apparatus for additive manufacturing, and, method for additively manufacturing an object from a meta

专利摘要:
APPARATUS FOR ADDITIVE MANUFACTURING, AND METHOD FOR ADDITIVELY MANUFACTURING AN OBJECT FROM A METAL POWDER. An apparatus for additive manufacturing is described. The additive manufacturing apparatus comprises a linear rail having a length. A linear rail is either rotating or rotating in a horizontal plane around a vertical geometric axis. The additive manufacturing apparatus further comprises an electromagnetic energy source movably coupled to the linear rail and movable in a polar coordinate system having a radius R.
公开号:BR102015024361B1
申请号:R102015024361-8
申请日:2015-09-22
公开日:2021-05-04
发明作者:Adam R. Broda
申请人:The Boeing Company；
IPC主号:

专利说明:

FOUNDATION
[001] Conventional techniques for manufacturing large-scale assemblies such as aircraft fuselages, wings, etc., generally require interconnecting several parts to form the final structure. To accommodate such interconnection several post-processing operations of large quantities of fasteners and associated equipment (eg sealing caps, shims, fillings, etc.) are used. For example, multiplicities of holes are drilled to accommodate the installation of fasteners. Furthermore, several aspects often have to be post-formed into the component parts and/or the final structure. Consequently, existing fabrication techniques for large-scale structures are labor intensive and increase fabrication cycle time and cost. Furthermore, design freedom is often limited by the requirements imposed by conventional manufacturing methodologies. SUMMARY
[002] Consequently, apparatus and methods designed to address the concerns identified above should find utility.
[003] What follows is a non-exhaustive list of examples, which may or may not be claimed, of the subject under this description.
[004] An example of the present description relates to an apparatus for additive manufacturing comprising a linear rail having a length L1. The linear rail is one of rotating or revolving in a horizontal plane around a vertical geometric axis A. The additive manufacturing apparatus additionally comprises an electromagnetic energy source movably coupled to the linear and movable rail in a polar coordinate system which has a radius R.
[005] Another example of the present description relates to an apparatus for additive manufacturing comprising linear rails each having a length L1. The linear rails are either rotating or revolving in a horizontal plane around a vertical geometric axis A. The additive manufacturing apparatus additionally comprises electromagnetic energy sources movably coupled to the linear and movable rails in a polar coordinate system having a radius R.
[006] Yet another example of the present description relates to a method for additively manufacturing an object from a metal powder. The method comprises distributing a first layer of metal powder in a powder bed volume at least partially delimited by a construction platform. The method further comprises melting a selected first portion of the first layer of the metal powder into a powder bed volume by exposing the selected first portion of the first layer of the metal powder to electromagnetic energy from an electromagnetic energy source while moving a source of electromagnetic radiation along a predetermined first path in a polar coordinate system to form at least a portion of a first layer of the object. The electromagnetic radiation source is movable in a linear path path along a linear rail, and the linear rail is one of rotating or rotating in a horizontal plane around a vertical geometric axis A. BRIEF DESCRIPTION OF THE DRAWINGS
[007] Having thus described examples of the present description in generic terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which like reference characters indicate the same or similar parts throughout the various views , and in which: Figure 1A is a first portion of a block diagram of an apparatus for additive manufacturing in accordance with one or more examples of the present description; Figure 1B is a second portion of the block diagram of apparatus for additive manufacturing in accordance with one or more examples of the present description; Figure 2 is a schematic illustration of a polar coordinate system of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 3 is a schematic top plan view of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 4 is a schematic partial side elevation view of the additive manufacturing apparatus of Figure 3, in accordance with one or more examples of the present description; Figure 5 is a schematic top plan view of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 6 is a schematic partial side elevation view of the additive manufacturing apparatus of Figure 5 in accordance with one or more examples of the present description; Figure 7 is a schematic top plan view of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 8 is a schematic partial side elevation view of the additive manufacturing apparatus of Figure 7 in accordance with one or more examples of the present description; Figure 9 is a schematic top plan view of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 10 is a schematic top plan view of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 11 is a schematic partial side elevation view of the additive manufacturing apparatus of Figure 10 in accordance with one or more examples of the present description; Figure 12 is a schematic top plan view of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 13 is a schematic partial side elevation view of the additive manufacturing apparatus of Figure 12 in accordance with one or more examples of the present description; Figure 14 is a schematic top plan view of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 15 is a schematic partial side elevation view of the additive manufacturing apparatus of Figure 14 in accordance with one or more examples of the present description; Figure 16 is a schematic top plan view of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 17 is a schematic partial side elevation view of the additive manufacturing apparatus of Figure 16 in accordance with one or more examples of the present description; Figure 18 is a schematic top plan view of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 19 is a schematic partial side elevation view of the additive manufacturing apparatus of Figure 18 in accordance with one or more examples of the present description; Figure 20 is a schematic top plan view of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 21 is a schematic partial side elevation view of the additive manufacturing apparatus of Figure 20 in accordance with one or more examples of the present description; Figure 22 is a schematic side elevation view in partial section of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 23 is a schematic side elevation view in partial section of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 24 is a schematic perspective view in partial section of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 25 is a schematic side elevation view of apparatus for additive manufacturing of 1A and 1B in accordance with one or more examples of the present description; Figure 26 is a partial schematic perspective view of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 27 is a schematic partial perspective view of a surface conditioning apparatus of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 28 is a schematic partial perspective view of a first dust removal subsystem of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 29 is a schematic top plan view of the dust containment compartment, the surface conditioning apparatus, the first dust removal subsystem and the second dust removal subsystem of the additive manufacturing apparatus of Figures 1A and 1B according to one or more examples of the present description; Figure 30 is a schematic perspective view of the second dust removal subsystem of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 31 is a schematic side elevation view of a powder dispensing apparatus of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 32 is a schematic perspective view of a powder distribution box of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 33 is a schematic top plan view of the powder dispensing apparatus of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 34 is a schematic perspective view of a gas shield system of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 35 is a schematic partial side elevation view of the gas shield system of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 36 is a schematic side elevation view of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 37 is a schematic perspective view of a building board of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 38 is a schematic perspective view of the building platform in the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 39 is a schematic side elevation view of an electromagnetic energy source and a building platform of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 40 is a schematic side elevation view of an electromagnetic energy source and a building platform of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 41 is a schematic side elevation view of an electromagnetic energy source and a building platform of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Figure 42 is a schematic side elevation view of an electromagnetic energy source and a building platform of the additive manufacturing apparatus of Figures 1A and 1B in accordance with one or more examples of the present description; Fig. 43A is a first portion of a block diagram of a method for additively fabricating an object from a metal powder in accordance with one or more examples of the present description; Fig. 43B is a second portion of the block diagram of the method for additively fabricating an object from a metal powder according to one or more examples of the present description; Figure 44 is a block diagram of aircraft production and service methodology; and Figure 45 is a schematic illustration of an aircraft. DETAILED DESCRIPTION
[008] In figures 1A and 1B referred to above, solid lines, if any, that connect several elements and/or components, may represent mechanical, electrical, fluid, optical, electromagnetic couplings and other couplings and/or comdkpc>õgu fgngUo Eqoq cswk wVükzcfq. “ceqrncfq” means associated directly as well as indirectly. For example, an A element may be directly associated with an B element or may be indirectly associated with it, for example, through another C element. It will be understood that not all relationships between the various elements described are necessarily represented. Consequently, couplings other than those outlined in the block diagrams can also exist. Dashed lines, if any, connecting the various elements and/or components represent couplings similar in function and purpose to those represented by solid lines, however, couplings represented by the dashed lines may either be provided selectively, or may relate to alternative examples options of this description. Likewise, elements and/or components, if any, represented with dashed lines indicate optional alternative examples of the present description. Environmental elements, if any, are represented with dotted lines. Virtual (imaginary) elements can also be shown for clarity. Those skilled in the art will appreciate that some of the aspects illustrated in Figures 1A and 1B can be combined in various ways without the need to include other aspects depicted in Figures 1A and 1B, other drawing figures, and/or the accompanying description, even although such combination or combinations are not explicitly illustrated here. Similarly, additional aspects not limited to the examples presented may be combined with some or all of the aspects shown and described here.
[009] In figures 1A and 1B and 43-45 referred to above, the blocks can represent operations and/or portions of them and lines that connect the various blocks do not imply any particular order or dependence of the operations or portions of them. Figures 1A and 1B and 43-45 and accompanying description describing the operations of the methods described herein should not be interpreted as necessarily determining a sequence in which the operations are to be performed. Rather, although an illustrative order is indicated, it should be understood that the sequence of operations can be modified where appropriate. Consequently, certain operations can be performed in a different order or simultaneously. Additionally, those skilled in the art will appreciate that not all of the operations described need to be performed.
[0010] In the description that follows, a number of specific details are described to provide a complete understanding of the concepts described, which can be made practical without any or all of these particulars. In other cases details of known devices and/or processes have been omitted to avoid needlessly obscuring the description. Although some concepts will be described in conjunction with specific examples, it will be understood that these examples are not intended to be limiting.
[0011] Unless otherwise indicated. qu Vgtoqu “rtkogktq”, “ugiwpfq”. gVeo. u«q cswk wVükzcfqu ogtcogpVg eqoq t„Vwnqu g p«q View is intended to impose requirements of order, rank, or hierarchy on the items to which these terms refer. Also, reference for example to a Òugiwpfq” kvgo. p«q tgswgt qw gzenwk c gzkuvêpekc fg. rqt gzgornq. wo “rtkogktq” kVgo qw kVgo fg púogtq ocku dckzq. glqw rqt gzgornq, wo “Vgtegktq” kVgo fg púogtq ocku gngxcfqo
[0012] Tghgtêpekc cswk c "wo gzgornq" ukipkhkec swg wo qw ocku aspect, structure, or feature described in connection with the example is kpenwífq go pq mípkoq woc korngogpVc>«qo C htcug "wo gzgornq can or go various places" not be referring to the same example.
[0013] Non-exhaustive illustrative examples that may or may not be claimed of the subject in accordance with the present description are provided below.
[0014] Referring for example to Figures 1A and 1B and 2-42, additive manufacturing apparatus 100 (generally referred to as apparatus 100) comprises linear rail 122 having length L1. Linear rail 122 is either rotating or revolving in a horizontal plane around a vertical geometric axis A (figures 3-21). Apparatus 100 further comprises an electromagnetic energy source 110 movably coupled to linear rail 122 and movable in polar coordinate system 250 having radius R (Fig. 2). The preceding theme of the present paragraph is in accordance with example 1 of the present description.
[0015] The additive manufacturing apparatus 100 facilitates movement of the electromagnetic energy source 110 and thus the electromagnetic energy 306 generated by the electromagnetic energy source 110 along the curvilinear path path 252 (figure 2) to any location defined by the coordinate system polar 250 when fabricating the object 300 (figure 1A) on a large scale.
[0016] The additive fabrication apparatus 100 is used to fabricate the object 300. During additive fabrication of the object 300 (figure 1A), moving the electromagnetic energy source 110 in the polar coordinate system 250 produces the object 300 (for example, the large-scale object 300) which has any fabricated shape such as a generally cylindrical shape (eg, an aircraft fuselage). As a specific non-limiting example, during a process for additive manufacturing, electromagnetic energy source 110 moves along curvilinear path path 252 (figure 2) in polar coordinate system 250 to manufacture object 300 that has at least one partially shape curvy.
[0017] Those of skill in the art will appreciate that linear rail 122 may be one or more linear rails (for example, a plurality of) linear rails 122. Each linear rail 122 has electromagnetic energy source 110 associated with and coupled to it. in a mobile way.
[0018] Additive fabrication includes any process for fabricating the three-dimensional object 300 in which successive layers of material are deposited, for example, under computer control. Object 300 can be of almost any projected shape or geometry and/or almost any fabricated shape or geometry. As an example, object 300 can be produced from a three-dimensional computer model or some other electronic data source.
[0019] The electromagnetic energy source 110 generates and/or emits electromagnetic energy 306 capable of radiating a base material to form a solid homogeneous mass of material (eg, object 300). As an example, additive fabrication apparatus 100 is used to fabricate an object 300 made of metal. The additive manufacturing apparatus 100 uses electromagnetic energy source 100, eg under computer control to form the metal object 300 by melting metal powder 302, layer by layer, with electromagnetic energy 306, to a solid homogeneous metal mass.
[0020] Metal powder 302 may include any metal or metal alloy in powder form. As an example, metal powder 302 includes the same material as object 300. For example, metal powder 302 can be pure material that has no fillers or additional materials. As an example, metal powder 302 includes additional materials other than object material 300. For example, metal powder 302 may include additional filler materials.
[0021] The object 300 manufactured by the process for additive manufacturing can significantly reduce the number of steps required in an assembly operation. Furthermore, the process for additive manufacturing can produce the object 300 which has a complex structure and/or shape. As an example, the additive manufacturing process using an additive manufacturing apparatus 100 can produce an object 300 that includes several specific aspects of the object (e.g., fastening holes, internal truss structures, openings, etc.), which it can substantially reduce or even eliminate the steps of assembling, machining and/or installing such aspects in object 300.
[0022] Referring generally to figures 1A and 1B and in rctVkewnct rqt exeoplo § 1'kgnra 4. eqoq wVükzcfq cswk “ukuVgoc fg eqqtfgpcfcu rqnctgu” fi a two-dimensional coordinate system in which a linear distance 264) from fixed point 258 and angle 260 from a fixed direction (eg, at zero degrees) determine each point 262 on a plane (eg, the horizontal plane). Distance 264 from fixed point 258 defines a radial coordinate. Angle 260 defines an angular coordinate.
[0023] In the examples described here the fixed point 258 (also known as the pole) is a point defined by an intersection of the vertical axis A (figures 3-21) and the horizontal plane. The radius R of a polar coordinate system 250 is the maximum distance 264 from the fixed point 258 of the polar coordinate system 250.
[0024] Those skilled in the art will recognize that although the motion (e.g., along curvilinear path 252) of electromagnetic energy source 110 is defined relative to polar coordinate system 250, additive fabrication apparatus 100 may locate the position of the electromagnetic energy source 110 with respect to polar coordinate system 250, Cartesian coordinate system (e.g., using two numerical coordinates that are distances from a fixed point on two fixed perpendicular directed lines to determine in a manner the position of a point on a plane), or any other suitable position determination system. As an example, additive manufacturing apparatus 100 may be operated by computer programmed commands to control the position and/or movement of electromagnetic energy source 110.
[0025] Referring generally to figures 1A and 1B and in particular for example figures 3-21, the electromagnetic energy source 110 comprises an electron beam generator or a laser beam generator. The preceding theme of the present paragraph is in accordance with example 2 of the present description, and example 2 includes the theme of example 1 above.
[0026] The electron beam generator and/or laser beam generator used in the process for additive manufacturing produce (for example, generate and/or emit) a sufficient amount of energy (for example, an electron beam or a beam laser, respectively) to promote the fusion of metal powder 302.
[0027] The object 300 produced by additive manufacturing operations (eg casting techniques) using the electron beam generator or the laser beam generator is completely dense free of voids and extremely strong.
[0028] The electron beam generator generates and/or emits an electron beam capable of fusing metal powder 302 to the object 300 made of metal. As a non-limiting generic example, the electron beam generator can be, for example, a system of several beams of a single crystalline cathode (eg 3000w). As a specific non-limiting example, the electron beam generator may be a commercially available electron beam fusion generator from Arcam AB Krokslatts Fabriker 27A, SE-431 37, Molndal, Sweden. As another specific non-limiting example, the electron beam generator may be a commercially available electron beam fusion generator from Steigerwald Strahktechnik GmbH, Emmy-Noether-Str. 282216 Maisach, Germany.
[0029] As an example, the operation for additive manufacturing can be wo rtqeguuq fg hwu«q fg hgkzg fg gnfiVtqpu *“GDO”+ swg wVükzc q hgkzg fg electrons as its energy source. The EBM process manufactures the object 300 by fusing the metal powder 302 layer by layer with the electron beam, for example, under computer control. The EBM process completely melts the 302 metal powder into a homogeneous solid metal mass.
[0030] The laser beam generator generates and/or emits a laser beam capable of melting metal powder 302 to the object 300 made of metal. As a non-limiting generic example, the laser beam generator may be a single-mode diode pumped CW ytterbium fiber laser system (eg 400W or 1000W). As a specific non-limiting example, the laser beam generator may be a commercially available laser beam casting generator from SLM Solutions GmbH Roggenhorster Strasse 9c, 23556 Lubeck, Germany.
[0031] As an example, the additive manufacturing operation can ugt wo rtqeguuq fg hwpfk>«q c ncugt ugngVkxq *“UNO”+ swg wVükzc wo hgkzg high power laser as its power source. The SLM process manufactures the object 300 by fusing the metal powder 302 layer by layer with the laser beam, for example, under computer control. The SLM process completely melts the 302 metal powder into a solid homogeneous metal mass.
[0032] Referring generally to Figures 1A and 1B and in particular for example Figures 7-13 and 26, the electromagnetic energy source 110 is configured to translate along the linear path 122 into linear path path 254. linear path 254 along linear path 122 has maximum length L2 equal to or greater than radius R of polar coordinate system 250. The preceding theme of the present paragraph is in accordance with example 3 of the present description and example 3 includes the theme of any of examples 1 and 2 above.
[0033] The maximum length L2 of the linear path path 254 being equal to or greater than the radius R of the polar coordinate system 250 defines the maximum range (e.g., facilitates greater coverage) of electromagnetic energy source 110 to travel from linearly through the entire polar coordinate system 250.
[0034] As an example, linear translation (for example along the linear path path 254) of the electromagnetic energy source 110 along the linear rail 122 while the linear rail 122 one between rotates or rotates in the horizontal plane around the axis vertical geometric A enables movement of the electromagnetic energy source 110 in the polar coordinate system 250.
[0035] As an example, the linear path path 254 may pass through the vertical axis A. The maximum length L2 of the linear path path 254 being equal to or greater than the radius R of the polar coordinate system 250, makes it possible to the electromagnetic energy source 110 to translate along the entire linear rail 122 through the vertical geometric axis A at a distance equal to or greater than the radius R. As best illustrated, for example, in figures 7, 9, 10 and 12 , the maximum length L2 of linear path path 254 is approximately twice the radius R of polar coordinate system 250.
[0036] Referring, for example, to Figures 3-21 and 26, as an example, the additive manufacturing apparatus 110 may include electromagnetic energy source drive 150 configured to linearly translate the electromagnetic energy source 110 along the linear rail 122 on linear path path 254. As an example, the electromagnetic energy source 110 can be attached to the electromagnetic energy source drive 150. The electromagnetic energy source drive 150 can be operatively coupled to the linear rail 122. linear rail 122 may include first end 212 and second end 214 opposite first end 212. Electromagnetic energy source drive 150 may translate linearly along linear rail 122 between first proximal end (e.g., at or together) to the first end 212 and proximal to the second end 214.
[0037] Electromagnetic energy source drive 150 may include any suitable drive mechanism configured to drive linear motion of electromagnetic energy source drive 150, and thus electromagnetic energy source 110 with respect to linear rail 122.
Referring generally to figures 1A and 1B and in particular for example figures 3-6. 14-21 and 26, electromagnetic energy source 110 is configured to translate along linear path 122 to linear path path 254. Linear path path 254 along linear path 122 has maximum length L2 equal to or less than than the radius R of the polar coordinate system 250. The preceding theme of the present paragraph is in accordance with example 4 of the present description and example 4 includes the theme of any of examples 1 and 2 above.
[0039] The maximum length L2 of the linear path path 254 being equal to or less than the radius R of the polar coordinate system 250 defines the maximum range of the electromagnetic energy source to travel linearly through approximately half of the system. polar coordinates 250.
[0040] As an example, linear translation (for example along the linear path path 254) of the electromagnetic energy source 110 along the linear rail 122 while the linear rail 122 rotates in the horizontal plane around the vertical geometric axis A, enables movement of the electromagnetic energy source 110 in the polar coordinate system 250.
[0041] As an example, the linear path path 254 may not pass through the vertical axis A. The maximum length L2 of the linear path path 254 being equal to or less than the radius R of the polar coordinate system 250 enables that the electromagnetic energy source 110 translates along the linear rail 122 a distance equal to or less than the radius R. As best illustrated for example in Figures 3, 5, 14, 16, 18 and 20, the maximum length L2 of the linear path path 254 is approximately equal to or slightly smaller than the radius R of polar coordinate system 250.
Referring generally to figures 1A and 1B, particularly for example to figures 7, 9, 10 and 12, the length L1 of the linear rail 122 is equal to or greater than the radius R of the polar coordinate system 250. The preceding theme of this paragraph is in accordance with example 5 of the present description and example 5 includes the theme of any of examples 1-4 above.
[0043] The length L1 of linear rail 122 being equal to or greater than the radius R of the polar coordinate system 250 facilitates the maximum length L2 of the linear path path 254 to be equal to or greater than the radius R of the coordinate system polar 250.
[0044] As an example, the linear path path 254 may extend from near (for example at or near) the first end 212 to near the second end 214. In the examples illustrated in Figures 7, 9, 10 and 12 the axis vertical geometric A is located substantially at a center of linear rail 122 between first end 212 and second end 214 of linear rail 122. As here wVknkzcfq. "uubukiiickdmgiitg" ukgpkl'kec fgpVtq fg Vqngtâpekcu fg hcdtkec>«q. As best illustrated for example in figures 7, 9, 10 and 12, the length L1 of linear rail 122 is at least approximately twice the radius R of the coordinate system polar 250.
[0045] Referring generally to figures 1A and 1B and in particular for example to figures 3, 5, 14, 16, 18 and 20, the length L1 of linear rail 122 is equal to or less than the radius R of the system of polar coordinates 250. The preceding theme of the present paragraph is in accordance with example 6 of the present description and example 6 includes the theme of any of examples 1, 2 and 4 above.
[0046] The length L1 of linear rail 122 being equal to or less than the radius R of the polar coordinate system 250, facilitates the maximum length L2 of the linear path path 254 to be equal to or less than the radius R of the system of polar coordinates 250.
[0047] As an example, the linear path path 254 may extend from near the first end 212 to the next second end 214. In the examples illustrated in Figures 3, 5, 14, 16, 18 and 20, the axis vertical geometric A is located near the first end 212 of linear rail 122. As best illustrated for example in Figures 3, 5, 14, 16, 18 and 20, the length L1 of linear rail 122 is approximately equal to the radius R of the system of polar coordinates 250. Those of ordinary skill in the art will recognize that the length L1 of linear rail 122 may be slightly less than the radius R, depending on the structural design of the additive manufacturing apparatus 100.
[0048] Referring generally to figures 1A and 1B and in particular for example to figures 5, 9, 12, 16, 20 and 26, apparatus 100 additionally comprises ring 104 and peripheral drive 148. Peripheral drive 148 is operatively coupled to the ring 104 is movable along the ring 104 and is configured to one of rotating or rotating the linear rail 122 around the vertical geometric axis A. The preceding theme of the present paragraph is in accordance with example 7 of the present description and example 7 includes the theme of any of the examples 1-6 above.
[0049] The ring 104 provides structural support for the linear rail 122. The peripheral drive 148 operatively interconnects the linear rail 122 and ring 104 to drive movement of the linear rail 122 along the ring 104 to rotate or rotate the linear rail 122 around the vertical axis A.
[0050] As an example an inner radius of ring 104 may be at least equal to or greater than the radius R of polar coordinate system 250. Ring 104 is substantially horizontal and defines the horizontal plane in which linear rail 122 is a of wheel or route around the vertical axis A. The vertical axis A is located substantially at the center of the ring 104.
[0051] Referring generally to Figures 5, 9, 12, 16 and 20, and in particular for example Figure 26, the peripheral drive 148 may include any suitable drive mechanism configured to drive movement of the linear rail 122 with respect to the ring 104. As an example, peripheral drive 148 may operatively engage at least a portion of ring 104 and travel along ring 104 (eg, in the direction of arrows 206). As an example, peripheral drive 148 may travel along an inner circumference of ring 104. As a specific non-limiting example, and as best illustrated, for example, in Fig. 26, ring 104 may include track 146 to guide peripheral drive 148, and peripheral drive 148 may travel along track 146. Other methods of operatively coupling peripheral drive 148 and ring 104 to drive a linear rail rotary or rotary motion 122 around vertical axis A are also considered without limitation.
[0052] Referring for example to figures 9 and 12, as an example, the length L1 of the linear rail 122 may be approximately equal to the inner diameter of the ring 104. The peripheral drive 148 may be connected near the first end 212 of the linear rail 122 and operatively coupled to ring 104. Peripheral drive 148 can be connected near the second end 214 of linear rail 122 and operatively coupled to ring 104. Peripheral drives 148 can rotate linear rail 122 about vertical axis A.
[0053] Referring for example to figures 5, 18 and 20, as an example, the length L1 of the linear rail 122 can be approximately equal to the inner radius of the ring 104. The peripheral drive 148 can be connected near the second end 214 of the linear rail 122 and operatively coupled to ring 104. Peripheral drive 148 can rotate linear rail 122 about vertical axis A.
[0054] Referring generally to Figures 1A and 1B, particularly for example Figures 5, 6, 16 and 17, the apparatus 100 further comprises passive hub 222 rotating around the vertical geometric axis A. The linear rail 122 is secured to the hub passive 222. The preceding theme of the present paragraph is in accordance with example 8 of the present description and example 8 includes the theme of example 7 above.
[0055] The passive hub 222 provides structural support to the linear rail 122 and allows the linear rail 122 to either freely rotate or freely rotate around the vertical axis A in response to motion triggered by the peripheral drive 148.
[0056] As an example and as best illustrated for example in Figures 5 and 16, the passive cube 222 is located substantially at the center of the ring 104. The vertical axis A passes through substantially a center of the passive cube 222. The passive cube 222 can be connected to bracket 218. As an example and as best illustrated for example in figures 6 and 17, for example, when the length L2 of the linear rail 122 is equal to or less than the radius R in the polar coordinate system 250 , the first end 212 of the linear rail 122 is connected to the passive cube 222. As an example (not shown), (for example when the length L2 of the linear rail 122 is equal to or greater than the radius R of the polar coordinate system 250), the linear rail 122 is connected to the passive hub 222 substantially at the center of the linear rail 122.
[0057] As an example and as best illustrated for example in figures 6 and 17, the passive hub 222 may include a fixed portion (eg upper portion of the passive hub 222 in figures 6 and 17), and rigidly connected to and supported by the support 218. Passive hub 222 may further include a rotatable portion (e.g., lower portion of passive hub 222 in Figures 6 and 17) rotatably connected to the fixed portion. The rotatable portion of the passive hub 222 may be freely rotatable about the vertical axis A with respect to the fixed portion of the passive hub 222. The passive hub 222 may include any suitable connection to enable free rotational movement of the rotatable portion with respect to the portion. fixed to facilitate rotary or rotary movement of the linear rail 122 around the vertical geometric axis A, for example in response to a driving force applied to the linear rail 122 by means of peripheral drive 148.
[0058] As an example, the linear rail 122 can be connected to the rotating portion of the passive hub 222. As an example and as best illustrated for example in figures 6 and 17, for example when the length L2 of the linear rail 122 is equal to or smaller than the radius R of the polar coordinate system 250, the first end 212 of the linear rail 122 is connected to the rotating portion of the passive hub 222, for example, to a lateral surface of the rotating portion. As an example (not shown), (for example, when the length L2 of the linear rail 122 is equal to or greater than the radius R of the polar coordinate system 250) the linear rail 122 is connected to the rotating portion of the passive cube 222 substantially at the center of the linear rail 122, for example, to an underside surface of the rotating portion.
[0059] Referring generally to figures 1A and 1B and particularly for example to figures 3, 4, 7, , 8, 10-15, 18 and 19, the apparatus 100 additionally comprises central drive 216 configured for a rotation or rotation of the linear path 122 around vertical geometric axis A. The preceding theme of the present paragraph is in accordance with example 9 of the present description and example 9 includes the theme of any of examples 1-7 above.
[0060] The center drive 216 provides structural support for the linear rail 122 and drives a rotary motion or rotation of the linear rail 122 around the vertical axis A.
[0061] As an example and as best illustrated for example in figures 3-7 and 14, the center drive 216 is located substantially at a center of the polar coordinate system 250. As an example and as best illustrated for example in figures 10, 12 and 18, center drive 216 is located substantially at the center of ring 104. Vertical axis A passes through substantially a center of center drive 216. Center drive 216 can be connected to bracket 218. As an example and as best illustrated for example in Figures 3, 14 and 18, for example when the length L2 of the linear rail 122 is equal to or less than the radius R of the polar coordinate system 251 the end 212 of the linear rail 122 is connected to the central drive 212 As an example of and as best illustrated for example in figures 7, 10 and 12, for example, when the length L2 of the linear rail 122 is equal to or greater than the radius R of the pole coordinate system. res 250, the linear rail 122 is connected to the central drive 216 substantially at the center of the linear rail 122.
[0062] As an example and as best illustrated for example in figures 4, 8, 11, 13, 15 and 19, the center drive 216 may include fixed portion (e.g. upper portion of the center drive 216 in figures 4, 8, 11, 13, 15 and 19) rigidly connected to and supported by bracket 218. Center drive 216 may further include a rotating portion (e.g., lower portion of center drive in Figures 4, 8, 11, 13, 15 and 19) connected rotatably to the fixed portion. The rotatable portion of the center drive 216 may be rotatably driven about the vertical axis A with respect to the fixed portion of the center drive 216. The center drive 216 may include any suitable drive mechanism to enable actuated rotational movement of the rotatable portion with respect to the fixed portion for one to rotate or rotate the linear rail 122 around the vertical geometric axis A.
[0063] As an example, the linear rail 122 can be connected to the rotating portion of the central drive 216. As an example and as best illustrated for example in figures 4, 15 and 19, for example, when the length L2 of the linear rail 122 is equal to or less than a radius R of the polar coordinate system 250 the first end 212 of the linear rail 122 is connected to the rotating portion of the center drive 216, for example, to a side surface of the rotating portion. As an example and as best illustrated for example in figures 8, 11 and 13 (for example, when the length L2 of the linear rail 122 is equal to or greater than the radius R of the polar coordinate system 250), the linear rail 122 is connected to the rotating portion of the center drive 216 substantially at the center of the linear rail 122, for example to an underside surface of the rotating portion.
[0064] As an example and as best illustrated for example in figures 3, 7 and 15, the central drive 216 supports the linear rail 122 and facilitates a rotary movement or rotation of the linear rail 122 around the vertical geometric axis A As an example and as best illustrated for example in Figure 12, a central drive 216 and peripheral drive 148 work together to support the linear rail 122 and facilitate a rotary or revolving movement of the linear rail 122 around the vertical geometric axis. THE.
[0065] Referring generally to Figures 1A and 1B and particularly for example Figures 10 and 18, the apparatus 100 additionally comprises ring 104 and peripheral passive support 226. The peripheral passive support 226 is fixed to the linear rail 122 and is coupled in a manner movable to ring 104. The preceding theme of the present paragraph is in accordance with example 10 of the present description and example 10 includes the theme of any of examples 1-6 above.
[0066] The peripheral passive support 226 interconnects the linear rail 122 and the ring 104 and allows free movement of the linear rail 122 along the ring 104 during a rotary or rotary movement of the linear rail 122 around the vertical geometric axis A.
[0067] As an example, the passive peripheral bracket 222 movably engages at least a portion of the ring 104 and travels along the ring 104, for example, in the direction of arrows 226. As an example, the passive peripheral bracket 226 may traveling freely along an inner circumference of ring 104. As a specific non-limiting example, passive peripheral support 226 can be guided by and traveling freely along track 146 of ring 104 (Fig. 26). Other methods for movably coupling the passive peripheral support 226 and the ring 104 to allow a rotational or rotating movement of the linear rail 122 about the vertical axis A are also considered without limitation.
[0068] Referring generally to Figures 1A and 1B and particularly for example Figures 10, 11, 18 and 19, the apparatus 100 further comprises central drive 216 configured to one of rotating or rotating the linear rail 122 around the vertical geometric axis A. The preceding theme of the present paragraph is in accordance with example 11 of the present description and example 11 includes the theme of example 10 above.
[0069] As an example and as best illustrated in Figures 10 and 18, the central drive 216 and the peripheral passive support 226 work together to support the linear rail 122 and facilitate a rotary movement or rotation of the linear rail 122 around of the vertical geometric axis A.
[0070] Referring generally to Figures 1A and 1B and particularly for example Figures 22-25, 27, 28, 30, 36 and 38-42, the apparatus 100 further comprises building platform 106 vertically mobile with respect to the power source electromagnetic 110. The foregoing theme of this paragraph is in accordance with example 12 of the present description and example 12 includes the theme of any of the examples 111 above.
[0071] The building platform 106 provides a built-up surface for supporting metal powder 302 and object 300 additively fabricated from it. The vertical movement of the building platform 106, for example in the direction of the arrow 246 (Fig. 23 in relation to the electromagnetic energy source 110, facilitates successive deposition of metal powder 302 onto the building platform 106.).
[0072] Referring for example to figures 39-42 as an example, during the additive manufacturing operation (e.g. method 500 of figures 43A and 43B), the building platform 106 can be positioned at a vertical distance D1 away from the electromechanical energy source 110. The first layer 230 of metal powder 302 can be distributed over the building platform 106. Electromagnetic energy 306 (Fig. 40) can melt a selected portion of metal powder 302 from the first layer 230 to form the first layer. layer 304 of object 300. Construction platform 106 can move vertically away from electromagnetic energy source 110 up to vertical distance D2. Second layer 232 of metal powder 302 can be distributed over construction platform 106. Electromagnetic energy 306 (FIG. 42) can fuse a selected portion of metal powder 302 from second layer 232 to form second layer 305 of object 300.
[0073] Each successive layer (eg, additional layer 310) of object 300 may be formed on top of a preceding layer to form a solid homogeneous mass of metal to form an object 300. Consequently, those skilled in the art will recognize that the line Dashed line separating first layer 304 and second layer 305, e.g. additional layer 310 in Fig. 42, is only for the purpose of illustrating the additive manufacturing operation, and does not imply any separation between layers forming object 300.
[0074] The construction platform 106 moves vertically away from the electromagnetic energy source 110 and the difference between the vertical distance D2 and the vertical distance D1 defines a thickness of each stratum and thus a thickness of each layer.
[0075] Referring, for example, to Figures 22-25, 30, 36 and 38, as an example the additive manufacturing apparatus 100 may include linear drive of the building platform 140 configured to vertically move the building platform 106 relative to the electromagnetic energy source 110. The linear drive of the building platform 140 can be connected to the building platform 106. As an example, the linear drive of the building platform 140 can be connected to substantially a center of an underside surface of the building platform 106. The vertical axis A may pass through substantially a center of the linear drive of the building platform 140.
[0076] The linear drive of the construction platform 140 may include any suitable linear drive mechanism, or linear actuator configured to drive linear, e.g. vertical, movement of the construction platform 106 relative to the electromagnetic energy source 110.
Referring generally to Figures 1A and 1B and particularly for example Figures 22-25, 30 and 36, apparatus 100 further comprises base 102. The subject of the present paragraph is in accordance with example 13 of the present description and the example 3 includes the theme from example 12 above.
[0078] The base 102 provides structural support for the building platform 106, linear rail 122, support 218 and/or ring 104. The vertical movement of the building platform 106 relative to the base 102 facilitates successive deposition during manufacturing in an additive manner of object 300.
[0079] Referring for example to figures 22-25, 30 and 36 as an example, the base 102 can support the construction platform 106. As an example, the base 102 can support the linear drive of the construction platform 140. as an example, linear drive of construction platform 140 may be coupled to base 102. As an example, linear drive of construction platform 140 may extend through and retract within base 102.
[0080] Referring for example to Figures 22-25, 30, 33, 34 and 36 as an example, the additive manufacturing apparatus 100 may include the base platform 234. The base platform 234 may be vertically spaced apart from the base 102. Base platform 234 may support ring 104 and/or support 218.
[0081] As an example and as best illustrated in Figures 22-26, the additive manufacturing apparatus 100 may include support pylons 144 connected to the base platform 234. As an example and as best illustrated in Figures 22-26, the ring 104 can be connected to and supported by a support pylon 144. As an example and as best illustrated in figures 5, 10, 12, 16, 18, support 218 can be connected to and supported by ring 104. Support 218 can be connected to ring 104 in a suitable manner so as not to interfere with movement of linear rail 122 relative to ring 104. As an example and as best illustrated in Figure 34, bracket 218 can be connected to and supported by support pylons 144.
[0082] Referring for example to figures 23, 26 and 34, as an example, the electromagnetic energy source 110 can be mobile vertically relative to the base 102, base platform 234 and/or construction platform 106 (for example, linearly in the direction of arrow 236). The electromagnetic energy source 110 can be movable vertically for a distance sufficient to distribute metal powder 302 (Fig. 23) on the building platform 106.
[0083] As an example, the additive manufacturing apparatus 100 may further include the linear rail drive 118. The linear rail drive 118 may be configured to vertically move the linear rail 122 and thus the electromagnetic energy source 110, for example linearly in the direction of arrow 236. As an example and as best illustrated in Figures 22-26 the linear rail drive 118 can be operatively coupled to ring 104 and to move ring 104 vertically relative to base 102, base platform 234 and/or building platform 106. As an example and as best illustrated in Figure 34, linear rail drive 118 may be operatively coupled to support 218 and vertically move support 218 relative to base 102, base platform 234 and/or construction platform 106.
[0084] As an example, linear rail drive 118 may include any suitable drive mechanism configured to drive vertical movement of ring 104 or bracket 218 and thus linear rail 122 and electromagnetic energy source 110 relative to base 102, platform base 234 and/or building platform 106. As an example, linear rail drive 118 may be coupled to support pylon 144. As an example, linear rail drive 118 may be integrated with support pylon 144.
[0085] Referring generally to Figures 1A and 1B and particularly for example Figures 25, 27 and 29, the apparatus 100 additionally comprises surface conditioning apparatus 116. The building platform 106 is rotatably movable with respect to the construction apparatus. surface conditioning 116. The foregoing theme of the present paragraph is in accordance with example 14 of the present description and example 14 includes the theme of example 13 above.
[0086] The surface conditioning apparatus 116 performs one or more surface conditioning operations, for example, surface processing on at least a portion of the outer surface 238 of the object 300 (figure 25) and following additive manufacturing and while object 300 is located on building platform 106. Rotatingly moving building platform 106 rotates object 300 with respect to surface conditioning apparatus 116 to facilitate positioning different portions of the outer surface 238 proximate to the surface conditioning apparatus 116 during surface conditioning operation.
[0087] As an example, the surface conditioning apparatus 116 can be located close to the outer surface 238 of the object 300. Following the additive fabrication of the object 300 for example, form the first layer 304 and additional layers 301 the conditioning apparatus of surface 116 may operatively engage a selected portion of the outer surface 238 of the object 300. The selected portion of the outer surface 238 may be the portion of the outer surface 238 aligned with the surface conditioning apparatus 100 at a given rotational orientation of the object 300 Thus, the selected portion of outer surface 238 can change with rotation of object 300.
[0088] Referring generally to Figures 1A and 1B and particularly for example Figures 25 and 29, the surface conditioning apparatus 116 is fixed vertically with respect to the base 102. The preceding theme of the present paragraph is in accordance with the example 15 of the present description and example 15 includes the subject of example 14 above.
[0089] Attaching the surface conditioning apparatus 116 relative to the base 102 facilitates positioning different portions of the outer surface 238 of the object 300 close to the surface conditioning apparatus 116 by vertically moving the building platform 106 relative to the base 102.
Referring generally to Figures 1A and 1B and particularly for example Figures 25, 27 and 29, the surface conditioning apparatus 116 is movable vertically with respect to the base 102. The foregoing theme in the present paragraph is in accordance with example 16 of the present description and example 16 includes the subject of example 14 above.
[0091] Vertically moving the surface conditioning apparatus 116 relative to the base 102 facilitates positioning different portions of the outer surface 238 of the object 300 close to the surface conditioning apparatus 116 by at least one of vertically moving the building platform 106 relative to to the base 102 and/or vertically moving the surface conditioning apparatus 116 relative to the base 102.
[0092] Referring for example to Figures 25 and 27, as an example, additive manufacturing apparatus 100 may further include vertical drive of surface conditioning apparatus 156. Vertical drive of surface conditioning apparatus 156 may be configured to vertically moving surface conditioning apparatus 116, for example, linearly in the direction of arrow 240. As an example, surface conditioning apparatus 116 may be operatively coupled to the vertical drive of surface conditioning apparatus 156.
[0093] As an example, the vertical drive of the surface conditioning apparatus 156 may include any suitable drive mechanism to drive vertical movement of the surface conditioning apparatus 116 relative to the base 102.
[0094] Referring generally to Figures 1A and 1B and particularly for example Figures 25, 27 and 29, the surface conditioning apparatus 116 is movable horizontally with respect to the base 102. The foregoing theme of the present paragraph is in accordance with example 17 of the present description and example 15 includes the subject of any of examples 14-16 above.
[0095] Moving the surface conditioning apparatus 116 horizontally relative to the base 102 facilitates positioning the surface conditioning apparatus 116 in different positions relative to the outer surface 238 of the object 300.
[0096] Referring for example to Figures 25 and 27, as an example, the additive manufacturing apparatus 100 may further include horizontal drive of surface conditioning apparatus 158. The horizontal drive of surface conditioning apparatus 158 may be configured to moving surface conditioning apparatus 116 horizontally, for example, linearly in the direction of arrow 242. As an example, surface conditioning apparatus 116 may be operatively coupled to the horizontal drive of surface conditioning apparatus 158. For example, the horizontal drive of surface conditioning apparatus 158 may be operatively coupled to the vertical drive of surface conditioning apparatus 156.
[0097] As an example, the surface conditioning apparatus 116 can be moved horizontally to a position close to the outer surface 238 of the object 300. As an example, the surface conditioning apparatus 116 can be moved horizontally to a spaced apart position of the outer surface 238 of the object 300. As an example, the surface conditioning apparatus 116 may be moved horizontally into a position in contact with the outer surface 238 of the object 300.
[0098] As an example, a horizontal positioning of the surface conditioning apparatus 158 may include any suitable drive mechanism to trigger horizontal movement of the surface conditioning apparatus 116 relative to the base 102.
Referring generally to figures 1A and 1B and particularly for example figures 25, 27 and 29, the surface conditioning apparatus 116 comprises a shot hammering machine. The foregoing theme of the present paragraph is in accordance with example 18 of the present description and example 18 includes the theme of any of examples 14-17 above.
[00100] Shot hammering results in improving fatigue strength of at least a portion of the object 300 that is subjected to high alternating stresses. As a specific non-limiting example, the shot hammering machine may be a large scale shot hammering system, for example commercially available from Guyson Corporation of USA, 13 Grande Boulevard, Saratoga Springs, New York 12866. As another specific example non-limiting, the shot hammering machine may be a small scale shot hammering system, for example, commercially available from Blast Pro Mfg. Inc. 6021 Melrose Lane Oklahoma City, Oklahoma 73127.
[00101] As an example, blasting object 300 (eg, outer surface 238 of object 300) produces a compressive residual stress layer and/or modifies mechanical properties of object 300. As an example, the hammering machine with Shot may impact the outer surface 238 of the object with shot (for example, round metallic, glass or ceramic particles) with sufficient force to create plastic deformation.
Referring generally to figures 1A and 1B and for example particularly figures 25, 27 and 29, the surface conditioning apparatus 116 comprises a grinding machine. The foregoing theme of the present paragraph is in accordance with example 19 of the present description and example 19 includes the theme of any of examples 14-18 above.
[00103] Grinding equalizes at least a portion of the outer surface 238 on the object 300 (eg after a shot hammering process) to reduce drag when air flows over the object 300. As a specific non-limiting example, the machine The grinding machine may be an automatic surface grinder, for example, commercially available from Willis Machinery and Tools, 4545 South Avenue, Toledo, Ohio 43615.
[00104] As an example, grinding the object 300 (for example, the outer surface 238 of the object 300) may flatten and/or shape a portion of the outer surface 238 of the object 300. As an example, the grinding machine may include a wheel mechanized, eg, rotary, covered with rough particles (eg, an abrasive grinding wheel) capable of cutting or otherwise removing material from the object 300, making the outer surface 238 flat.
Referring generally to Figures 1A and 1B particularly for example Figures 25, 27 and 29, the surface conditioning apparatus 116 comprises a sander. The foregoing theme of the present paragraph is in accordance with example 20 of the present description and example 20 includes the theme of any of examples 14-19 above.
[00106] Sanding smoothes at least a portion of the outer surface 238 of the object 300 to produce a smooth metallic surface, for example, after shot hammering and/or grinding processes in preparation for painting. As a specific non-limiting example, the sanding machine may be a wide belt sander, for example, commercially available from Houfek a.s. Obora 797,582 82 Goleuv Jenikov, Czech Republic.
[00107] Sanding object 300 (for example, the outer surface 238 of the object 300) may smooth and/or finish a portion of the outer surface 238 of the object 300. As an example, the sander may include a mechanized abrasive sandpaper (for example , rotating, vibrating, etc.) capable of scratching, scratching, disfiguring, spraying object material 300 making the outer surface smooth 238.
Referring generally to Figures 1A and 1B, particularly for example Figures 25, 27 and 29, the surface conditioning apparatus 116 comprises a hammer. The preceding theme of the present paragraph is in accordance with example 21 of the present description and example 21 includes the theme of any of examples 14-20 above.
[00109] Hammering results in improving fatigue strength of at least a portion of the object 300 that is subjected to high alternating stresses. As a non-limiting generic example, the hammering machine can be a rotary hammering system. As another non-limiting generic example the hammering machine can be a laser hammering system.
[00110] As an example, hammering the object 300, for example the outer surface 238 of the object 300, can work (eg cold working) the outer surface 238 of the object 300 to improve material properties of the object 300. How for example, the hammering machine may impact the outer surface 238 of object 300 with hammer strikes, laser beams, e.g., laser hammering, or the like, to induce compressive stresses, alleviate tensile stresses and/or encourage hardening by deformation of the object 300.
Referring generally to figures 1A and 1B, particularly for example figures 25, 27 and 29, the surface conditioning apparatus 116 comprises an abrasive blasting machine. The foregoing theme of the present paragraph is in accordance with example 22 of the present description and example 22 includes the theme of any of examples 14-21 above.
[00112] Abrasive blasting smoothes and finishes at least a portion of the outer surface 238 of object 300, for example, after hammering and/or grinding processes in paint preparation. As a specific non-limiting example, the abrasive blasting machine may be a pressure blasting system, for example commercially available from Empire Blasting Equipment, 2101 W, Cabot Boulevard, Langhorne, Pennsylnania 19047.
[00113] As an example, abrasive blasting of object 300, for example, the outer surface 238 of the object 300, may smooth a portion of the outer surface 238 or roughen, for example, form a surface texture of a portion of the outer surface 238 or shaping a portion of the outer surface 238 and/or removing contaminants from the outer surface 238. As an example, the abrasive blasting machine can forcefully impel a stream of abrasive material, e.g., aluminum oxide, or the like, against the surface. exterior 238 under high pressure, eg approximately between 103.4 kPa and 344.7 kPa (15 psi and 50 psi), suitable for smoothing exterior surface 238.
Referring generally to figures 1A and 1B, particularly for example figures 25, 27 and 29, the surface conditioning apparatus 116 comprises a polishing machine. The foregoing theme of the present paragraph is in accordance with example 23 of the present description and example 23 includes the theme of any of examples 14-22 above.
[00115] Polishing smoothes and finishes at least a portion of the outer surface 238 of object 300, for example, after hammering and/or grinding processes and in preparation for painting. As a specific non-limiting example, the polishing machine may be an abrasive polishing system, for example, commercially available from Precision Surface International Inc., 922 Ashland Street, Houston, Texas 77008.
[00116] As an example, polishing the object 300, for example the outer surface 238 of the object 300, may smooth and/or shine a portion of the outer surface 238 of the object 300. As an example, the polishing machine may include a mechanized polishing wheel, belt or cloth to rub, abrade and/or lighten a portion of the outer surface 238 or a combination of chemical and mechanical forces, e.g., chemical etching.
Referring generally to figures 1A and 1B, particularly for example figures 25, 27 and 29, the surface conditioning apparatus 116 comprises a cutting machine. The foregoing theme of the present paragraph is in accordance with example 24 of the present description and example 24 includes the theme of any of examples 14-23 above.
[00118] Cut conforms to object 300, for example, for final production and/or assembly to another object. As a non-limiting generic example, the cutting machine can be a laser cutting system. As a specific non-limiting example the cutting machine can be a CO2 laser cutting system, a neodymium (Nd) laser cutting system, or a yttrium-aluminum-garnet (Nd-) neodymium laser cutting system. YAG), for example commercially available from System & Parts Engineering, Eunos Avenue 7, Block 1082, #01-174 Singapore.
[00119] As an example, cutting the object 300, for example, the outer surface 238 of the object 300 may cut and/or shape a portion of the outer surface 238 of the object 300. As an example, the cutting machine may include a cutter machine capable of cutting, or otherwise removing, material from object 300.
Referring generally to figures 1A and 1B, particularly for example figures 25, 27 and 29, the surface conditioning apparatus 116 comprises a coating machine. The foregoing theme of the present paragraph is in accordance with example 25 of the present description and example 25 includes the theme of any of examples 14-24 above.
[00121] Coating applies one or more types of coatings to the outer surface 238 of object 300. As a specific non-limiting example, the coating machine can be a powder coating system, for example, commercially available from Powder-X Coating Systems , 7404 Highway 43, Florence, Alabama 35634.
[00122] As an example, coating the object 300, for example, the outer surface 238 of the object 300, can apply a decorative coating, functional coating, or both, a coating that is both decorative and functional to the outer surface 238 of the object 300. As an example, the coating machine may include a material deposition apparatus, e.g., a sprinkler, a roller, a brush, etc., capable of depositing decorative material, e.g. paint, lacquer, etc. , and/or functional material, for example adhesive material or corrosion resistant material, a wear resistant material, waterproof material, an anti-reflective material, an ultraviolet light absorbing material, etc., to an outer surface portion 238 of object 300.
Referring generally to Figures 1A and 1B, particularly for example Figures 22-25, 27, 28, 30, 31, 34 and 36, apparatus 100 further comprises powder containment compartment 138 configured to contain metal powder 302 and have a metal bed volume 108. The building platform 106 at least partially delimits the powder bed volume 108. The foregoing theme of the present paragraph is in accordance with example 26 of the present description and example 26 includes the theme of any of the examples from 12-25 above.
[00124] The powder containment compartment 138 defines at least a portion of the powder bed volume 108, for example at least partially delimits the powder bed volume 108. Metal powder 302 is contained by the powder containment compartment 138 when deposited on the construction platform 106.
[00125] In one example the dust containment compartment 138 may include sidewall 244 extending from base 102 to base platform 234. Building platform 106 and construction platform 140 linear drive may be located within the dust containment compartment 138.
[00126] Referring generally to figures 1A and 1B, particularly for example figures 30 and 38, the building platform 106 comprises dust removal ventilation 174. The preceding theme of the present paragraph is in accordance with example 27 of the present description and example 27 includes the theme of example 26 above.
[00127] Once additive fabrication of object 300 is completed, metal dust removal 302 from the powder bed volume 108 may be necessary to remove completed object 300. Dust removal vent 174 facilitates removal of at least one portion of the metal powder 302 contained within the powder bed volume 108, for example defined by the powder containment compartment 138 and building platform 106.
[00128] As an example, the dust removal vent 174 defines a passage, eg, an outlet opening through the building platform 106 for discharging metal dust 302 from the powder bed volume 108. The vent dust removal vent 174 can be closed to keep metal dust 302 on the building platform 106 and within the dust containment compartment 138. The dust removal vent 174 can be opened to allow metal 302 to be discharged from the volume of powder bed 108.
[00129] As an example, the dust removal vent 174 may include any suitable closing mechanism eg shutters, retractable door, etc., movable between a closed configuration to seal the powder bed volume 108 and an open position for discharging metal powder 302 from the powder bed volume 108.
[00130] Referring generally to figures 1A and 1B, particularly for example to figure 30, the apparatus 100 further comprises vibrating mechanism 176 operatively coupled to the construction platform 106. The preceding theme of the present paragraph is in accordance with example 28 of the present description and example 28 includes the subject of example 27 above.
[00131] The vibrating mechanism 176 facilitates the breaking and/or displacement of compacted or cobbled metal powder 302 within the powder bed volume 108.
[00132] As an example, the vibratory mechanism 176 may include any suitable mechanical device capable of generating vibrations. Vibrations produced by vibrating mechanism 176 can be transferred through building platform 106 to metal powder 302 contained within powder bed volume 108. Metal powder 302 particularly metal powder 302 near building platform 106 can become highly compacted or cobbled. Vibrations can facilitate the falling of compacted or cobbled metal dust 302 and/or passage of metal dust 302 through the dust removal vent 174, for example, prior to or during removal of metal dust 302 from the bed volume. dust 108 through the dust removal vent 174.
[00133] Referring generally to Figures 1A and 1B, particularly for example Figures 30 and 38, the apparatus 100 further comprises collector 178 extending downwards from the construction platform 106. The collector 178 is in selective communication with the dust bed volume 108 through dust removal vent 174. The foregoing theme of the present paragraph is in accordance with example 29 of the present description and example 29 includes the theme of any of examples 27-28 above.
[00134] Metal dust 302 discharged through the dust removal vent 174 accumulates inside collector 178 for disposal or recirculation.
[00135] As an example, the collector 178 may be a body such as a funnel or other conduit connected to the building platform 106, in selective communication with the dust removal vent 174, for example, when the dust removal vent 174 is open to transport metal powder 302 of powder bed volume 108.
[00136] Referring generally to Figures 1A and 1B, particularly for example Figures 22-25, 30 and 36, the building platform 106 is vertically movable within the powder containment compartment 138 and powder bed volume 108 is variable . The foregoing theme of the present paragraph is in accordance with example 30 of the present description and example 30 includes the theme of any of examples 26-29 above.
[00137] Vertically moving the construction platform 106 within the powder bed compartment 138 varies the volume of the powder bed 108.
[00138] As an example, and as best illustrated in Figure 23, when the building platform 106 moves vertically for example in the direction of arrow 246 away from the electromagnetic energy source 110 and/or towards the base 102, the volume of the powder bed 108 can increase thereby facilitating further distribution of metal powder 302 and formation of additional layer 310 of object 300.
Referring generally to Figures 1A and 1B, particularly for example Figures 24 and 28, the apparatus 100 further comprises dust removal apparatus 126 configured to remove metal dust 302 from the dust containment compartment 138.
[00140] The dust removal apparatus 126 facilitates the removal of metal dust 302 from the dust containment compartment 138 for disposal or recycling.
[00141] As an example, the dust removal apparatus 126 may be in selective communication with the dust containment compartment 138 and/or collector 178.
[00142] Referring generally to Figures 1A and 1B, particularly for example Figures 23, 24, 25 and 28-30, the dust removal apparatus 126 comprises first dust removal subsystem 128 movable between a first location laterally outwards of the dust containment compartment 138 and a second location laterally into the dust containment compartment 138. The dust removal apparatus further comprises second dust removal subsystem 130 located laterally into the dust containment compartment 138. The preceding theme of the present paragraph is in accordance with example 32 of the present description and example 32 includes the theme of example 31 above.
[00143] The first dust removal subsystem 128 facilitates the removal of metal dust 302 (figure 23) accumulated within the dust containment compartment 138 between the object 300 and sidewall 244. The second dust removal subsystem 130 facilitates removing the metal dust 302 accumulated within the dust containment compartment within the object 300.
[00144] As an example, and as best illustrated in Figures 28 and 29, the dust containment compartment 138 may include the first door of the dust removal subsystem 164. The first door of the dust removal subsystem 164 may open to allow that the first dust removal subsystem 128 enters the dust containment compartment 138, for example, to move to the second location laterally into the dust containment compartment 138. As an example, the door of the first dust removal subsystem powder 164 can retract within sidewall 244 of dust removal compartment 138.
[00145] Referring generally to Figures 1A and 1B, particularly for example Figures 28 and 29, the first dust removal subsystem 128 is vertically movable with respect to the dust containment compartment 138. The preceding theme of the present paragraph is according to example 33 of the present description and example 33 includes the subject of example 32 above.
[00146] Vertical movement of the first dust removal subsystem 128 relative to the dust containment compartment 138 facilitates the removal of metal dust 302 from various vertical locations within the dust containment compartment 138. Referring to, for example, Figures 28 and 29 , as an example, the additive manufacturing apparatus 100 may further include first vertical drive of dust removal subsystem 160. The first vertical drive of dust removal subsystem 160 may be configured to vertically move the first dust removal subsystem. dust removal 128, for example linearly in the direction of arrow 248. As an example, the first dust removal subsystem 128 may be operatively coupled to the first vertical drive of the dust removal subsystem 160.
[00147] As an example, the first vertical drive of the dust removal subsystem 160 may include any drive mechanism suitable for driving vertical movement of the first dust removal subsystem 128 relative to the dust containment compartment 138.
[00148] Referring generally to Figures 1A and 1B, particularly for example Figures 28 and 29, the first dust removal subsystem 128 is movable horizontally with respect to the dust containment compartment 138. The preceding theme of the present paragraph is according to example 34 of the present description and example 34 includes the subject of any of examples 32-33 above.
[00149] Horizontal movement of the first dust removal subsystem 128 relative to the dust containment compartment 138 facilitates the removal of metal dust 302 from the various horizontal locations within the dust containment compartment 138.
[00150] Referring to Figures 28 and 29, as an example, additive manufacturing apparatus 100 may further include first horizontal drive of dust removal subsystem 162. First horizontal drive of dust removal system 162 may be configured to move horizontally the first dust removal subsystem 128, e.g. linearly in the direction of arrow 312. As an example, the first dust removal subsystem 128 can be operatively coupled to the first horizontal dust removal subsystem drive 162. In an example, the first horizontal dust removal subsystem drive 162 may be operatively coupled to the first vertical dust removal subsystem drive 160.
[00151] As an example, the first horizontal drive of dust removal subsystem 162 may include any suitable drive mechanism for driving horizontal movement of the first dust removal subsystem 128 relative to the dust containment compartment 138.
[00152] Referring generally to figures 1A and 1B, particularly for example to figure 28, the first dust removal subsystem 128 comprises vacuum source 168. The preceding theme of the present paragraph is in accordance with example 35 of the present description and example 35 includes the theme of any of examples 32-34 above.
[00153] The vacuum source 168 generates suction capable of removing, for example by vacuuming, metal dust 32 from the dust containment compartment 138, for example metal dust 302 accumulated between an object 300 and the side wall 244.
[00154] Referring generally to Figures 1A and 1B, particularly for example Figure 28, the first dust removal subsystem 128 comprises pressurized fluid source 170. The preceding theme of the present paragraph is in accordance with example 36 of the present description and example 36 includes the subject of any of examples 32-35 above.
[00155] The pressurized fluid source 170 generates a pressurized fluid flow, for example pressurized air, capable of blowing and/or dislodging metal powder 302 within the powder containment compartment 138, for example metal powder 302 accumulated between a object 300 and sidewall 244.
Referring generally to Figures 1A and 1B, particularly for example Figures 29 and 30, the second dust removal subsystem 130 is located centrally within the dust containment compartment 138. The building platform 106 is mobile vertically with respect to the second dust removal subsystem 130. The preceding theme of the present paragraph is in accordance with example 37 of the present description and example 37 includes the theme of any of examples 32-36 above.
[00157] The vertical movement of the building platform 106 relative to the second dust removal subsystem 130 facilitates the removal of metal dust 302 from within the dust containment compartment 138 accumulated within an open area defined by object 300 positioning dust of accumulated metal 302 near a second dust removal system 130.
[00158] As an example, and as best illustrated in Figure 30, the additive manufacturing apparatus 100 may further include tower structure 166. The second dust removal subsystem 130 may be coupled to the tower structure 138. The tower structure 166 can extend from base 102 to near an upper portion of dust containment compartment 138. Tower structure 138 can extend through building platform 106 and building platform 106 can be movable vertically with respect to the structure. of tower 166. When object 300 is additively manufactured, tower structure 166 can be located within the open interior area of object 300.
Referring generally to Figures 1A and 1B, particularly for example Figure 30, the second dust removal subsystem 130 is rotatable with respect to the dust containment compartment 138. The preceding theme of the present paragraph is in accordance with example 38 of the present description and example 38 includes the subject of any of examples 3237 above.
[00160] Rotating the second dust removal subsystem 130 relative to the dust containment compartment 138 facilitates the removal of metal dust 302 from various locations within the dust containment compartment 138, for example, metal dust 302 accumulated within of the open area defined by object 300.
[00161] As an example, tower structure 166 may rotate relative to dust containment compartment 138. As an example, tower structure 166 may rotate around vertical axis A. Rotation of tower structure 166 may position the second dust removal subsystem 130 in various rotational orientations.
Referring generally to Figures 1A and 1B, particularly for example Figure 30, the second dust removal subsystem 130 is movable vertically with respect to the dust containment compartment 138. with example 39 of the present description and example 39 included the subject of any of examples 32-38 above.
[00163] Vertical movement of the second dust removal subsystem 130 relative to the dust containment compartment 138 facilitates the removal of metal dust 302 from the various vertical locations within the dust containment compartment 138, for example, metal dust 302 accumulated within the open area defined by object 300.
[00164] Referring for example to Figure 30, as an example, the additive manufacturing apparatus 100 may further include the second vertical drive of the dust removal subsystem 180. The second vertical drive of the dust removal subsystem 180 may be configured to vertically move the second dust removal subsystem 130, for example, linearly in the direction of arrow 314. As an example, the second dust removal subsystem 130 may be operatively coupled to the second vertical drive of the dust removal subsystem 180 .
[00165] As an example, the second vertical drive of the dust removal subsystem 180 may be coupled to the tower structure 166. As an example, the second vertical drive of the dust removal subsystem 180 may be integral with the tower structure 166 .
[00166] As an example, the second vertical drive of the dust removal subsystem 180 may include any suitable drive mechanism for driving vertical movement of the second dust removal subsystem 130 relative to the dust containment compartment 138.
[00167] Referring generally to figures 1A and 1B, particularly for example to figure 30, the second dust removal subsystem 130 comprises vacuum source 168. The preceding theme of the present paragraph is in accordance with example 40 of the present description and example 40 includes the theme of any of examples 32-39 above.
[00168] Vacuum source 168 generates suction capable of removing, for example by vacuuming, metal dust 302 from dust containment compartment 138, for example metal dust 302 accumulated within the open area defined by object 300.
[00169] Referring generally to figures 1A and 1B, particularly for example to figure 30, the second dust removal subsystem 130 comprises pressurized fluid source 170. The preceding theme of the present paragraph is in accordance with example 41 of the present description and example 41 includes the subject of any of examples 32-40 above.
[00170] The pressurized fluid source 170 generates a pressurized fluid flow, for example pressurized air, capable of blowing and/or displacing metal powder 302 within the powder containment compartment 138, for example metal powder 302 accumulated within the open area defined by object 300.
Referring generally to Figures 1A and 1B, particularly for example Figure 30, the second dust removal subsystem 130 comprises an agitator arm 172. The preceding theme of the present paragraph is in accordance with example 42 of the present description and example 42 includes the theme of any of examples 32-41 above.
[00172] The agitator arm 172 passes through metal powder 302 within the powder containment compartment, for example metal powder 302 accumulated within the open area defined by object 300, to loosen or break metal powder 302.
[00173] As an example, agitator arm 172 may extend from tower structure 166 radially outward towards sidewall 244 of powder containment compartment 138.
[00174] Referring for example to Figures 27 and 29, as an example, the dust containment compartment 138 may further include surface conditioning apparatus door 154. The surface conditioning apparatus door 154 may open to allow the surface conditioning apparatus 116 penetrates the powder containment compartment 138, for example, to move to a location laterally into the powder containment compartment 138. As an example, the surface conditioning apparatus door 154 may retract inside sidewall 244 of dust containment compartment 138.
Referring generally to Figures 1A and 1B, particularly for example Figures 24 and 25, apparatus 100 further comprises dust recirculation apparatus 138 operatively connected to dust removal apparatus 126. Metal dust 302 removed from the dust compartment. dust containment 138 is transferable from dust removal apparatus 126 to dust recycling apparatus 136. The foregoing subject of the present paragraph is in accordance with example 43 of the present description and example 43 includes the subject of any of examples 31-42 above.
[00176] The powder recirculation apparatus 136 facilitates the cleaning and/or conditioning of the metal powder 302 removed from the powder containment compartment 138 for reuse in the additive manufacturing process.
[00177] As an example, metal dust 302 removed from dust containment compartment 138 by dust removal apparatus 126 can be transferred to dust recycling apparatus 136. As an example, metal dust 302 removed from among the object 300 and sidewall 244 by the first after removal subsystem 128, eg vacuum source 168, can be transferred to a dust recycling apparatus 136. As an example, metal dust 302 removed from within the open area of object 300 by second dust removal subsystem 130, for example vacuum source 138, can be transferred to dust recycling apparatus 136. As an example, metal dust 302 discharged through dust removal vent 174, collected by collector 178, and removed by vacuum source 168 (figure 30) located near a lower portion of the collector, can be transferred to powder recycling apparatus 136.
Referring generally to Figures 1A and 1B, particularly for example Figures 24, 25, 31 and 33, apparatus 100 further comprises powder dispensing apparatus 132 configured to deposit metal powder 302 in the powder containment compartment. 138. The foregoing theme of the present paragraph is in accordance with example 44 of the present description and example 44 includes the theme of any of examples 26-43 above.
[00179] The powder dispensing apparatus 132 facilitates depositing metal powder 302 in the powder containment compartment 138 and on the construction platform 106 in successive layers, for example, first layer 230, second extract 232, etc.) (figures 39-42).
[00180] Referring generally to figures 1A and 1B, particularly for example figures 24, 25 and 31-33, powder dispensing apparatus 132 comprises powder source 182, powder feed 184 in selective communication with the powder source 182 and powder distribution box 186, configured to receive metal powder 302 from powder feed 184. Powder distribution box 186 is movable horizontally laterally into powder containment compartment 138. This paragraph is in accordance with example 45 of the present description and example 45 includes the subject of example 44 above.
[00181] As an example, the powder source 182 may include a container configured to store a volume of new or recirculated metal powder 302 for use in the additive manufacturing process. Metal powder 302 can be transferred from powder source 182 to powder feed 184. As an example, powder feed 184 can include any transfer mechanism suitable for transporting metal powder 302, e.g., a hopper, an auger , etc. Powder feed 184 may be in selective communication with powder distribution box 186 to transfer metal 302 to powder distribution box 186. As an example, powder dispensing apparatus 132 may further include a powder slider 188 extending from powder feed 184 to powder distribution box 186.
[00182] As an example and as best illustrated in Figures 24, 25, 31 and 33, the additive manufacturing apparatus 100 may further include powder distribution box drive 190. The powder distribution box drive 190 can be configured to move the powder distribution box 186 horizontally, for example linearly in the direction of arrow 316 (figure 33). The powder distribution box 186 can deposit a fresh layer of metal powder 302 in the powder containment compartment 138 on the building platform 106 during each horizontal movement over the powder containment compartment 138.
[00183] As an example, the powder distribution box 186 can be operatively coupled to the powder distribution box drive 190. The powder distribution box drive 190 can be connected to the base platform 234 on laterally opposite sides of the dust containment compartment 138.
[00184] As an example, the powder distribution box drive 190 may include any suitable drive mechanism for driving horizontal movement of the powder distribution box 186 relative to the powder containment compartment 138.
[00185] As an example, and as best illustrated in Figure 32, the powder distribution box 186 may include powder coating arm 192 configured to evenly spread metal 302 deposited in the powder bed 108 on the building platform 106. In one example, powder distribution box 186 may further include roller 194 configured to compact metal powder 302 deposited in powder bed 108 on building platform 106.
[00186] Referring generally to Figures 1A and 1B, particularly for example Figures 34 and 35, the apparatus 100 further comprises gas shielding system 196 configured to dispense shielding gas 308 to protect a portion of metal dust 302 which is being radiated by the electromagnetic energy source 110 in the powder bed volume 108. The preceding subject of the present paragraph is in accordance with example 46 of the present description and example 46 includes the subject of any of examples 26-45 above.
[00187] The shielding gas 308 prevents oxidation and/or eliminates the formation of smoke during the irradiation of the metal powder portion 302 by the electromagnetic energy source 110.
[00188] As an example, the shielding gas system 198 may include shielding gas source 198 in selective communication with the electromagnetic energy source 110. The shielding gas 308 may be any suitable inert gas. The shielding gas source 198 may include a container that defines an internal volume suitable for storing a shielding gas 308. The shielding gas source 198 may be connected directly to the electromagnetic energy source 110 via the shielding gas line 228.
[00189] In one example, 308 shielding gas can be pressurized. As an example, shielding gas source 198 may pressurize shielding gas 308. As an example shielding gas system 198 may include shielding gas pump 202.
Referring generally to Figures 1A and 1B, particularly for example Figures 36-38, apparatus 100 further comprises building plate 204 releasably coupled to building platform 106. The foregoing theme of the present paragraph is in accord with example 47 of the present description and example 47 includes the subject of any of examples 26-46 above.
[00191] Building plate 204 facilitates removal of object 300 from building platform 106 and dust containment compartment 138 following completion of the additive manufacturing process and any surface conditioning operations.
[00192] As an example and as best illustrated in Figure 36 the building plate 204 can be releasably coupled to the building platform 106. Metal dust 302 can be deposited on the building plate 204. When the first layer 230 of metal powder 302 (figure 39) is radiated by electromagnetic energy 306 to form the first layer 304 of the object 300 (figure 40) the first layer 304 can be bonded (e.g. cast) to the building plate 204 instead of the building platform. building 106.
[00193] Following the additive manufacturing process, the building plate 204 and the object 300 attached to the building plate 204 can be removed from the building platform 106 and dust containment compartment 138. The building plate 204 can be removed from the 300 object by a suitable cutting or grinding operation.
[00194] Referring for example to Figures 37 and 38, as an example, the building platform 106 may include first alignment aspect 208. The building plate 204 may include second alignment aspect 210. The first alignment aspect 208 and the second alignment aspect 210 may be correspondingly engaged to properly position and align the building plate 204 with respect to the building platform 106.
Referring generally to figures 1A and 1B, particularly for example to figure 37, the building plate 204 is annular. The preceding theme of the present paragraph is in accordance with example 48 of the present description and example 48 includes the theme of example 47 above.
[00196] The annular building plate 204 facilitates the removal of metal dust 302 through the dust removal vent 174 placed on the building platform 106 (figure 38).
[00197] As an example, the building plate 204 can be sized to cover near a periphery of the building platform 106 so as not to interfere with passage of metal dust 302 accumulated within the open space of the object 300 through the vent of dust removal 174.
Referring for example to Figures 37 and 38, as an example, the building platform 106 may include first alignment aspect 208. The building plate 204 may include second alignment aspect 210. The first alignment aspect 20 and the second alignment aspect 210 can be correspondingly engaged to properly position and align the building plate 204 with respect to the building platform 106.
[00199] Referring generally to figures 1A and 1B, particularly for example to figures 36 and 37, the building plate 204 comprises handling aspect 206. The preceding theme of the present paragraph is in accordance with example 49 of the present description and example 49 includes the theme of any of examples 47-48 above.
[00200] The handling aspect 206 facilitates coupling the building plate 204 to the building platform 106 and/or removing the building plate 204 from the building platform 106, for example, by means of an object handling machine (not shown ).
[00201] As an example, the handling aspect 206 may include an opening placed at least partially through the building plate 204. The handling aspect 206 may be configured to receive a lift from the building plate of the object handling machine. As an example, handling aspects 206 may be suitably sized to receive forks from a fork lift truck.
[00202] Referring, for example, to figures 24, 29 and 30, as an example, dust containment compartment 138 may further include access door 152. Access door 152 may open to allow removal of object 300 from the platform of building 106 and dust containment compartment 138 or removal of building plate 204 and object 300 from building platform 106 and dust containment compartment 138. As an example, access door 152 may retract into sidewall 244 of the dust containment compartment 138. As an example, access door 152 may retract into base 102. Figures 24 and 30 delineate dust containment compartment 138 with access door 152 in an open configuration.
[00203] Referring for example to Figures 1A, 1B, 2 and 14-21, the additive manufacturing apparatus 100 (generally referred to as apparatus 100) comprises linear rails 122, each having length L1. Linear rails 122 are one of rotating or revolving in a horizontal plane around the vertical geometric axis A. The apparatus 100 additionally comprises electromagnetic energy sources 110 movably coupled to linear rails 122 and movable in a polar coordinate system 250 having radius A. The preceding theme of this paragraph is in accordance with example 50 of the present description.
[00204] Linear rails 122 facilitate use of electromagnetic energy sources 110. The use of electromagnetic energy sources 110 increases a cycle time for the additive manufacturing process.
Referring generally to Figures 1A and 1B, particularly for example Figures 14-21, linear rails 122 are not movable relative to one another. The preceding theme of the present paragraph is in accordance with example 51 of the present description, and example 51 includes the theme of example 50 above.
[00206] Fixing the linear rails 122 relative to one another maintains an angular orientation of electromagnetic energy sources 110 relative to one another.
[00207] As an example, and as best illustrated in figures 15, 17, 19 and 21, first ends 212 of linear rails 122 can be fixedly connected to the central drive 216 (figures 15 and 19), passive hub 222 (figure 17) or each other (figure 21).
Referring generally to Figures 1A and 1B, particularly for example Figures 14, 16, 18 and 20, and 20, electromagnetic energy sources 110 are configured to translate along linear rails 122 in linear path paths 254. Each of the linear path paths 254 along linear rails 122 has a maximum length L2 equal to or less than the radius R of the polar coordinate system 250. The preceding theme of this paragraph is in accordance with example 52 of the present description and example 52 includes the subject of any of examples 50 and 51 above.
[00209] The maximum length L2 of the linear path path 254 being equal to or less than the radius R of the polar coordinate system 250, defines the maximum range of the electromagnetic energy source 110 to travel linearly through approximately half of the polar coordinate system 250.
[00210] As an example, linear translation, for example, along linear path paths 254 of electromagnetic energy sources 110 along linear rails 122 while linear rails 122 rotate in the horizontal plane around the vertical geometric axis A, enables movement of the electromagnetic energy sources 110 in the polar coordinate system 250.
[00211] As an example, linear path paths 254 may not pass through the vertical axis A. The maximum length L2 of linear path paths 254 being equal to or less than the radius R of the polar coordinate system 250, may enable electromagnetic energy sources 110 to translate along linear rails 122 a distance equal to or less than radius R. As best shown, for example, in figures 14, 16, 18 and 20, the maximum length L2 of paths of Linear paths 254 may be smaller than the radius R of polar coordinate system 250.
[00212] Referring generally to figures 1A and 1B, particularly for example to figures 14, 16, 18 and 20, the length L1 of each of the linear rails 122 is equal to or less than the radius R of the polar coordinate system 250. The foregoing theme of the present paragraph is in accordance with example 53 of the present description and example 53 includes the theme of any of examples 50-52 above.
[00213] The length L1 of linear rails 122 being equal to or less than the radius R of the polar coordinate system 250 facilitates the maximum length L2 of linear path paths 254 to be equal to or less than the radius R of the system of polar coordinates 250.
[00214] As an example, linear path paths 254 may extend from near the first ends 212 to near the second ends 214 of linear rails 122. In the examples illustrated in Figures 14, 16, 18 and 20, the geometric axis vertical A can be located near the first end 212 of the linear rail 122. As best illustrated, for example, in Figures 14, 16, 18 and 20, the length L1 of the linear rails 122 may be smaller than the radius R of the system of polar coordinates 250.
Referring generally to Figures 1A and 1B, particularly for example Figures 43A and 43B, method 500 for additively fabricating object 300 from metal powder 302 is described. Method 500 comprises distributing first layer 230 of metal powder 302 in powder bed volume 108 at least partially bounded by building platform 106 (block 502). Method 500 further comprises melting a first selected portion of first layer 230 of metal powder 302 in the powder bed volume 108 by exposing the first selected portion of first layer 230 of metal powder 302 to electromagnetic energy 306 from the energy source. electromagnetic radiation 110 while moving the electromagnetic radiation source 110 along a predetermined first path in polar coordinate system 250 to form at least a portion of the first layer 304 of the object 300 (block 504). The electromagnetic radiation source is movable in a linear path path 254 along the linear rail 122. The linear rail 122 is one of rotating or revolving in a horizontal plane around the vertical geometric axis A. The preceding theme of this paragraph is according to example 54 of the present description.
[00216] Additively fabricating the object by moving the electromagnetic energy source 110 along the first predetermined path, for example, curvilinear path path 252 (figure 2) in a polar coordinate system 250 produces the object 300 on a large scale .
[00217] Continuing to refer generally to Figures 1A and 1B, and 2-42, and particularly, for example, to Figure 43A method 500 further comprises vertically moving the building platform 106 a predetermined distance away from the electromagnetic energy source 110 after forming the first layer 304 of object 300 (block 506). Method 500 further comprises distributing second layer 232 of metal powder 302 in powder bed volume 108 over first layer 304 of object 300 (block 508). The preceding theme of the present paragraph is in accordance with example 55 of the present description and example 55 includes the theme of example 54 above.
[00218] Distributing the second layer 232 of metal powder 302 in the powder bed volume 108 over the first layer 304 of the object 300 facilitates the formation of the second layer 305 on top of the first layer 304.
[00219] Continuing to refer generally to Figures 1A and 1B and 2-42, and particularly, for example, Figure 43A the method further comprises melting a selected second portion of the second layer 232 of the metal powder 302 in the bed volume of powder 108 exposing the second selected portion of second layer 232 of metal powder 302 to electromagnetic energy 306 from electromagnetic energy source 110 while moving electromagnetic radiation source 110 along a second predetermined path in polar coordinate system 250, to form at least a portion of the second layer 305 of the object 300 (block 510). The preceding theme of the present paragraph is in accordance with example 56 of the present description and example 56 includes the theme of example 55 above.
[00220] Melting the selected second portion of the second layer 232 of metal powder 302 to form at least a portion of the second layer 305 on top of the first layer 304 forms the object 300 made of a solid homogeneous metal material.
[00221] As an example, the second predetermined path in polar coordinate system 250 may be a curvilinear path path 252 (figure 2).
[00222] Continuing to refer generally to Figures 1A and 1B and 2-42, and particularly for example to Figure 43A the second predetermined path of electromagnetic radiation source 110 in polar coordinate system 250 and the first predetermined path of radiation source electromagnetic 110 in the polar coordinate system 250 are identical. The preceding theme of the present paragraph is in accordance with example 57 of the present description and example 57 includes the theme of example 56 above.
[00223] The second predetermined path of electromagnetic radiation source 110 in polar coordinate system 250 and the first predetermined path of electromagnetic radiation source 110 in polar coordinate system 250 being identical build the second layer 305 having a shape that is the same that a first layer 304 and directly on top of the first layer 304 to form a portion of the object 300.
[00224] Continuing to refer generally to Figures 1A and 1B and 2-42 and particularly, for example, to Figure 43A the second predetermined path of electromagnetic radiation source 110 in the polar coordinate system 250 and the first predetermined path of radiation source electromagnetic radiation 110 in the polar coordinate system 250 are different. The foregoing theme of the present paragraph is in accordance with example 58 of the present description and example 58 includes the theme of example 56 above.
[00225] The second predetermined path of electromagnetic radiation source 110 in polar coordinate system 250 and the first predetermined path of electromagnetic radiation source 110 in polar coordinate system 250 being different build the second layer 305 having a different shape from the first layer 304 to form a different portion of the object 300, for example, to form a specific aspect of the object.
[00226] Continuing to refer generally to Figures 1A and 1B and 2-42, and particularly to Figure 43A, method 500 further comprises forming the first layer 304 of object 300 on the building plate 204 releasably connected to the platform of building 106 (block 512). The foregoing theme of the present paragraph is in accordance with example 59 of the present description and example 59 includes the theme of any of examples 54-58 above.
[00227] Forming the first layer 304 of the object 300 on the building plate 204, for example, rather than on the building platform 106, facilitates the removal of the object 300 from the building platform 106 and holding containment compartment 138.
[00228] Continuing to refer generally to Figures 1A and 1B and 2-42 and particularly, for example, to Figure 43A method 500 further comprises removing metal powder 302 from the powder bed volume 108 after forming the first layer 304 and selected number of additional object layers 300 (block 514). The foregoing theme of the present paragraph is in accordance with example 60 of the present description and example 60 includes the theme of any of examples 54-59 above.
[00229] Removal of metal dust 302 from the powder bed volume 108 facilitates the surface conditioning operation and/or removal of object 300 from the construction platform 106 and dust containment compartment 138.
[00230] Continuing to refer generally to Figures 1A and 1B, and 2-42, and particularly, for example, Figure 43A method 500 further comprises first surface conditioning layer 304 and selected number of additional layers 310 of object 300 (block 516). The preceding theme of the present paragraph is in accordance with example 61 of the present description and example 61 includes the theme of example 60 above.
[00231] Surface conditioning of the first layer 304 and selected number of additional layers 310 of the object 300 facilitates one or more surface conditioning operations, for example, surface processing over at least a portion of the outer surface 238 of the object 300 thereafter to additive manufacturing while object 300 is located on construction platform 106.
[00232] Referring generally to figures 1A and 1B and 2-42, and particularly for example to figure 43B, conditioning the surface of the first layer 304 and selected number of additional layers of the object 300 comprises rotating the building platform 106 with respect to the surface conditioning apparatus 116 (block 518). The preceding theme of the present paragraph is in accordance with example 62 of the present description and example 62 includes the theme of example 61 above.
[00233] Rotating the building platform 106 relative to the surface conditioning apparatus 116 rotates the object 300 relative to the surface conditioning apparatus 116 to facilitate positioning different portions of the first layer 304 and selected number of additional layers 310 of the object 300 , for example, the outer surface 238 near the surface conditioning apparatus 116 during surface conditioning operation.
[00234] Continuing to refer generally to Figures 1A, 1B, and 2-42 and particularly, for example, Figure 43B, conditioning the surface of the first layer 304 and selected number of additional layers 310 of the object 300 comprises hammering the first layer 304 and selected number of additional layers 310 of object 300 (block 520a). The foregoing theme of the present paragraph is in accordance with example 63 of the present description and example 63 includes the theme of any of examples 61 and 62 above.
[00235] Hammering the first layer 304 and selected number of additional layers 310 of object 300 facilitates improving material properties of object 300.
[00236] Continuing to refer generally to Figures 1A, 1B and 2-42 and particularly, for example to Figure 43B, surface conditioning of the first layer 304 and selected number of additional layers 310 of the object 300 comprises hammering the first layer 304 and selected number of additional layers 310 of object 300 (block 520b). The preceding theme of the present paragraph is in accordance with example 64 of the present description and example 64 includes the theme of any of examples 61-63 above.
[00237] Hammering the first layer 304 and selected number of additional layers 310 of the object 300 facilitates introducing a compressive residual stress layer to the object 300 and/or modifying mechanical properties of the object 300.
[00238] Continuing to refer generally to Figures 1A, 1B and 2-42, and particularly, for example, Figure 43B, surface conditioning of the first layer 304 and selected number of additional layers 310 of the object 300 comprises grinding the first layer 304 and selected number of additional layers 310 of object 300 (block 520c). The preceding theme of the present paragraph is in accordance with example 65 of the present description and example 65 includes the theme of any of examples 61-64 above.
[00239] Grinding the first layer 304 and selected number of additional layers 310 of the object 300 facilitates flattening or shaping the object 300.
[00240] Continuing to refer generally to Figures 1A, 1B, 2-42 and particularly, for example, Figure 43B, surface conditioning of the first layer 304 and selected number of additional layers 310 of the object 300 comprises sanding the first layer 304 and selected number of additional layers 310 of object 300 (block 520d). The foregoing theme of the present paragraph is in accordance with example 66 of the present description and example 66 includes the theme of any of examples 61-65 above.
[00241] Sanding the first layer 304 and selected number of additional layers 310 of the object 300, facilitates smoothing and/or finishing the object 300.
[00242] Continuing to refer generally to Figures 1A, 1B and 242, and particularly, for example, Figure 43B, surface conditioning of the first layer 304 and selected number of additional layers 310 of object 300 comprises abrasive blasting of the first layer 304 and from a selected number of additional layers 310 of object 300 (block 520e). The preceding theme of the present paragraph is in accordance with example 67 of the present description and example 67 includes the theme of any of examples 61-66 above.
[00243] Abrasive blasting of the first layer 304 and selected number of additional layers 310 of the object 300 facilitates smoothing, roughening, shaping and/or removal of contaminants from the object 300.
[00244] Continuing to refer generally to Figures 1A, 1B, 2-42 and particularly, for example, Figure 43B, surface conditioning of the first layer 304 and selected number of additional layers 310 of the object 300 comprises polishing the first layer 304 and selected number of additional layers 310 of object 300 (block 520f). The preceding theme of the present paragraph is in accordance with example 68 of the present description and example 68 includes the theme of any of examples 61-67 above.
[00245] Polishing the first layer 304 and selected number of additional layers 310 of the object 300 facilitates smoothing or making the object 300 shine.
[00246] Continuing to refer generally to Figures 1A, 1B, 2-42 and particularly, for example, Figure 43B, surface conditioning of the first layer 304 and selected number of additional layers 310 of the object 300 comprises cutting the first layer 304 and selected number of additional layers 310 of object 300 (block 520g). The foregoing theme of the present paragraph is in accordance with example 69 of the present description and example 69 includes the theme of any of examples 61-68 above.
[00247] Cutting the first layer 304 and selected number of additional layers 310 from the object 300 facilitates cutting material from and/or shaping the object 300.
[00248] Continuing to refer generally to Figures 1A, 1B, 2-42 and particularly, for example, Figure 43B, surface conditioning of the first layer 304 and selected number of additional layers 310 of the object 300 comprises coating the first layer 304 and selected number of additional layers 310 of object 300 (block 520h). The foregoing theme of the present paragraph is in accordance with example 70 of the present description and example 70 includes the theme of any of examples 61-69 above.
[00249] Coating the first layer 304 and selected number of additional layers 310 of the object 300 facilitates applying a decorative coating, a functional coating, or both, a decorative and a functional coating, to the object 300.
[00250] Continuing to refer generally to Figures 1A, 1B, 2-42 and particularly, for example, Figure 43A, method 500 further comprises dispensing shielding gas 308 to protect a portion of metal dust 302 which is irradiated by the electromagnetic energy source 110 in powder bed volume 108 (block 522). The preceding theme of the present paragraph is in accordance with example 71 of the present description and example 71 includes the theme of any of examples 54-70 above.
[00251] Dispensing shielding gas 308 to a portion of metal powder 302 that is being radiated by the electromagnetic energy source 110 in the powder bed volume 108, facilitates preventing oxidation and/or eliminating smoke formation during irradiation of the powder portion of metal 302 by means of the electromagnetic energy source 110.
[00252] Examples of the present description can be described in the context of aircraft manufacturing and service method 1100 as shown in figure 44 and aircraft 1102 as shown in figure 45. During pre-production, illustrative method 1100 may include specification and design ( block 1104) of aircraft 1102 and material acquisition (block 1106). During production, fabrication and component subassembly (block 1108) and system integration (block 1110) of aircraft 1102 can take place. Thereafter, the 1102 aircraft can undergo certification and delivery (block 1112) to be put into service (block 1114). While in service the 1102 aircraft can be scheduled for routine maintenance and service (block 1116). Routine maintenance and service may include modification, reconfiguration, modernization, etc., of one or more systems of the 1102 aircraft.
[00253] Each of the processes of illustrative method 1100 can be performed or performed by a system integrator, a third party partner and/or an operator, for example a customer. For purposes of this description, a system integrator may include without limitation any number of aircraft manufacturers and main system subcontractors; a third party partner may include without limitation any number of vendors, subcontractors and suppliers, and an operator may be an airline, leasing company, military entity, service organization, and so on.
[00254] As shown in Figure 46, aircraft 1102 produced by means of illustrative method 1100 may include fuselage 1118 with a plurality of high-level systems 1120 and interior 1122. Examples of high-level systems 1120 include one or more propulsion systems 1124, electrical system 1126, hydraulic system 1128, environmental system 1130. Any number of other systems can be included. Although an aerospace example is shown, the principles described here can be applied to other industries such as the automotive industry. Accordingly, in edition to aircraft 1102, the principles described herein may apply to other vehicles, e.g., land vehicles, marine vehicles, space vehicles, etc.
[00255] Apparatus to methods shown or described herein may be employed during any one or more of the stages of manufacturing and service method 1100. For example, subassembly components that correspond to component manufacturing and subassembly 1108 may be manufactured or manufactured in a similarly to components or subassemblies produced while the 1102 aircraft is in service. Also, one or more examples of the apparatus, methods, or combination thereof, may be used during production stages 1108 and 1110, for example, substantially speeding up the assembly of or reducing the cost of aircraft 1102. Similarly, one or more examples of apparatus embodiments or methods, or a combination thereof, may be used, for example, without limitation, while the aircraft 1102 is in service, for example, the maintenance and service stage (block 1116).
[00256] Different examples of the apparatus and methods described here include a variety of components, aspects and features. It should be understood that the various examples of apparatus and methods described herein may include any of the components, aspects and functionality of any of the other examples of apparatus and methods described herein, in any combination, and all such possibilities are designed to be within the spirit and scope of this description.
[00257] Various modifications of the examples described herein will come to mind of one versed in the art to which the present description belongs, taking advantage of the teachings presented in the preceding descriptions and associated drawings.
[00258] Therefore, it is to be understood that the present description is not to be limited to the specific examples presented, and that modifications and other examples are intended to be included within the scope of the appended claims. Furthermore, although the foregoing description and associated drawings describe examples of the present description 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 depart from the scope of the appended claims.

权利要求:
Claims (15)
[0001]
1. An additive manufacturing apparatus (100), comprising: an electromagnetic energy source (110); a building platform (106) movable vertically with respect to the electromagnetic energy source (110); a powder containment compartment (138) configured to contain a metal powder (302) and having a metal bed volume (108), wherein the building platform (106) at least partially delimits the bed volume of metal (108); a linear rail (122) having a length L1; and, wherein the linear rail (122) is either rotatable or rotatable in a horizontal plane around a vertical geometric axis A; and, the electromagnetic energy source (110) movably coupled to the linear rail (122) and movable in a polar coordinate system (250) having a radius R; characterized in that: the building platform (106) comprises a dust removal vent (174) which defines a passage through the building platform (106) for discharging metal powder (302) from the bed volume. of powder (108).
[0002]
2. Apparatus (100) according to claim 1, characterized in that the dust removal vent (174) includes a closing mechanism movable between a closed configuration to seal the powder bed volume (108) and a open position for discharging metal powder (302) from the powder bed volume (108).
[0003]
3. Apparatus (100) according to claim 1 or 2, characterized in that it additionally comprises a vibrating mechanism (176) operatively coupled to the construction platform (106), the vibrating mechanism (176) being configured to facilitate breaking and/or compacted displacement or cobbled metal powder within the powder bed volume (108).
[0004]
4. Apparatus (100) according to any one of claims 1 to 3, characterized in that: the electromagnetic energy source (110) is configured to translate along the linear rail (122) in a linear path path (254); and, the linear path path (254) along the linear path (122) has a maximum length L2 equal to or greater than the radius R of the polar coordinate system (250).
[0005]
5. Apparatus (100) according to any one of claims 1 to 3, characterized in that: the electromagnetic energy source (110) is configured to translate along the linear rail (122) in a linear path path (254); and, the linear path path (254) along the linear rail (122) has a maximum length L2 equal to or less than the radius R of the polar coordinate system (250).
[0006]
6. Apparatus (100) according to any one of claims 1 to 5, characterized in that it additionally comprises: a ring (104); and, a peripheral drive (148) operatively coupled to the ring (104), movable along the ring (104) and configured to rotate or rotate the linear rail (122) around the vertical axis A.
[0007]
7. Apparatus (100) according to claim 6, characterized in that it additionally comprises a passive cube (222) rotating around the vertical axis A, in which the linear rail (122) is attached to the passive cube ( 222).
[0008]
8. Apparatus (100) according to any one of claims 1 to 6, characterized in that it additionally comprises a central drive (216) configured to rotate or rotate the linear rail (122) around the geometric axis vertical A.
[0009]
9. Apparatus (100) according to any one of claims 1 to 5, characterized in that it additionally comprises: a ring (104); and, a peripheral passive support (226) secured to the linear rail (122) and movably coupled to the ring (104); and, optionally further comprising a central drive (216) configured to rotate or rotate the linear rail (122) around the vertical geometric axis A.
[0010]
10. Apparatus (100) according to any one of claims 1 to 9, characterized in that it further comprises a base (102), wherein the building platform (106) is movable vertically with respect to the base (102) .
[0011]
11. Apparatus (100) according to any one of claims 1 to 10, characterized in that it further comprises a surface conditioning apparatus (116), wherein the building platform (106) is rotatably movable in with respect to surface conditioning apparatus (116).
[0012]
12. Apparatus (100) according to any one of claims 1 to 11, characterized in that: the construction platform is vertically movable within the dust containment compartment (138); and, the powder bed volume is variable.
[0013]
13. Apparatus (100) according to any one of claims 1 to 12, characterized in that it further comprises a dust removal apparatus (126) configured to remove metal dust (302) from the dust containment compartment (138).
[0014]
14. Apparatus (100) according to claim 13, characterized in that the dust removal apparatus (126) comprises: a first dust removal subsystem (128) movable between a first location laterally out of the compartment powder containment (138), and a second location laterally into the powder containment compartment (138); and, a second dust removal subsystem (130) located laterally into the dust containment compartment (138).
[0015]
15. Method (500) for additively fabricating an object (300) from a metal powder (302), the method (500) comprising: distributing a first layer (230) of the metal powder (302) in a powder bed volume (108) at least partially bounded by a building platform (106); characterized in that it further comprises: melting a selected first portion of the first layer (230) of the metal powder (302) into the powder bed volume (108) exposing the selected first portion of the first layer (230) of the metal powder (302) to electromagnetic energy (306) from an electromagnetic energy source (110) while moving the electromagnetic energy source (110) along a first predetermined path in a polar coordinate system (250) to form at least a portion of a first layer (304) of the object (300), in which the electromagnetic energy source (110) is movable in a linear path path (254) along a linear rail (122) and the linear rail ( 122) is one of rotating or revolving in a horizontal plane around a vertical geometric axis A; and, removing, once additive form fabrication of the object (300) is complete, metal dust (302) from the powder bed volume (108) using a dust removal vent (174) which defines a passage through the building platform (106).

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法律状态:
2016-05-31| B03A| Publication of a patent application or of a certificate of addition of invention [chapter 3.1 patent gazette]|

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2018-10-30| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-08-06| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2021-03-30| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-05-04| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 22/09/2015, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US14/540,057|US10016852B2|2014-11-13|2014-11-13|Apparatuses and methods for additive manufacturing|

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US14/540,057|2014-11-13|

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