shaft 104. In one or more embodiments, the rotational drive 116 is coupled to a bearing. Activation of the rotary drive 116 rotates the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 relative to the shaft 104.

Referring to fig. 1A and 1B generally, and to fig. 2-4, 27, and 28 in particular, for example, and for purposes of illustration only and not by way of limitation, the powder supply arm 108 further includes a conveyor screw 140 located within the interior volume 124 of the hollow body 122 and extending along the powder deposition opening 126. The powder supply arm 108 also includes a motor 138 configured to rotate a conveyor screw 140. The foregoing section of this paragraph describes features of embodiment six of the subject matter disclosed herein, wherein embodiment six further includes any of the above embodiments one through five.

Rotation of the conveyor screw 140 facilitates movement of the powder material 202 through the interior volume 124 of the hollow body 122 along the powder supply arm central axis a2, e.g., from the proximal end of the powder supply arm 108 to the distal end of the powder supply arm 108.

The conveyor screw 140 is any suitable screw conveyor mechanism, which conveyor screw 140 uses the rotation of a helical screw blade to move the powder material 202 along the powder supply arm central axis a2 in a direction away from the vertical axis a 1. In one or more embodiments, the conveyor screw 140 is a shaftless or centerless screw conveyor. In one or more embodiments, the conveyor screw 140 is an auger. The motor 138 is any suitable rotary drive mechanism, and the motor 138 is coupled to the conveyor screw 140 and configured to rotate the conveyor screw 140 about an axis of rotation relative to the hollow body 122.

Alternatively, the additive manufacturing apparatus 100 may use a different device that conveys the powder material 202 along the powder supply arm central axis a2 through the internal volume 124 of the hollow body 122. In one or more embodiments, the additive manufacturing apparatus 100 includes a positive pressure system or blower mechanism to move the powder material 202 through the hollow body 122. In one or more embodiments, additive manufacturing apparatus 100 uses centrifugal forces acting on powder material 202 during rotation of powder supply arm 108 to move powder material 202 through hollow body 122.

Referring to fig. 1A and 1B generally, and to fig. 11 and 13 for example in particular, for illustrative purposes only and not by way of limitation, the width W of the powder deposition opening 126 is constant along the powder supply arm central axis a 2. The foregoing section of this paragraph describes features of embodiment seven of the subject matter disclosed herein, wherein embodiment seven further includes any of the above embodiments one through six.

The width W of the powder deposition opening 126 is constant along the powder deposition opening 126, which facilitates depositing approximately equal amounts of powder material 202 closer to the vertical axis a1 and further from the vertical axis a 1.

By constant width W, it is meant that the width W of the powder deposition opening 126 is substantially the same at every location along the powder deposition opening 126, for example, from a proximal end of the powder deposition opening 126 located adjacent to the vertical axis a1 to a distal end of the powder deposition opening 126 opposite the proximal end and spaced away from the vertical axis a 1. During rotation of the powder supply arm 108 about the vertical axis a1, the powder material 202 is expelled from the interior volume 124 of the hollow body 122 through the powder deposition opening 126. The constant width W of the powder deposition opening 126 enables approximately the same amount of powder material 202 to be discharged along the length of the powder deposition opening 126, resulting in approximately the same amount of powder material 202 being deposited into the powder bed volume 204 at a location closer to the vertical axis a1 and further from the vertical axis a 1.

Referring to fig. 1A and 1B generally, and to fig. 12 and 14, for example, in particular, for illustrative purposes only and not by way of limitation, the width W of the powder deposition opening 126 increases in a direction along the powder supply arm central axis a2 and away from the vertical axis a 1. The foregoing section of this paragraph describes features of embodiment eight of the subject matter disclosed herein, wherein embodiment eight further includes any of the above embodiments one through six.

The increase in the width W of the powder deposition opening 126 in a direction along the powder supply arm central axis a2 and away from the vertical axis a1 facilitates the deposition of a lesser amount of powder material 202 closer to the vertical axis a1 and a greater amount of powder material 202 further from the vertical axis a 1.

By increased width W is meant that the width W of the powder deposition opening 126 is smaller at a location at or near the proximal end of the powder deposition opening 126 and larger at a location at or near the distal end of the powder deposition opening 126. The increased width W of the powder deposition opening 126 increases the amount of powder material 202 discharged along the length of the powder deposition opening 126, resulting in a smaller amount of powder material 202 being deposited to the powder bed volume 204 at a location closer to the vertical axis a1, and a larger amount of powder material 202 being deposited to the powder bed volume 204 at a location further from the vertical axis a 1.

In one or more embodiments, the width W of the powder deposition opening 126 increases in proportion to the distance from the vertical axis a 1. Thus, the amount of powder material 202 discharged from the powder deposition opening 126, and thus the amount of powder material 202 deposited to the powder bed volume 204, increases in proportion to the distance from the vertical axis a 1.

It will be appreciated that the relative surface area of the powder bed volume 204 is greater at locations further from the vertical axis a1 as compared to the surface area of the powder bed volume 204 at locations closer to the vertical axis a 1. Therefore, it is beneficial to deposit a greater amount of powder material 202 at a location away from the vertical axis a 1. When the powder material 202 is dispensed using the powder dispensing blade 128 during rotation of the powder supply arm 108, the larger amount of powder material 202 deposited in a direction extending away from the vertical axis a1 provides a sufficient amount of powder material 202 to adequately and uniformly cover the powder bed volume 204.

Referring to fig. 1A and 1B generally, and to fig. 6, 7, 9-12, 15-17, 24, 25, and 31-33 for example, in particular, for illustrative purposes only and not by way of limitation, the powder deposition opening 126 is continuous and extends along the powder supply arm central axis a 2. The foregoing section of this paragraph describes features of embodiment nine of the subject matter disclosed herein, wherein embodiment nine further includes any of the above embodiments one through eight.

The powder deposition opening 126 is continuous and extends along the powder supply arm central axis a2, which facilitates the deposition of an approximately continuous amount of powder material 202 in a direction extending away from the vertical axis a 1.

The approximately continuous amount of powder material 202 deposited to the powder bed volume 204 in a direction extending away from the vertical axis a1 provides substantially continuous coverage of the powder material 202 and reduces reliance on the powder distribution blades 128 to evenly distribute the powder material 202 during rotation of the powder supply arm 108. In one or more embodiments, the powder deposition openings 126 are continuous elongated openings or slots formed in the hollow body 122.

Referring to fig. 1A and 1B generally, and to fig. 13 and 14 for example in particular, for illustrative purposes only and not by way of limitation, the powder deposition openings 126 are a plurality of holes 142 extending along a powder supply arm central axis a 2. The foregoing section of this paragraph describes features of embodiment ten of the subject matter disclosed herein, wherein embodiment ten further includes any of the above embodiments one through eight.

The powder deposition openings 126, which are a plurality of holes 142, extend along the powder supply arm central axis a2, which facilitates the deposition of discrete amounts of powder material 202 in a direction extending away from the vertical axis a 1. The powder deposition openings 126 as a plurality of apertures 142 also increase the structural integrity of the hollow body 122 as compared to the powder deposition openings 126 as continuous elongated openings.

In one or more embodiments, each of the plurality of holes 142 is formed in the hollow body 122 and is in communication with the internal volume 124 of the hollow body 122 such that a portion of the powder material 202 can be transferred out of the internal volume 124 through a corresponding hole of the plurality of holes 142. Each of the plurality of apertures 142 has any of a variety of suitable geometries, such as a two-dimensional shape and size viewed along the vertical axis a 1. It will be appreciated that the geometry of the plurality of holes 142 may depend on the type of powder material 202, the desired discharge rate for the powder material 202, the rotational speed of the powder supply arm 108, and the like.

Referring to fig. 1A and 1B generally, and to fig. 11-14, 26, and 31 in particular, for illustration purposes only and not by way of limitation, the powder supply arm 108 further includes a door 144 coupled to the hollow body 122. The door 144 is movable relative to the hollow body 122 to at least partially open or close the powder deposition opening 126. The foregoing section of this paragraph describes features of embodiment eleven of the subject matter disclosed herein, wherein embodiment eleven further includes any one of the above embodiments one through ten.

The door 144 enables the powder deposition opening 126 to be selectively opened (e.g., partially or fully) and closed such that the powder material 202 can be selectively discharged from the powder deposition opening 126 during rotation of the powder supply arm 108.

The door 144 includes or takes the form of any suitable body configured to selectively cover the powder deposition opening 126 and enclose the interior volume 124 of the hollow body 122. In one or more embodiments, the door 144 extends along the powder deposition opening 126. In one or more embodiments, the door 144 translates relative to the hollow body 122 to at least partially open or close the powder deposition opening 126. In one or more embodiments, the door 144 rotates or pivots relative to the hollow body 122 to at least partially open or close the powder deposition opening 126.

In one or more embodiments, when the door 144 is positioned relative to the hollow body 122 of the powder supply arm 108 such that the powder deposition opening 126 is partially open, the door 144 is configured to selectively control the width W of the powder deposition opening 126. By selectively controlling the width W of the powder deposition opening 126, the rate at which the powdered material 202 is discharged from the powder deposition opening 126 can be selectively controlled while rotating the powder supply arm 108 about the vertical axis a 1. It may be appreciated that for a given additive manufacturing operation, it may be beneficial to adjust the width of the powder deposition opening 126, for example, based on the type of powder material 202, the desired discharge rate of the powder material 202, the rotational speed of the powder supply arm 108, and so forth.

Referring to fig. 1A and 1B generally, and to fig. 31 for example in particular, for illustrative purposes only and not by way of limitation, when the door 144 is positioned relative to the hollow body 122 of the powder supply arm 108 such that the powder deposition opening 126 is partially open, the width W of at least a portion of the powder deposition opening 126 increases along the powder supply arm central axis a2 of the powder supply arm 108 in a direction away from the vertical axis a 1. The foregoing section of this paragraph describes features of example twelve of the subject matter disclosed herein, wherein example twelve further comprises example eleven above.

By positioning the door 144 such that the powder deposition opening 126 is partially open, the width W of the powder deposition opening 126 can be increased in a direction extending away from the vertical axis a1, thereby facilitating the deposition of a smaller amount of powder material 202 closer to the vertical axis a1 and a larger amount of powder material 202 further from the vertical axis a 1.

In one or more embodiments, when the door 144 is positioned relative to the hollow body 122 of the powder supply arm 108 such that the powder deposition opening 126 is partially open, the width W of the powder deposition opening 126 at a first location along the powder deposition opening 126 is greater than the width W of the powder deposition opening 126 at a second location along the powder deposition opening 126 that is closer to the vertical axis a1 than the first location. In one or more embodiments, when the door 144 is positioned relative to the hollow body 122 of the powder supply arm 108 such that the powder deposition opening 126 is partially open, the width W of the powder deposition opening 126 increases in proportion to the distance from the vertical axis a 1.

Referring to fig. 1A and 1B generally, and to fig. 11, 13 and 31 for example in particular, for purposes of illustration only and not by way of limitation, when the door 144 is positioned relative to the hollow body 122 of the powder supply arm 108 such that the powder deposition opening 126 is fully open, the width W of the powder deposition opening 126 is constant along the powder supply arm central axis a 2. The foregoing section of this paragraph describes features of embodiment thirteen of the subject matter disclosed herein, wherein embodiment thirteen further includes the above embodiment eleven or twelve.

By positioning the door 144 such that the powder deposition opening 126 is fully open, powder deposition openings 126 having a constant width W along the powder deposition opening 126 can be used, thereby facilitating deposition of substantially the same amount of powder material 202 closer to the vertical axis a1 and further from the vertical axis a 1.

In one or more embodiments, when the door 144 is positioned relative to the hollow body 122 of the powder supply arm 108 such that the powder deposition opening 126 is fully open, the width W of the powder deposition opening 126 at a first location along the powder deposition opening 126 is substantially the same as the width W of the powder deposition opening 126 at a second location along the powder deposition opening 126 that is closer to the vertical axis a1 than the first location.

Referring to fig. 1A and 1B generally, and to fig. 12 and 14 in particular, for example, in one or more embodiments, when the door 144 is positioned relative to the hollow body 122 of the powder supply arm 108 such that the powder deposition opening 126 is partially open, the width W of at least a portion of the powder deposition opening 126 increases along the powder supply arm central axis a2 of the powder supply arm 108 in a direction away from the vertical axis a 1.

Referring to fig. 1A and 1B generally, and to fig. 11 in particular, for purposes of illustration only and not by way of limitation, the powder deposition opening 126 has an opening length L1. The powder distribution blade 128 has a blade length L2. The vane length L2 is equal to or greater than the opening length L1. The foregoing section of this paragraph describes features of embodiment fourteen of the subject matter disclosed herein, wherein embodiment fourteen further includes any one of the above embodiments one to thirteen.

The powder distribution blade 128, which is as long or longer than the powder deposition opening 126, facilitates full distribution of the quantity of powder material 202 discharged from the powder deposition opening 126 during rotation of the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1.

Referring to fig. 1A and 1B generally, and to fig. 32 and 33 for example in particular, and for illustrative purposes only and not by way of limitation, the powder supply arm 108 has a powder supply arm proximal end 134 and a powder supply arm distal end 136 located opposite the powder supply arm proximal end 134 along a powder supply arm central axis a 2. The energy supply arm 112 has an energy supply arm proximal end 154 and an energy supply arm distal end 156 positioned opposite the energy supply arm proximal end 154 along an energy supply arm central axis a 3. The powder supply arm central axis a2 and the energy supply arm central axis A3 are inclined to each other when viewed along the vertical axis a 1. The foregoing section of this paragraph describes features of embodiment fifteen of the subject matter disclosed herein, wherein embodiment fifteen further includes any of the embodiments one through fourteen described above.

The powder supply arm central axis a2 and the energy supply arm central axis A3 being inclined to each other angularly displace the powder supply arm 108 and the energy supply arm 112 relative to each other during rotation of the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1.

In one or more embodiments, the powder supply arm central axis a2 and the energy supply arm central axis A3 being inclined to each other facilitate a delay between depositing and dispensing a layer of powder material 202 using the powder supply arm 108 and consolidating a portion of a layer of powder material 202 using the energy supply arm 112 during rotation of the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1. In one or more embodiments, during rotation of the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1, the powder supply arm central axis a2 and the energy supply arm central axis A3 that are inclined to each other facilitate a delay between consolidating a portion of a previous layer of powder material 202 using the energy supply arm 112 and depositing and dispensing a subsequent layer of powder material 202 using the powder supply arm 108.

Referring to fig. 1A and 1B generally, and to fig. 7 and 10 for example in particular, and for purposes of illustration only and not by way of limitation, the powder supply arm 108 has a powder supply arm proximal end 134 and a powder supply arm distal end 136 located opposite the powder supply arm proximal end 134 along a powder supply arm central axis a 2. The energy supply arm 112 has an energy supply arm proximal end 154 and an energy supply arm distal end 156 positioned opposite the energy supply arm proximal end 154 along an energy supply arm central axis a 3. The powder supply arm central axis a2 and the energy supply arm central axis A3 are orthogonal to each other when viewed along the vertical axis a 1. The foregoing section of this paragraph describes features of embodiment sixteen of the subject matter disclosed herein, wherein embodiment sixteen further includes any of the above embodiments one through fourteen.

During rotation of the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1, the powder supply arm central axis a2 and the energy supply arm central axis A3, which are orthogonal to each other, angularly displace the powder supply arm 108 and the energy supply arm 112 relative to each other.

In one or more embodiments, the mutually orthogonal powder supply arm central axis a2 and energy supply arm central axis A3 facilitate a delay between depositing and dispensing a layer of powder material 202 using the powder supply arm 108 and consolidating a portion of the layer of powder material 202 using the energy supply arm 112 during rotation of the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1. In one or more embodiments, during rotation of the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1, the powder supply arm central axis a2 and the energy supply arm central axis A3, which are orthogonal to each other, facilitate a delay between consolidating a portion of a previous layer of powder material 202 using the energy supply arm 112 and depositing and dispensing a subsequent layer of powder material 202 using the powder supply arm 108.

Referring to fig. 1A and 1B generally, and to fig. 5, 8, and 9 in particular, for illustration purposes only and not by way of limitation, the powder supply arm 108 has a powder supply arm proximal end 134 and a powder supply arm distal end 136 located opposite the powder supply arm proximal end 134 along a powder supply arm central axis a 2. The energy supply arm 112 has an energy supply arm proximal end 154 and an energy supply arm distal end 156 positioned opposite the energy supply arm proximal end 154 along an energy supply arm central axis a 3. When viewed along vertical axis a1, powder supply arm central axis a2 and energy supply arm central axis A3 are collinear with each other, and powder supply arm 108 and energy supply arm 112 extend in opposite directions away from vertical axis a 1. The foregoing section of this paragraph describes features of an embodiment seventeen of the subject matter disclosed herein, wherein embodiment seventeen further includes any of the above embodiments one through fourteen.

During rotation of the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1, the powder supply arm central axis a2 and the energy supply arm central axis A3, which are collinear with each other and extend in opposite directions away from the vertical axis a1, angularly displace the powder supply arm 108 and the energy supply arm 112 relative to each other.

In one or more embodiments, the powder supply arm central axis a2 and the energy supply arm central axis A3 are collinear with each other and extend in opposite directions away from the vertical axis a1, which facilitates a delay between depositing and dispensing a layer of powder material 202 using the powder supply arm 108 and consolidating a portion of a layer of powder material 202 using the energy supply arm 112 during rotation of the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1. In one or more embodiments, the powder supply arm central axis a2 and the energy supply arm central axis A3 are collinear with each other and extend in opposite directions away from the vertical axis a1, which facilitates a delay between consolidating a portion of a previous layer of powder material 202 using the energy supply arm 112 and depositing and dispensing a subsequent layer of powder material 202 using the powder supply arm 108 during rotation of the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1.

Referring to fig. 1A and 1B generally, and to fig. 15 in particular, for purposes of illustration only and not by way of limitation, the powder distribution blade 128 has a blade central axis a 4. The vane central axis a4 is oblique to the powder supply arm central axis a2 when viewed along the vertical axis a 1. The foregoing section of this paragraph describes features of embodiment eighteen of the subject matter disclosed herein, wherein embodiment eighteen further includes any of the above embodiments one through seventeen.

When the powder supply arm 108 is rotated about the vertical axis a1, the vane central axis a4, which is oblique to the powder supply arm central axis a2, facilitates movement of the powder material 202 in a direction away from the vertical axis a1 (e.g., radially outward relative to the vertical axis a1) using the powder distribution vanes 128 to form a uniform layer of the powder material 202 within the powder bed volume 204.

As expressed above, it can be appreciated that the relative surface area of the powder bed volume 204 is greater at locations further from the vertical axis a1 as compared to the surface area of the powder bed volume 204 at locations closer to the vertical axis a 1. Thus, it is beneficial to move a portion of the powder material 202 at a position closer to the vertical axis a1 in a direction away from the vertical axis a1 to a position further away from the vertical axis a 1. When the powder material 202 is dispensed using the powder dispensing blade 128 during rotation of the powder supply arm 108, a portion of the powder material 202 moving in a direction extending away from the vertical axis a1 provides a sufficient amount of the powder material 202 to sufficiently and uniformly cover the powder bed volume 204.

During rotation of the powder supply arm 108, the powder dispensing blade 128 engages a quantity of powder material 202 newly deposited from the powder deposition opening 126. The powder dispensing blade 128 dispenses (e.g., pushes or moves) the powder material 202 in a direction of movement perpendicular to the blade central axis a4 during rotation of the powder supply arm 108. By orienting the vane central axis a4 oblique to the powder supply arm central axis a2, the direction of movement of the powder material 202 is adjusted such that a portion of the powder material 202 moves in a direction away from (e.g., radially outward of) the vertical axis a 1.

The relative angular orientation between the vane central axis a4 and the powder supply arm central axis a2 is any of a variety of inclination angles. In one or more embodiments, the selected tilt angle depends on various factors, such as the type of powder material 202 used, the rotational speed of the powder supply arm 108, the configuration and geometry of the powder deposition opening 126, and the like. In one or more embodiments, the relative angular orientation between the vane central axis a4 and the powder supply arm central axis a2 is less than about ninety degrees. In one or more embodiments, the relative angular orientation between the vane central axis a4 and the powder supply arm central axis a2 is less than about forty-five degrees.

Referring to fig. 1A and 1B generally, and to fig. 16 in particular, for illustrative purposes only and not by way of limitation, the powder supply arm 108 has a powder supply arm proximal end 134 and a powder supply arm distal end 136 positioned opposite the powder supply arm proximal end 134. The powder supply arm 108 also includes a powder barrier 146 that is coupled to the powder distribution blade 128 proximate the powder supply arm proximal end 134 and extends between the powder deposition opening 126 and the vertical axis a 1. The foregoing section of this paragraph describes features of embodiment nineteen of the subject matter disclosed herein, wherein embodiment nineteen further includes any of the embodiments one to eighteen described above.

The powder barrier 146 prevents the powder material 202 from moving in a direction toward the vertical axis a1 (e.g., radially inward with respect to the vertical axis a1) when the powder supply arm 108 is rotated about the vertical axis a1 during the dispensing of the powder material 202 using the powder dispensing blade 128.

In one or more embodiments, the powder barrier 146 is coupled to the hollow body 122 of the powder supply arm 108 and extends downward from the hollow body 122. In one or more embodiments, the powder barrier 146 is positioned adjacent to the proximal end of the powder deposition opening 126. In one or more embodiments, the powder barrier 146 has a length that is greater than the width W (fig. 11-14) of the powder deposition opening 126.

Referring to fig. 1A and 1B generally, and to fig. 2-4, 27 and 28, for example, in particular, for illustrative purposes only and not by way of limitation, the source of powder material 106 includes a hopper 148. The powder supply arm 108 also includes a powder supply opening 132 formed in the hollow body 122. The powder supply opening 132 communicates with the interior volume 124 of the hollow body 122. The hopper 148 is in communication with the powder supply opening 132 such that the powder material 202 may be transferred from the hopper 148 to the internal volume 124 through the powder supply opening 132. The foregoing section of this paragraph describes features of embodiment twenty of the subject matter disclosed herein, wherein embodiment twenty further includes any of the above embodiments one through nineteen.

The hopper 148 facilitates discharging the powder material 202 via the powder supply opening 132 into the interior volume 124 of the hollow body 122 of the powder supply arm 108.

The hopper 148 is any suitable container, and the hopper 148 is configured to store a volume of powder material 202 and transfer a portion of the powder material 202 to the internal volume 124 of the hollow body 122 through the powder supply opening 132. In one or more embodiments, the hopper 148 has a downward taper and is configured to discharge the powder material 202 from the bottom.

Referring to fig. 1A and 1B generally, and to fig. 2, 4, 27 and 28, for example, in particular, for illustrative purposes only and not by way of limitation, a hopper 148 is mounted on the powder supply arm 108. The foregoing section of this paragraph describes features of embodiment twenty-one of the subject matter disclosed herein, where embodiment twenty-one also includes embodiment twenty above.

The hopper 148 mounted on the powder supply arm 108 facilitates discharge of the powder material 202 directly into the interior volume 124 of the hollow body 122 of the powder supply arm 108 through the powder supply opening 132. The hopper 148 mounted on the powder supply arm 108 also facilitates different configurations of the powder supply arm 108 and the rotary drive 116 for rotating the powder supply arm 108 about the vertical axis a 1.

In one or more embodiments, as shown in fig. 2, the powder supply arm 108 is coupled to the shaft 104 and fixed relative to the shaft 104, and the hopper 148 is mounted on the powder supply arm 108. The shaft 104 is coupled to the support 102 and is rotatable relative to the support 102. The rotation drive 116 is configured to rotate the shaft 104 relative to the support 102 about a vertical axis a 1. Rotation of the shaft 104 about the vertical axis a1 in turn rotates the powder supply arm 108 and the hopper 148 relative to the support 102 about the vertical axis a 1.

In one or more embodiments, as shown in fig. 3, the powder supply arm 108 is coupled to the shaft 104 and is rotatable relative to the shaft 104, and the hopper 148 is mounted on the powder supply arm 108. The shaft 104 is coupled to the support 102 and is fixed relative to the support 102. The rotary drive 116 is configured to rotate the powder supply arm 108 and the hopper 148 about a vertical axis a1 relative to the shaft 104.

In one or more embodiments, the hopper 148 is coupled to the powder supply arm 108 such that the discharge opening of the hopper 148 is in communication with the powder supply opening 132 and the powder material 202 is discharged directly into the internal volume 124 of the hollow body 122 through the powder supply opening 132.

Referring to fig. 1A and 1B generally, and to fig. 4 in particular, for illustrative purposes only and not by way of limitation, the source of powder material 106 also includes a tubular chamber 150, the tubular chamber 150 being coupled to the powder supply arm 108 and the energy supply arm 112. The hopper 148 is in communication with the tubular chamber 150 such that the powder material 202 may be transferred from the hopper 148 to the tubular chamber 150. The tubular chamber 150 is in communication with the powder supply opening 132 such that the powder material 202 may be transferred from the tubular chamber 150 to the interior volume 124 of the hollow body 122 through the powder supply opening 132. The rotary drive 116 is configured to rotate the tubular chamber 150 about the vertical axis a1 with the powder supply arm 108 and the energy supply arm 112. The foregoing section of this paragraph describes features of embodiment twenty two of the subject matter disclosed herein, wherein embodiment twenty two further includes embodiment twenty above.

The tubular chamber 150 facilitates discharge of the powder material 202 from the hopper 148 into the tubular chamber 150 and out of the tubular chamber 150 through the powder supply opening 132 into the interior volume 124 of the hollow body 122. The tubular chamber 150 coupled to the powder supply arm 108 facilitates rotation of the shaft 104 relative to the support 102 about the vertical axis a1 to rotate the powder supply arm 108 about the vertical axis a 1.

In one or more embodiments, the powder supply arm 108 and the energy supply arm 112 are coupled to the shaft 104 and are fixed to be rotatable relative to the shaft 104. The tubular chamber 150 is coupled to the powder supply arm 108 and the energy supply arm 112. In one or more embodiments, the tubular chamber 150 is also coupled to the shaft 104. The shaft 104 is coupled to the support 102 and is rotatable relative to the support 102. The rotation drive 116 is configured to rotate the shaft 104 relative to the support 102 about a vertical axis a 1. Rotation of the shaft 104 about the vertical axis a1 in turn rotates the powder supply arm 108, the energy supply arm 112, and the tubular chamber 150 about the vertical axis a1 relative to the support 102.

In one or more embodiments, the powder supply opening 132 is located inside the tubular chamber 150 such that the interior of the tubular chamber 150 is in communication with the powder supply opening 132. The powder material 202 is discharged from the tubular chamber 150 directly into the interior volume 124 of the hollow body 122 through the powder supply opening 132.

In one or more embodiments, the tubular chamber 150 includes a seal at the interface between the tubular chamber 150 and the powder supply arm 108 and the energy supply arm 112. The seal is configured to prevent escape of the powdered material 202 from within the tubular chamber 150.

In one or more embodiments, the hopper 148 is positioned away from the tubular chamber 150. The powder material 202 is discharged from the hopper 148 directly into the interior of the tubular chamber 150. In one or more embodiments, the powder material source 106 further includes a transfer mechanism configured to transfer the powder material 202 from the hopper 148 into the tubular chamber 150. In one or more embodiments, the source of powder material 106 includes a conduit or other suitable material transfer tube connected to the discharge opening of the hopper 148 and in communication with the tubular chamber 150.

Referring to fig. 1A and 1B generally, and to fig. 18 in particular, for purposes of illustration only and not by way of limitation, the energy supply arm 112 has an energy supply arm proximal end 154 and an energy supply arm distal end 156 located opposite the energy supply arm proximal end 154. The plurality of energy emitters 114 are positioned in a linear array 172 extending along an energy supply arm central axis a3 between the energy supply arm proximal end 154 and the energy supply arm distal end 156. The foregoing section of this paragraph describes features of an embodiment twenty-three of the subject matter disclosed herein, wherein embodiment twenty-three further includes any of the above embodiments one through twenty-two.

The linear array 172 of energy emitters 114 extending along the energy supply arm central axis A3, for example from the energy supply arm proximal end 154 to the energy supply arm distal end 156, increases the area of powder material 202 that can be consolidated per revolution of the energy supply arm 112 about the vertical axis a1, and thereby improves the efficiency of the additive manufacturing apparatus 100.

In one or more embodiments, the energy emitters 114 of the linear array 172 are suitably positioned (e.g., spaced apart) relative to one another such that the focal point 226 of the energy beam 228 (fig. 28 and 30) emitted by a directly adjacent pair of the energy emitters 114 of the linear array 172 contacts or at least partially overlaps the substantially same location on the powder bed volume 204 during rotation of the energy supply arm 112 about the vertical axis a 1. The focal points 226 of the energy beams 228 emitted by the directly adjacent pair of energy emitters 114 that are in contact or at least partially overlapping provide a continuous or overlapping scan field such that a continuous portion of the powder material 202 is consolidated using at least a portion of the energy emitters 114 of the linear array 172 as the energy supply arm 112 is rotated about the vertical axis a 1.

Referring to fig. 1A and 1B generally, and to fig. 19-21 for example in particular, for illustrative purposes only and not by way of limitation, the second plurality of energy emitters 114 is arranged in a second linear array 178 extending along an energy supply arm central axis a3 between the energy supply arm proximal end 154 and the energy supply arm distal end 156. The second linear array 178 of energy emitters 114 is offset along the energy supply arm central axis a3 relative to the linear array 172 of energy emitters 114. The foregoing section of this paragraph describes features of an embodiment twenty-four of the subject matter disclosed herein, wherein embodiment twenty-four also includes the above embodiment twenty-three.

The second linear array 178 of energy emitters 114 extending along the energy supply arm central axis A3, e.g., from the energy supply arm proximal end 154 to the energy supply arm distal end 156, further increases the area of powder material 202 that can be consolidated per revolution of the energy supply arm 112 about the vertical axis a1, and thereby improves the efficiency of the additive manufacturing apparatus 100. The second linear array 178 of energy emitters 114, which is offset along the energy supply arm central axis A3 relative to the linear array 172 of energy emitters 114, also facilitates consolidating a continuous portion of the powder material 202 using the linear array 172 and at least a portion of the energy emitters 114 of the second linear array 178 as the energy supply arm 112 rotates about the vertical axis a 1.

In one or more embodiments, the energy emitters 114 of the linear array 172 and the second linear array 178 are suitably positioned (e.g., spaced) relative to each other such that the focal point 226 of the energy beam 228 (fig. 28 and 30) emitted by at least one of the energy emitters 114 of the linear array 172 and at least one of the energy emitters 114 of the second linear array 178 contacts or at least partially overlaps a substantially same location on the powder bed volume 204 during rotation of the energy supply arm 112 about the vertical axis a 1. The focal points 226 of the energy beams 228 emitted by corresponding ones of the energy emitters 114 of the linear array 172 and the second linear array 178 that contact or at least partially overlap provide a continuous or overlapping scan field such that at least a portion of the energy emitters 114 of the linear array 172 and the second linear array 178 are used to consolidate the continuous portion of the powder material 202 as the energy supply arm 112 rotates about the vertical axis a 1.

Referring to fig. 1A and 1B in general, and to fig. 21 in particular, for illustrative purposes only and not by way of limitation, the third plurality of energy emitters 114 is arranged in a third linear array 232 extending along the energy-supply-arm central axis a3 between the energy-supply-arm proximal end 154 and the energy-supply-arm distal end 156. The third linear array 232 of energy emitters 114 is offset along the energy supply arm central axis a3 with respect to at least one of the linear array 172 of energy emitters 114 and the second linear array 178 of energy emitters 114. The foregoing section of this paragraph describes features of embodiment twenty-five of the subject matter disclosed herein, whereby embodiment twenty-five also includes the above embodiment twenty-four.

The third linear array 232 of energy emitters 114 extending along the energy-supply-arm central axis A3, for example from the energy-supply-arm proximal end 154 to the energy-supply-arm distal end 156, further increases the area of powder material 202 that can be consolidated per revolution of the energy-supply arm 112 about the vertical axis a1, and thereby improves the efficiency of the additive manufacturing apparatus 100. The third linear array 232 of energy emitters 114 that is offset along the energy supply arm central axis A3 relative to at least one of the linear array 172 of energy emitters 114 and the second linear array 178 of energy emitters 114 also facilitates consolidating a continuous portion of the powdered material 202 using at least a portion of the energy emitters 114 of the linear array 172 and the second linear array 178 as the energy supply arm 112 is rotated about the vertical axis a 1.

In one or more embodiments, the energy emitters 114 of the third linear series 232 are suitably positioned (e.g., spaced apart) relative to the energy emitters 114 of at least one of the linear array 172 and the second linear array 178 such that the focal point 226 of the energy beam 228 (fig. 28 and 30) emitted by at least one of the energy emitters 114 of the third linear series 232 and at least one of the energy emitters 114 of at least one of the linear array 172 and the second linear array 178 contacts or at least partially overlaps with substantially the same location on the powder bed volume 204 during rotation of the energy-supply arm 112 about the vertical axis a 1. The focal points 226 of the energy beams 228 emitted by the corresponding ones of the energy emitters 114 of the third linear series 232 and at least one of the linear array 172 and the second linear array 178 that contact or at least partially overlap provide a continuous or overlapping scan field such that, as the energy-supply arm 112 rotates about the vertical axis a1, a continuous portion of the powdered material 202 is consolidated using at least a portion of the energy emitters 114 of the third linear series 232 and at least one of the linear array 172 and the second linear array 178.

In one or more embodiments, the third linear array 232 of energy emitters 114 is offset along the energy delivery arm central axis a3 relative to both the linear array 172 of energy emitters 114 and the second linear array 178 of energy emitters 114. In such embodiments, the energy emitters 114 of the third linear series 232 are suitably positioned (e.g., spaced apart) relative to the linear arrays 172 and the energy emitters 114 of the second linear array 178 such that the focal point 226 of the energy beam 228 emitted by at least one of the energy emitters 114 of the third linear series 232, at least one of the energy emitters 114 of the linear array 172, and at least one of the energy emitters 114 of the second linear array 178 contacts or at least partially overlaps with approximately the same location on the powder bed volume 204 during rotation of the energy-supply arm 112 about the vertical axis a 1.

Referring to fig. 1A and 1B generally, and to fig. 22 in particular, for illustrative purposes only and not by way of limitation, the energy emitters 114 are arranged in groups 184, each group containing a plurality of energy emitters 114. The groups 184 are arranged along a circular path 230, the circular path 230 encircling the vertical axis a1 and centered on the vertical axis a 1. The foregoing section of this paragraph describes features of embodiment twenty-six of the subject matter disclosed herein, whereby embodiment twenty-six also includes any of the above embodiments one through twenty-five.

Arranging the energy emitters 114 in groups 184 along respective ones of the circular paths 230 such that the focal points 226 of the energy beams 228 (fig. 29 and 30) emitted by each of the respective groups of energy emitters 114 in the groups 184 at least partially overlap at a given position on the powder bed volume 204 (fig. 29 and 30) disposed along the respective ones of the circular paths 230 when the energy supply arm 112 is rotated about the vertical axis a 1.

In one or more embodiments, during consolidation of a portion of the powder material 202, each of the corresponding groups of energy emitters 114 in the group 184 sequentially passes over substantially the same location on the powder bed volume 204 (fig. 29 and 30) while rotating the energy supply arm 112 about the vertical axis a 1. As such, the focal point 226 of the energy beam 228 emitted by each of the energy emitters 114 of the corresponding group 184 sequentially heats substantially the same portion of the powder material 202 to at least partially consolidate the powder material 202. Thus, a single rotation of the energy supply arm 112 can heat the same portion of powder material 202 in the powder bed volume 204 for a longer period of time or multiple times, which improves the efficiency of the additive manufacturing apparatus 100.

In one or more embodiments, one of the energy emitters 114 of each of the groups 184 is one of the energy emitters 114 of the linear array 172 (fig. 21), one of the energy emitters 114 of each of the groups 184 is one of the energy emitters 114 of the second linear array 178 (fig. 21), and one of the energy emitters 114 of each of the groups 184 is one of the energy emitters 114 of the third linear series 232 (fig. 21).

Referring to fig. 1A and 1B generally, and to fig. 23 in particular, for illustration purposes only and not by way of limitation, each of the groups 184 of energy emitters 114 is arranged along a corresponding one of the circular paths 230. Each of the group 184 of energy emitters 114 includes a preheat emitter 186 configured to heat a portion of the powdered material 202 to a first temperature. Each of the set 184 of energy emitters 114 also includes a melt emitter 188, the melt emitter 188 being configured to heat a portion of the powdered material 202 to a second temperature that is higher than the first temperature. The foregoing section of this paragraph describes features of embodiment twenty-seven of the subject matter disclosed herein, wherein embodiment twenty-seven also includes the above embodiment twenty-six.

The preheating emitters 186 and the melting emitters 188 of each of the groups 184 are arranged along respective ones of the circular paths 230, which enables the preheating emitters 186 to preheat a portion of the powder material 202 and the melting emitters 188 to subsequently melt the portion of the powder material 202 at respective locations on the powder bed volume 204 during rotation of the energy supply arm 112 about the vertical axis a1, which increases the efficiency and quality of the consolidation operation and improves the material properties of the object 200.

In one or more embodiments, preheating the portion of the powder material 202 to the first temperature using the preheating emitter 186 is accomplished by at least one of heating the portion of the powder material 202 for a predetermined period of time (e.g., depending on the rotational speed of the energy supply arm 112) and heating the portion of the powder material 202 at a predetermined energy level. The first temperature depends on various factors, such as the type of powder material 202, the thermal profile of the consolidation operation, and the like.

In one or more embodiments, heating a portion of the powder material 202 to the second temperature using the melting emitter 188 is accomplished by at least one of heating the portion of the powder material 202 for a predetermined period of time (e.g., depending on the rotational speed of the energy supply arm 112) and heating the portion of the powder material 202 at a predetermined energy level. The second temperature depends on various factors, such as the type of powder material 202, the thermal profile of the consolidation operation, and the like. Typically, the second temperature is the consolidation temperature (e.g., the melting temperature of the sintering temperature) of the powder material 202.

In one or more embodiments, the preheat emitter 186 and the melt emitter 188 are configured in combination to gradually increase the temperature of the portion of the powder material 202 being consolidated to the consolidation temperature, as compared to consolidation operations that rapidly heat the powder material to the consolidation temperature by only the melt emitter.

In one or more embodiments, the preheat emitter 186 of each of the groups 184 is one of the energy emitters 114 of the linear array 172 (fig. 20), and the melt emitter 188 of each of the groups 184 is one of the energy emitters 114 of the second linear array 178 (fig. 20).

Referring to fig. 1A and 1B generally, and to fig. 23 in particular, for illustrative purposes only and not by way of limitation, each of the groups 184 of energy emitters 114 further includes a post-heat emitter 192 configured to heat a portion of the powder material 202 to a third temperature that is lower than the second temperature. The melting emitter 188 is located between the preheat emitter 186 and the post-heat emitter 192. The foregoing section of this paragraph describes features of an embodiment twenty-eight of the subject matter disclosed herein, wherein embodiment twenty-eight also includes the above embodiment twenty-seven.

The post-heating emitters 192 of each of the groups 184 are arranged along a corresponding circular path in the circular paths 230, which enables the post-heating emitters 192 to subsequently control cooling of the portion of the powder material 202 after melting the portion of the powder material at a corresponding location on the powder bed volume 204 during rotation of the energy supply arm 112 about the vertical axis a1, which increases the quality of the consolidation operation and improves the material properties of the object 200.

In one or more embodiments, post-heating a portion of the powder material 202 to a third temperature using the post-heat emitter 192 is accomplished by at least one of heating the portion of the powder material 202 for a predetermined period of time (e.g., depending on the rotational speed of the energy supply arm 112) and heating the portion of the powder material 202 at a predetermined energy level. The third temperature depends on various factors, such as the type of powder material 202, the thermal profile of the consolidation operation, and the like.

In one or more embodiments, post-heat emitter 192 is configured to gradually reduce the temperature of the portion of powdered material 202 being consolidated as compared to a consolidation operation in which the powdered material is rapidly cooled.

In one or more embodiments, the post-heating emitter 192 of each of the groups 184 is one of the energy emitters 114 of the third linear series 232 (FIG. 21).

Referring to fig. 1A and 1B in general, and to fig. 4-6 and 11-13 in particular, for illustrative purposes only and not by way of limitation, the powder supply arm 108 is curved in a viewing plane perpendicular to the vertical axis a 1. The foregoing section of this paragraph describes features of embodiment twenty-nine of the subject matter disclosed herein, wherein embodiment twenty-nine further includes any of the above embodiments one through eight and fourteen through twenty-eight.

The curved powder supply arm 108 contributes to a likewise curved powder distribution blade 128.

In one or more embodiments, the powder distribution blade 128 is coupled to the hollow body 122 of the powder supply arm 108 and is curved in a viewing plane perpendicular to the vertical axis a1, corresponding to the curved profile of the powder supply arm 108. Thus, in one or more embodiments, the powder supply arm central axis a2 and the vane central axis a4 are curved. When the powder supply arm 108 is rotated about the vertical axis a1, the powder supply arm 108, and thus the curved powder distribution blades 128, facilitate movement of the powder material 202 in a direction away from the vertical axis a1 (e.g., radially outward relative to the vertical axis) to form a uniform layer of powder material 202 within the powder bed volume 204.

As expressed above, it can be appreciated that the relative surface area of the powder bed volume 204 is greater at locations further from the vertical axis a1 as compared to the surface area of the powder bed volume 204 at locations closer to the vertical axis a 1. Thus, it is beneficial to move a portion of the powder material 202 at a location closer to the vertical axis a1 in a direction away from the vertical axis a1 to a location further from the vertical axis a 1. During rotation of the powder supply arm 108, when the powder material 202 is dispensed using the powder dispensing blade 128, a portion of the powder material 202 moving in a direction extending away from the vertical axis a1 provides a sufficient amount of the powder material 202 to sufficiently and uniformly cover the powder bed volume 204.

During rotation of the powder supply arm 108, the powder dispensing blade 128 engages a quantity of powder material 20 newly deposited from the powder deposition opening 126. In the event that the powder distribution blade 128 is curved, the powder distribution blade 128 distributes (e.g., pushes or moves) the powder material 202 in a direction of movement perpendicular to a tangent at a given point along the blade central axis a4 during rotation of the powder supply arm 108. The direction of movement of the powder material 202 is adjusted by providing a curved powder distribution blade 128 such that a portion of the powder material 202 moves in a direction away from the vertical axis a1 (e.g., radially outward).

In one or more embodiments, the conveyor screw 140 is flexible to accommodate the curvature of the hollow body 122 of the powder supply arm 108.

Referring to fig. 1A and 1B in general, and to fig. 2-4, 27, and 28 in particular, for example, and for purposes of illustration only and not by way of limitation, additive manufacturing apparatus 100 further includes a first energy transmission line 166 configured to be in one of electrical or optical communication with energy source 110, a rotational energy connector 170 configured to be in one of electrical or optical communication with first energy transmission line 166, and a second energy transmission line 168 configured to be in one of electrical or optical communication with rotational energy connector 170. The foregoing section of this paragraph describes features of an embodiment thirty of the subject matter disclosed herein, wherein embodiment thirty further includes any of the above embodiments one through twenty-nine.

The rotational energy connector 170 enables the second energy transmission line 168 to rotate relative to the first energy transmission line 166 during rotation of the energy supply arm 112 about the vertical axis a 1.

In one or more embodiments, as shown in fig. 2, 4, 27, and 28, a second energy transmission line 168 extends through the shaft 104 and through at least a portion of the energy supply arm 112 to connect to the energy emitter 114. The rotational energy connector 170 is configured to enable the second energy transmission line 168 to rotate relative to the first energy transmission line 166 during rotation of the shaft 104 and the energy supply arm 112 relative to the support 102 about the vertical axis a 1.

In one or more embodiments, each of the first and second energy-transmission lines 166, 168 includes at least one electrical transmission line (e.g., a cable or wire) configured to transfer electrical power (e.g., electricity) from the energy source 110 to the energy emitter 114. In these embodiments, the rotational energy connector 170 comprises or takes the form of a rotational electrical connector.

In one or more embodiments, each of the first and second energy transmission lines 166, 168 includes at least one optical transmission line (e.g., an optical fiber) configured to transmit optical energy (e.g., laser light) from the energy source 110 to the energy emitter 114. In these embodiments, the rotational energy connector 170 comprises or takes the form of a rotational optical connector.

Referring generally to fig. 1A and 1B, for purposes of illustration only and not by way of limitation, each energy emitter 114 includes a laser emitting diode 160, the laser emitting diode 160 configured to be in electrical communication with a second energy transmission line 168 and the energy source 110. The foregoing section of this paragraph describes features of embodiment thirty-one of the subject matter disclosed herein, wherein embodiment thirty-one also includes the above embodiment thirty.

The energy emitters 114 as laser emitting diodes 160 enable a simple, independent control of each of the energy emitters 114.

In one or more embodiments, the laser emitting diode 160 is electrically coupled to the energy source 110 via a second energy transmission line 168, a rotational energy connector 170, and a first energy transmission line 166. In one or more embodiments, the laser emitting diodes 160 are selectively actuated and the peak power or energy level of the laser emitting diodes 160 is selectively controlled, for example, using the controller 238.

Referring generally to fig. 1A and 1B, for purposes of illustration only and not by way of limitation, each energy emitter 114 includes an optical output 162, the optical output 162 configured to be in optical communication with a second energy transmission line 168 and the energy source 110. The foregoing section of this paragraph describes features of embodiment thirty-two of the subject matter disclosed herein, wherein embodiment thirty-two further includes the above embodiment thirty.

Each of the energy emitters 114 as optical outputs 162 in communication with the second energy transmission line 168 enables a greater number of energy emitters 114 to be positioned on the energy supply arm 112 than each of the energy emitters 114 as laser emitting diodes 160.

In one or more embodiments, the optical output 162 of the second energy transmission line 168 is optically coupled to the energy source 110 via the rotational energy connector 170 and the first energy transmission line 166. In one or more embodiments, the optical output 162 of the second energy transmission line 168 is selectively actuated, and the peak power or energy level of the optical output 162 of the second energy transmission line 168 is selectively controlled, for example, using the controller 238.

Referring to fig. 1A and 1B generally, and to fig. 27 and 28 in particular, for illustration purposes only and not by way of limitation, additive manufacturing apparatus 100 further includes a build platform 206 and a trough 208 surrounding build platform 206. The foregoing section of this paragraph describes features of an embodiment thirty-three of the subject matter disclosed herein, wherein embodiment thirty-three further includes any of the above embodiments one through thirty-two.

The build platform 206 provides or serves as a build surface that supports the powder bed volume 204 and the object 200 additively manufactured from the powder material 202. The trough 208 collects excess powder material 202 that is moved by the powder distribution blade 128 beyond the peripheral boundaries of the build platform 206 and the powder bed volume 204 during rotation of the powder supply arm 108.

In one or more embodiments, additive manufacturing apparatus 100 includes a powder-containing compartment configured to contain a powder material 202 that forms a powder bed volume 204. The build platform 206 is located within the powder containment compartment and at least partially defines the powder bed volume 204. The powder material 202 is contained by the powder containment compartment when deposited on the build platform 206.

The build platform 206, viewed along vertical axis a1, has any of a variety of two-dimensional shapes. In one or more embodiments, the build platform 206 has a circular shape. Thus, in one or more embodiments, the powder bed volume 204 has a circular shape as viewed along the vertical axis a 1.

In one or more embodiments, the powder containment compartment includes a sidewall extending from a base of the powder containment compartment. In one or more embodiments, the groove 208 forms an upper portion of the sidewall of the powder containment compartment. The trough 208 is positioned proximate (e.g., at or near) a peripheral edge of the build platform 206 or a peripheral boundary of the powder bed volume 204 such that excess powder material 202 moving in a direction extending away from the vertical axis a1 and away from the build platform 206 is collected within the trough 208.

Referring to fig. 1A and 1B generally, and to fig. 27 and 28 in particular, for illustrative purposes only and not by way of limitation, build platform 206 is movable relative to powder supply arm 108 and energy supply arm 112 along a vertical axis a 1. The foregoing section of this paragraph describes features of an embodiment thirty-four of the subject matter disclosed herein, wherein embodiment thirty-four also includes the above embodiment thirty-three.

Vertical movement of build platform 206 relative to powder supply arm 108 and energy supply arm 112 facilitates continuous layering of powder material 202 on build platform 206.

In one or more embodiments, vertical axis a1 passes through the center of build platform 206. In one or more embodiments, build platform 206 continuously moves away from powder supply arm 108 and energy supply arm 112 during continuous rotation of powder supply arm 108 and energy supply arm 112 about vertical axis a 1. The speed of the linear movement of the build platform 206 corresponds to the rotational speed of the powder supply arm 108 and the energy supply arm 112 such that the build platform 206 is properly positioned for deposition and dispensing of each subsequent layer of powder material 202.

In one or more embodiments, additive manufacturing apparatus 100 includes a linear drive configured to move build platform 206 vertically relative to powder supply arm 108 and energy supply arm 112. In one or more embodiments, the linear drive is connected to the build platform 206. For example, a linear drive may be attached to the center of the underside surface of build platform 206. In one or more embodiments, the linear drive includes or takes the form of any suitable linear drive mechanism or linear actuator configured to drive linear (e.g., vertical) movement of the build platform 206 relative to the powder supply arm 108 and the energy supply arm 112, such as a worm gear, hydraulic actuator, pneumatic actuator, or the like.

Referring to fig. 1A and 1B generally, and to fig. 26-27 in particular, for illustration purposes only and not by way of limitation, the build platform 206 is movable relative to the trough 208 along a vertical axis a 1. The foregoing section of this paragraph describes features of embodiments thirty-five of the subject matter disclosed herein, wherein embodiments thirty-five further include embodiments thirty-three or thirty-four described above.

Moving the build platform 206 vertically relative to the trough 208 maintains the trough 208 in position for collecting excess powder material 202 that moves away from the build platform 206 or beyond the peripheral boundaries of the powder bed volume 204 during rotation of the powder supply arm 108 about vertical axis a 1.

The trough 208 comprises or takes the form of any suitable elongated open container that extends around the entire perimeter of the build platform 206 and powder bed volume 204. In one or more embodiments, the position of the slot 208 along the vertical axis a1 is fixed relative to the powder supply arm 108 and the energy supply arm 112.

During rotation of the powder supply arm 108, the powder distribution blade 128 distributes the powder material 202 in the powder bed volume 204 to form a layer of powder material 202. In one or more embodiments, the powder distribution blade 128 moves the powder material 202 in a direction away from the vertical axis a 1. In this embodiment, excess powder material 202 is pushed off the build platform 206 or moved beyond the perimeter boundaries of the powder bed volume 204 and collected within the trough 208.

Referring to fig. 1A and 1B generally, and to fig. 27 and 28 in particular, for illustration purposes only and not by way of limitation, the additive manufacturing apparatus 100 further includes a powder recovery device 210, the powder recovery device 210 in communication with the tank 208 and the source of powder material 106 such that the powder material 202 may be transferred from the tank 208 to the source of powder material 106. The foregoing section of this paragraph describes features of an embodiment thirty-six of the subject matter disclosed herein, wherein embodiment thirty-six also includes the above embodiment thirty-three.

Powder recovery device 210 enables powder material 202 to be reused in an additive manufacturing operation.

In one or more embodiments, a powder recovery device 210 is coupled to an outlet of the tank 208. A portion of the powder material 202 that moves beyond the perimeter boundary of the build platform 206 or powder bed volume 204 and is collected in the trough 208 is transferred back to the source of powder material 106 using the powder recovery device 210. In one or more embodiments, powder recovery device 210 is configured to clean and/or condition powder material 202 collected by trough 208 for reuse in an additive manufacturing process.

In one or more embodiments, the powder recovery device 210 includes a powder transfer mechanism in communication with the interior of the tank 208 and configured to convey or otherwise transfer the powder material 202 back to the source of powder material 106.

Referring to fig. 1A and 1B generally, and to fig. 24 in particular, for illustrative purposes only and not by way of limitation, the additive manufacturing apparatus 100 also includes a second powder supply arm 196, the second powder supply arm 196 including a second hollow body 214, the second hollow body 214 having a second interior volume 216 in communication with a second powder material source 236 such that the powder material 202 may be transferred from the powder material source 106 to the second interior volume 216. The second powder supply arm 196 also includes a second powder deposition opening 218 formed in the second hollow body 214. The second powder deposition opening 218 is in communication with the second interior volume 216 of the second hollow body 214 such that the powder material 202 may be transferred out of the second interior volume 216 through the second powder deposition opening 218. The second powder supply arm 196 further comprises a second powder distribution blade 220, the second powder distribution blade 220 being coupled to the second hollow body 214 and extending along the second powder deposition opening 218. Additive manufacturing apparatus 100 also includes a second energy supply arm 198. Additive manufacturing apparatus 100 also includes a second energy emitter 222 coupled to second energy supply arm 198. The second energy emitter 222 is in one of electrical and optical communication with the energy source 110. The rotary drive 116 is also configured to rotate the second powder supply arm 196 and the second energy supply arm 198 about a vertical axis a 1. The foregoing section of this paragraph describes features of an embodiment thirty-seven of the subject matter disclosed herein, wherein embodiment thirty-seven further includes any one of the above embodiments one through thirty-six.

Second powder supply arm 196 and second energy supply arm 198 enable powder supply arm 108, energy supply arm 112, second powder supply arm 196, and second energy supply arm 198 to deposit, dispense, and consolidate two layers of powder material 202 per rotation, thereby improving the efficiency of additive manufacturing apparatus 100.

In one or more embodiments, the second powdered material source 236 is substantially identical to the powdered material source 106.

In one or more embodiments, the second powder supply arm 196 is substantially identical to the powder supply arm 108. For example, the second hollow body 214 is substantially identical to the hollow body 122, the second internal volume 216 is substantially identical to the internal volume 124, the second powder deposition opening 218 is substantially identical to the powder deposition opening 126, and the second powder distribution blade 220 is substantially identical to the powder distribution blade 128.

In one or more embodiments, the second energy supply arm 198 is substantially identical to the energy supply arm 112. In one or more embodiments, the second energy emitter 222 is substantially identical to the energy emitter 114.

In one or more embodiments, the rotary drive 116 is configured to rotate the powder supply arm 108, the energy supply arm 112, the second powder supply arm 196, and the second energy supply arm 198 about the vertical axis a1 at a constant speed. In one or more embodiments, a second powder supply arm 196 and a second energy supply arm 198 are coupled to the shaft 104.

In one or more embodiments, the second powder supply arm 196 and the second energy supply arm 198 are fixed to the shaft 104 such that the second powder supply arm 196 and the second energy supply arm 198 are not rotatable and translatable relative to the shaft 104. The rotation drive 116 is configured to rotate the shaft 104 relative to the support 102 about a vertical axis a 1.

In one or more embodiments, the rotary drive 116 is configured to rotate the second powder supply arm 196 and the second energy supply arm 198 about a vertical axis a1 relative to the shaft 104.

In one or more embodiments, additive manufacturing apparatus 100 includes more than two powder supply arms and/or more than two energy supply arms. Typically, the additive manufacturing apparatus 100 comprises at least one energy supply arm associated with each powder supply arm.

Referring to fig. 1A and 1B generally, and to fig. 25 in particular, for illustration purposes only and not by way of limitation, the additive manufacturing apparatus 100 further includes a second energy supply arm 198. Additive manufacturing apparatus 100 also includes a second energy emitter 222 coupled to second energy supply arm 198. The second energy emitter 222 is in one of electrical and optical communication with the energy source 110. The additive manufacturing apparatus 100 also includes a third energy supply arm 212 and a third energy emitter 224 coupled to the third energy supply arm 212. The third energy emitter 224 is in one of electrical and optical communication with the energy source 110. The rotary drive 116 is also configured to rotate the second and third energy supply arms 198, 212 about a vertical axis a 1. The foregoing section of this paragraph describes features of an embodiment thirty-eight of the subject matter disclosed herein, wherein embodiment thirty-eight further includes any of the above embodiments one to thirty-six.

Second energy supply arm 198 and third energy supply arm 212 enable substantially continuous portions of powder material 202 or portions of powder material 202 of the same layer of powder material 202 to be consolidated to form a portion of object 200 or a portion of multiple objects 200 per revolution of energy supply arm 112, second energy supply arm 198, and third energy supply arm 212, thereby improving the efficiency of additive manufacturing apparatus 100.

In one or more embodiments, the second energy supply arm 198 and the third energy supply arm 212 are substantially identical to the energy supply arm 112. In one or more embodiments, the second energy emitter 222 and the third energy emitter 224 are substantially identical to the energy emitter 114.

In one or more embodiments, the second energy supply arm 198 and the third energy supply arm 212 are fixed to the shaft 104 such that the second energy supply arm 198 and the third energy supply arm 212 are not rotatable and translatable relative to the shaft 104. The rotation drive 116 is configured to rotate the shaft 104 relative to the support 102 about a vertical axis a 1.

In one or more embodiments, the rotational drive 116 is configured to rotate the second and third energy supply arms 198, 212 about a vertical axis a1 relative to the shaft 104.

Referring to fig. 35 in general, and to fig. 1A, 1B, and 2-33 in particular for example, for illustrative purposes only and not by way of limitation, a method 1000 of additive manufacturing an object 200 from a powder material 202 is disclosed. The method 1000 includes (block 1012) discharging the powder material 202 from the powder deposition opening 126 in the hollow body 122 of the powder supply arm 108 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1. The method 1000 further includes (block 1022) dispensing the powder material 202 within the powder bed volume 204 using a powder dispensing blade 128 coupled to the hollow body 122 and extending along the powder deposition opening 126 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1. The method 1000 further includes (block 1032) consolidating at least a portion of the powder material 202 in the powder bed volume 204 using an energy emitter 114 coupled to the energy supply arm 112 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1. The foregoing section of this paragraph describes features of thirty-nine embodiments of the subject matter disclosed herein.

Method 1000 enables substantially continuous (e.g., uninterrupted) deposition, dispensing, and consolidation of at least a portion of powder material 202 while rotating powder supply arm 108 and energy supply arm 112 about vertical axis a1, which improves the processing speed of the additive manufacturing operation by eliminating changes in direction (e.g., the need for back and forth movement) and thus eliminating corresponding acceleration and deceleration of operational components of additive manufacturing apparatus 100 during deposition, dispensing, and consolidation of powder material 202.

The method 1000 advantageously facilitates reducing time and energy associated with additive manufacturing of the object 200 from the powder material 202, which in turn facilitates increasing an overall efficiency of the method 1000. The method 1000 advantageously facilitates automated deposition, dispensing, and consolidation of the powder material 202 to form the object 200.

According to the method 1000, during rotation of the powder supply arm 108 about the vertical axis a1, a quantity of powder material 202 is discharged from the powder deposition opening 126 into the powder bed volume 204. The powder bed volume 204 is an enclosed volume of powder material 202 (a contained volume of powder material) in which the object 200 is formed layer by layer from the powder material 202. In one or more embodiments, a single rotation of the powder supply arm 108 discharges a sufficient amount of powder material 202 into the powder bed volume 204 to form a new layer of powder material 202.

After discharging the powder material 202, the powder material 202 is dispensed throughout the powder bed volume 204 using the powder dispensing blade 128 to form a layer of powder material 202 during rotation of the powder supply arm 108 about the vertical axis a 1. In one or more embodiments, a single rotation of the powder supply arm 108 completely dispenses the powder material 202 to form a uniform layer of powder material 202.

After dispensing the powder material 202, during rotation of the energy supply arm 112, a portion of the powder material 202 is consolidated using the energy emitter 114 to form at least a portion of a layer of the object 200. In one or more embodiments, a single rotation of powder supply arm 108 fully consolidates a portion of powder material 202 to form the portion of the layer of object 200.

Subsequent rotations of the powder supply arm 108 and the energy supply arm 112 repeat the above process to expel a subsequent amount of powder material 202, to dispense a subsequent amount of powder material 202 to form a subsequent layer of powder material 202, and to consolidate a portion of the powder material 202 of each of the subsequent layers of powder material 202 to form a subsequent layer of the object 200.

Referring to fig. 35 in general, and to fig. 1A, 1B, and 2-4 for example, and for illustrative purposes only and not by way of limitation, method 1000 further includes (block 1006) rotating powder supply arm 108 and energy supply arm 112 about vertical axis a1 at a constant speed. The foregoing section of this paragraph describes features of embodiment forty of the subject matter disclosed herein, wherein embodiment forty further includes the above embodiment thirty-nine.

Continuously rotating the powder supply arm 108 and the energy supply arm 112 at a constant speed (e.g., at a constant angular speed) improves the processing time and efficiency of the method 1000 by eliminating accelerations and decelerations associated with speed variations. Rotating the energy supply arm 112 at a constant speed simplifies the command and control of the actuation of the energy emitter 114.

In one or more embodiments, when rotating the energy supply arm 112 about the vertical axis a1, each of the energy emitters 114 is selectively actuated to consolidate a portion of the powder material 202 when each of the energy emitters 114 is located at a preselected polar coordinate associated with a corresponding location on the powder bed volume 204. Thus, when rotating the energy supply arm 112 at a constant speed, the position of each of the energy emitters 114 can be easily calculated and accurately predicted at any time during formation of the object 200. In one or more embodiments, during rotation of the energy supply arm 112, one or more of the energy emitters 114 are selectively actuated at a predetermined time or for a predetermined period of time based on the position of the energy supply arm 112 to consolidate a portion of the powder material 202.

In one or more embodiments, during consolidation of the powder material 202, actuation of each of the energy emitters 114 is performed under computer control, such as by the controller 238.

Referring to fig. 35 in general, and to fig. 1A, 1B, 2, and 3 in particular, for illustrative purposes only and not by way of limitation, in accordance with the method 1000, the powder supply arm 108 and the energy supply arm 112 are coupled to a shaft 104, the shaft 104 being coupled to the support 102. In accordance with the method 1000, (block 1006) rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 includes (block 1008) rotating the shaft 104 about the vertical axis a 1. The foregoing section of this paragraph describes features of embodiment forty-one of the subject matter disclosed herein, wherein embodiment forty-one also includes embodiment forty above.

The shaft 104 structurally supports the powder supply arm 108 and the energy supply arm 112 during rotation about the vertical axis a 1. Rotating the shaft 104 relative to the support 102 about the vertical axis a1 in turn rotates the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1. In one or more embodiments, the rotational drive 116 is configured to rotate the shaft 104 relative to the support 102 about a vertical axis a 1.

Referring to fig. 35 in general, and to fig. 1A, 1B, and 4 for example in particular, for illustrative purposes only and not by way of limitation, in accordance with the method 1000, the powder supply arm 108 and the energy supply arm 112 are coupled to a shaft 104, which shaft 104 is coupled to the support 102. Also in accordance with the method 1000, (block 1006) rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 includes (block 1010) rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 relative to the shaft 104. The foregoing section of this paragraph describes features of embodiment forty two of the subject matter disclosed herein, wherein embodiment forty two also includes the above embodiment forty.

Rotating the powder supply arm 108 and the energy supply arm 112 relative to the shaft 104 rotates the powder supply arm 108 and the energy supply arm 112 about a vertical axis a 1. In one or more embodiments, the rotary drive 116 is configured to rotate the powder supply arm 108 and the energy supply arm 112 about a vertical axis a1 relative to the shaft 104.

Referring to fig. 35 in general, and to fig. 1A, 1B, and 4 for example in particular, for illustrative purposes only and not by way of limitation, the method 1000 further includes (block 1002) transferring the powder material 202 from the powder material source 106 to the interior volume 124 of the hollow body 122 of the powder supply arm 108. The foregoing section of this paragraph describes features of embodiment forty-three of the subject matter disclosed herein, wherein embodiment forty-three further includes any one of the above embodiments thirty-nine through forty-two.

Transferring the powder material 202 from the powder material source 106 to the interior volume 124 of the hollow body 122 supplies the powder material 202 to the powder supply arm 108 for discharge from the powder deposition opening 126 in communication with the interior volume 124 of the hollow body 122.

In one or more embodiments, the powder material 202 is transferred from the hopper 148 directly to the interior volume 124 of the hollow body 122 of the powder supply arm 108. In one or more embodiments, the powder material 202 is transferred from the hopper 148 to the tubular chamber 150, and then from the tubular chamber 150 to the interior volume 124 of the hollow body 122 of the powder supply arm 108.

Referring to fig. 35 in general, and to fig. 1A and 1B, 27, and 28 in particular, for illustrative purposes only and not by way of limitation, the method 1000 further includes (block 1004) conveying the powder material 202 through the interior volume 124 of the hollow body 122 in a direction away from the vertical axis a1 and perpendicular to the vertical axis a 1. The foregoing section of this paragraph describes features of embodiment forty-four of the subject matter disclosed herein, wherein embodiment forty-four also includes the above embodiments forty-three.

Transporting the powder material 202 through the interior volume 124 of the hollow body 122 facilitates movement of the powder material 202 from the powder supply arm proximal end 134 to the powder supply arm distal end 136 and ensures that the powder material 202 is discharged from the entire length L1 of the powder deposition opening 126.

In one or more embodiments, the powdered material 202 is conveyed through the internal volume 124 of the hollow body 122 in a direction away from the vertical axis a1 and perpendicular to the vertical axis a1 using a conveyor screw 140 located within the internal volume 124 of the hollow body 122 and extending along the powder deposition opening 126.

Referring to fig. 35 in general, and to fig. 1A, 1B, and 26 for example in particular, for illustrative purposes only and not by way of limitation, the method 1000 further includes (block 1016) at least partially opening or closing the powder deposition opening 126. The foregoing section of this paragraph describes features of embodiment forty-five of the subject matter disclosed herein, wherein embodiment forty-five also includes the above-described embodiments forty-three or forty-four.

Selectively opening or closing the powder deposition opening 126 enables the powder material 202 to be selectively discharged from the powder deposition opening 126 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a 1.

In one or more embodiments, the powder deposition opening 126 is at least partially opened or closed using a door 144. In one or more embodiments, partially opening the powder deposition opening 126 enables selective control of the width W of the powder deposition opening 126. Selectively controlling the width W of the powder deposition opening 126 enables selective control of the rate at which the powdered material 202 is discharged from the powder deposition opening 126 while rotating the powder supply arm 108 about the vertical axis a 1.

Referring to fig. 35 in general, and to fig. 1A, 1B, 12-14, and 31 for example only, and not by way of limitation, in accordance with the method 1000, (block 1012) discharging powder material 202 from the powder deposition opening 126 in the hollow body 122 of the powder supply arm 108 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 includes (block 1014) discharging a greater amount of powder material 202 from the powder deposition opening 126 at a first location along the powder deposition opening 126 than at a second location along the powder deposition opening 126, wherein the second location is closer to the vertical axis a1 than the first location. The foregoing section of this paragraph describes features of embodiment forty-six of the subject matter disclosed herein, wherein embodiment forty-six further includes any of the above embodiments forty-three to forty-five.

Discharging a greater amount of powder material 202 from the powder deposition opening 126 at a first location along the powder deposition opening 126 than at a second location along the powder deposition opening 126 facilitates depositing a greater amount of powder material 202 at the first location in the powder bed volume 204 and depositing a lesser amount of powder material 202 at the second location in the powder bed volume 204 that is closer to the vertical axis a1 than the first location.

In one or more embodiments, the amount of powder material 202 discharged from the powder deposition opening 126 and deposited into the powder bed volume 204 increases in proportion to the distance from the vertical axis a 1. In one or more embodiments, increasing the amount of powder material 202 discharged from the powder deposition opening 126 is accomplished by increasing the width W of the powder deposition opening 126 in a direction along the powder supply arm central axis a2 and away from the vertical axis a 1. In one or more embodiments, when the door 144 is positioned relative to the hollow body 122 of the powder supply arm 108 such that the powder deposition opening 126 is partially open, the width W of at least a portion of the powder deposition opening 126 increases along the powder supply arm central axis a2 of the powder supply arm 108 in a direction away from the vertical axis a 1.

Referring to fig. 35 in general, and to fig. 1A, 1B, 6, 7, and 11-13 for example only for illustrative purposes and not by way of limitation, according to the method 1000, (block 1022) dispensing the powder material 202 within the powder bed volume 204 using the powder dispensing blade 128 coupled to the hollow body 122 and extending along the powder deposition opening 126 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 includes (block 1024) moving a portion of the powder material 202 in a direction away from the vertical axis a 1. The foregoing section of this paragraph describes features of embodiment forty-seven of the subject matter disclosed herein, wherein embodiment forty-seven also includes any of the above embodiments forty-three through forty-six.

The use of the powder distribution blade 128 to move a portion of the powder material 202 in a direction away from the vertical axis a1 while rotating the powder supply arm 108 about the vertical axis a1 facilitates movement of the powder material 202 radially outward relative to the vertical axis a1 to form a uniform layer of the powder material 202 within the powder bed volume 204.

In one or more embodiments, the blade central axis a4 is oblique to the powder supply arm central axis a2 when viewed along the vertical axis a1, which facilitates movement of the powder material 202 in a direction away from (e.g., radially outward relative to) the vertical axis a1 using the powder distribution blade 128 while rotating the powder supply arm 108 about the vertical axis a 1.

In one or more embodiments, the powder supply arm 108 and the powder distribution blade 128 are curved in a viewing plane perpendicular to the vertical axis a1, which facilitates movement of the powder material 202 in a direction away from (e.g., radially outward relative to) the vertical axis a1 using the powder distribution blade 128 while rotating the powder supply arm 108 about the vertical axis a 1.

Referring to fig. 35 in general, and to fig. 1A, 1B, and 26-28 in particular for example, for purposes of illustration only and not by way of limitation, the method 1000 further includes (block 1028) collecting excess powdered material 202 moved beyond the perimeter boundaries of the powder bed volume 204 by the powder dispensing blade 128 in the trough 208. The foregoing section of this paragraph describes features of embodiment forty-eight of the subject matter disclosed herein, with embodiment forty-eight also including the above embodiments forty-seven.

Collecting excess powder material 202 facilitates recovery of powder material during additive manufacturing operations.

In one or more embodiments, the trough 208 surrounds the build platform 206 and collects excess powder material 202 that is moved by the powder distribution blade 128 beyond the peripheral boundaries of the build platform 206 and the powder bed volume 204 during rotation of the powder supply arm 108.

Referring to fig. 35 in general, and to fig. 1A, 1B, and 26-28 in particular, for illustration purposes only and not by way of limitation, the method 1000 further includes (block 1030) transferring excess powdered material 202 from the trough 208 to the powdered material source 106. The foregoing section of this paragraph describes features of embodiment forty-nine of the subject matter disclosed herein, wherein embodiment forty-nine also includes the above embodiments forty-eight.

Transferring excess powder material 202 back to the powder material source 106 facilitates reusing the powder material in an additive manufacturing operation.

In one or more embodiments, the transfer of excess powder material 202 from the tank 208 back to the source of powder material 106 is performed using a powder recovery device 210 in communication with the tank 208 and the source of powder material 106.

Referring to fig. 35 in general, and to fig. 1A, 1B, and 16 for example in particular, for illustrative purposes only and not by way of limitation, method 1000 further includes (block 1026) preventing at least some of powder material 202 from moving in a direction toward vertical axis a1 while rotating powder supply arm 108 and energy supply arm 112 about vertical axis a 1. The foregoing section of this paragraph describes features of embodiment fifty of the subject matter disclosed herein, wherein embodiment fifty further encompasses any of the above embodiments forty-three to forty-nine.

Preventing at least some of the powder material 202 from moving in a direction toward the vertical axis a1 prevents the powder material 202 from accumulating at the center of the build platform 206 or the center of the powder bed volume 204.

In one or more embodiments, preventing at least some of the powder material 202 from moving in a direction toward the vertical axis a1 is performed using a powder barrier 146 coupled to the powder dispensing blade 128 proximate the powder supply arm proximal end 134 and extending between the powder deposition opening 126 and the vertical axis a 1.

Referring to fig. 35, and in particular to fig. 1A, 1B, 29, and 30 for example, for illustration purposes only and not by way of limitation, in accordance with the method 1000, the energy emitter 114 is in one of electrical or optical communication with the energy source 110. Also in accordance with the method 1000, (block 1032) consolidating at least a portion of the powder material 202 in the powder bed volume 204 using the energy emitter 114 coupled to the energy supply arm 112 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 includes (block 1034) heating at least a portion of the powder material 202. The foregoing section of this paragraph describes features of embodiment fifty one of the subject matter disclosed herein, wherein embodiment fifty one further includes any of the above embodiments thirty-nine through fifty.

Heating at least a portion of the powder material 202 enables at least a portion of the powder material 202 to be one of melted or sintered to form at least a portion of the object 200.

In one or more embodiments, electrical energy is provided by the energy source 110 to the energy emitter 114. In one or more embodiments, energy source 110 is an electrical generator.

In one or more embodiments, each of the energy emitters 114 includes a laser emitting diode 160 or takes the form of a laser emitting diode 160. In one or more embodiments, the laser emitting diode 160 is configured to generate and emit optical energy in the form of a laser beam to heat at least a portion of the powdered material 202 and form at least a portion of the object 200.

In one or more embodiments, each of the energy emitters 114 includes or takes the form of an electron beam emitter. In one or more embodiments, the electron beam emitter is configured to generate and emit energy in the form of an electron beam to heat at least a portion of the powdered material 202 and form at least a portion of the object 200.

In one or more embodiments, optical energy is provided to the energy emitter 114 by the energy source 110. In one or more embodiments, the energy source 110 is a laser.

In one or more embodiments, each of the energy emitters 114 is an optical output 162 (e.g., an exit of a fiber optic cable) in optical communication with a second energy transmission line 168. In one or more embodiments, the optical output 162 is configured to emit optical energy in the form of a laser beam to heat at least a portion of the powdered material 202 and form at least a portion of the object 200.

Referring to fig. 35, and in particular to, for example, fig. 1A, 1B, 29, and 30, for illustration purposes only and not by way of limitation, according to the method 1000, (block 1032) consolidating at least a portion of the powder material 202 in the powder bed volume 204 using the energy emitter 114 coupled to the energy supply arm 112 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 includes (block 1036) at least partially overlapping the energy beams 228 emitted from the energy emitter 114. The foregoing section of this paragraph describes features of embodiment fifty-two of the subject matter disclosed herein, wherein embodiment fifty-two further includes any of the above embodiments thirty-nine through fifty-one.

At least partially overlapping the energy beams 228 emitted from the energy emitters 114 provides at least partially overlapping scan fields such that substantially continuous portions of the powder material 202 may be consolidated into substantially continuous portions of the object 200 during a single rotation of the energy supply arm 112, which in turn improves the efficiency of the method 1000.

In one or more embodiments, the focal point 226 of at least two of the energy beams 228 corresponding to at least two of the energy emitters 114 encounters or at least partially overlaps with substantially the same location on the powder bed volume 204 during rotation of the energy supply arm 112 about the vertical axis a 1.

In one or more embodiments, the focal points 226 of at least two of the energy beams 228 corresponding to at least two of the energy emitters 114 of the linear array 172 (fig. 18) encounter or at least partially overlap substantially the same location on the powder bed volume 204 during rotation of the energy supply arm 112 about the vertical axis a 1.

In one or more embodiments, the focal points 226 of at least two of the energy beams 228 corresponding to at least one of the energy emitters 114 of the linear array 172 and at least one of the energy emitters 114 of the second linear array 178 (fig. 19 and 20) encounter or at least partially overlap a substantially same location on the powder bed volume 204 during rotation of the energy supply arm 112 about the vertical axis a 1.

In one or more embodiments, the focal point 226 of at least one of the energy beams 228 corresponding to at least one of the energy emitters 114 of the linear array 172 and at least one of the energy emitters 114 of the second linear array 178 and/or the third linear series 232 (fig. 21) encounters or at least partially overlaps with substantially the same location on the powder bed volume 204 during rotation of the energy-supply arm 112 about the vertical axis a 1.

In one or more embodiments, the focal point 226 of the energy beam 228 corresponding to the energy emitter 114 of each of the groups 184 (fig. 22) encounters or at least partially overlaps with substantially the same location on the powder bed volume 204 during rotation of the energy supply arm 112 about the vertical axis a 1.

Referring to FIG. 35, and in particular to, for example, FIGS. 1A, 1B, 22, and 23, for illustration purposes only and not by way of limitation, in accordance with method 1000, energy emitter 114 includes preheat emitter 186 and melt emitter 188 arranged along a circular path 230, circular path 230 encircling vertical axis A1 and centered about vertical axis A1. Also in accordance with the method 1000, (block 1032) consolidating at least a portion of the powder material 202 in the powder bed volume 204 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 using the energy emitter 114 coupled to the energy supply arm 112 includes (block 1038) preheating at least a portion of the powder material 202 to a first temperature using the preheating emitter 186, and (block 1040) heating at least a portion of the powder material 202 to a second temperature greater than the first temperature using the melting emitter 188 after preheating at least a portion of the powder material 202 using the preheating emitter 186. The foregoing section of this paragraph describes features of embodiment fifty-three of the subject matter disclosed herein, wherein embodiment fifty-three further includes any of the above embodiments thirty-nine to fifty-two.

The preheating emitters 186 and melting emitters 188 of each of the groups 184 arranged along a respective one of the circular paths 230 enable preheating a portion of the powder material 202 and subsequently melting the portion of the powder material 202 at a respective location on the powder bed volume 204 during one rotation of the energy supply arm 112 about the vertical axis a1, which increases the efficiency and quality of the consolidation operation and improves the material properties of the object 200.

In one or more embodiments, preheating and subsequently melting the powder material 202 gradually increases the temperature of the portion of the powder material 202 being consolidated to the consolidation temperature, as compared to consolidation operations in which the powder material is rapidly heated to the consolidation temperature.

Referring to fig. 35 in general, and to fig. 1A, 1B, 22, and 23 in particular, for illustrative purposes only and not by way of limitation, in accordance with method 1000, energy emitter 114 further includes a post-heat emitter 192, the post-heat emitter 192 being disposed along circular path 230 between preheat emitter 186 and post-heat emitter 192. Also in accordance with method 1000, (block 1032) consolidating at least a portion of the powder material 202 in the powder bed volume 204 while rotating the powder supply arm 108 and the energy supply arm 112 about the vertical axis a1 using the energy emitter 114 coupled to the energy supply arm 112 further comprises (block 1042) post-heating at least a portion of the powder material 202 to a third temperature less than the second temperature using the post-heating emitter 192 after heating the at least a portion of the powder material 202 using the melting emitter 188. The foregoing section of this paragraph describes features of embodiment fifty-four of the subject matter disclosed herein, wherein embodiment fifty-four also includes the above embodiment fifty-three.

The post-heating emitters 192 of each of the sets 184 are arranged along a corresponding one of the circular paths 230 such that after melting the portion of the powder material at a corresponding location on the powder bed volume 204 during rotation of the energy supply arm 112 about the vertical axis a1, cooling of the portion of the powder material 202 can be controlled, which increases the quality of the consolidation operation.

In one or more embodiments, post-heating the powder material 202 gradually reduces the temperature of the portion of the powder material 202 being consolidated as compared to a consolidation operation in which the powder material is rapidly cooled.

Referring to fig. 35 in general, and to fig. 1A, 1B, and 26-28 in particular, for illustration purposes only and not by way of limitation, the method 1000 further includes (block 1018) supporting the powder bed volume 204 on the build platform 206. Method 1000 also includes (block 1020) moving build platform 206 away from powder supply arm 108 and energy supply arm 112 along vertical axis a1 while rotating powder supply arm 108 and energy supply arm 112 about vertical axis a 1. The foregoing section of this paragraph describes features of embodiment fifty-five of the subject matter disclosed herein, wherein embodiment fifty-five further includes any of the above embodiments thirty-nine through fifty-four.

Moving build platform 206 relative to powder supply arm 108 and energy supply arm 112 along vertical axis a1 facilitates continuous layering of powder material 202 in powder bed volume 204. Moving build platform 206 along vertical axis a1 also maintains trough 208 in position for collecting excess powder material 202 that moves beyond the perimeter boundaries of powder bed volume 204 during rotation of powder supply arm 108 about vertical axis a 1.

In one or more embodiments, build platform 206 continuously moves away from powder supply arm 108 and energy supply arm 112 during continuous rotation of powder supply arm 108 and energy supply arm 112 about vertical axis a 1. The speed of movement of the build platform 206 corresponds to the rotational speed of the powder supply arm 108 and the energy supply arm 112 such that the build platform 206 is properly positioned for deposition and dispensing of each subsequent layer of powder material 202.

Embodiments of the subject matter disclosed herein may be described in the context of aircraft manufacturing and service method 1100 as shown in FIG. 36 and aircraft 1102 as shown in FIG. 37, during pre-production, illustrative method 1100 may include specification and design of aircraft 1102 (block 1104) and material procurement (block 1106). During production, component and subassembly manufacturing (block 1108) and system integration (block 1110) of aircraft 1102 may occur. Thereafter, the aircraft 1102 may undergo certification and delivery (block 1112) to be placed in service (block 1114). In use, aircraft 1102 may be scheduled for routine maintenance and repair (block 1116). Routine maintenance and repair may include modification, reconfiguration, refurbishment, and the like of one or more systems of aircraft 1102.

Each of the processes of the illustrative method 1100 may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For purposes of this description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major-system subcontractors; the third party may include, but is not limited to, any number of suppliers, subcontractors, and suppliers; and the operator may be an airline, leasing company, military entity, maintenance organization, and so on.

As shown in fig. 37, the aircraft 1102 produced by the illustrative method 1100 may include a fuselage 1118 with a plurality of high-level systems 1120 and an interior 1122. Embodiments of high-level system 1120 include one or more of a propulsion system 1124, an electrical system 1126, a hydraulic system 1128, and an environmental system 1130. Any number of other systems may be included. Although an aerospace embodiment is shown, the principles disclosed herein may be applied to other industries, such as the automotive industry. Thus, in addition to aircraft 1102, the principles disclosed herein may be applied to other vehicles, such as land vehicles, marine vehicles, space vehicles, and the like.

The apparatus(s) and method(s) shown or described herein may be employed during any one or more of the stages of the manufacturing and service method 1100. For example, components or subassemblies corresponding to the manufacture of components and subassemblies (block 1108) may be manufactured or processed (block 1114) in a manner similar to components or subassemblies produced while aircraft 1102 is in service. Moreover, during production stages 1108 and 1110, one or more embodiments of the device(s), method(s), or a combination thereof may be utilized, for example, by substantially expediting assembly of, or reducing the cost of, aircraft 1102. Similarly, for example and without limitation, one or more embodiments or combinations thereof may be implemented using an apparatus or method while the aircraft 1102 is in service (block 1114) and/or during maintenance and repair (block 1116).

Different embodiments of the apparatus(s) and method(s) disclosed herein include various components, features, and functions. It should be understood that the various embodiments of the apparatus(s) and method(s) disclosed herein may include any combination of any of the components, features, and functions of any other embodiment of the apparatus(s) and method(s) disclosed herein, and all such possibilities are intended to be within the scope of the present disclosure.

Many modifications to the embodiments set forth herein will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings.

Therefore, it is to be understood that the subject matter disclosed herein is not to be limited to the specific embodiments shown and that modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although the foregoing descriptions and the associated drawings describe embodiments of the subject matter disclosed herein in the context of certain illustrative combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions may be provided by alternative implementations without departing from the scope of the appended claims. Accordingly, the reference signs placed between parentheses in the appended claims are for illustrative purposes only and are not intended to limit the scope of the claimed subject matter to the specific embodiment provided in the present disclosure.