Apparatus and methods for production additive manufacturing

Patent metadata

Field	Value
Publication number	US-10357827-B2
Application number	US-201514812159-A
Country	US
Kind code	B2
Filing date	Jul 29, 2015
Priority date	Jul 29, 2015
Publication date	Jul 23, 2019
Grant date	Jul 23, 2019

Abstract

An additive manufacturing apparatus includes: a build module comprising a build chamber, and a least one of but less than all of the following elements: (a) a directed energy source; (b) a powder supply; (c) a powder recovery container; and (d) a powder applicator; and a workstation comprising the remainder of elements (a)-(d) not included in the build module.

First claim

What is claimed is:

1. An additive manufacturing apparatus, comprising:
a build module comprising:
a build chamber;
a powder recovery chamber; and
a build-module worksurface including a build chamber opening communicating with the build chamber; and
at least one of but less than all of the following elements:
(a) a directed energy source;
(b) a powder supply; and
(c) a powder applicator; and

a workstation comprising:
the remainder of elements (a)-(c) not included in the build module; and
an enclosure sized to enclose the build module, the directed energy source, the powder supply, and the powder applicator; and

a transport mechanism comprising a conveyor or a turntable disposed partially within the enclosure and defining a transport-mechanism worksurface configured to receive the build module therein, the transport-mechanism worksurface being coplanar with the build-module worksurface so as to define a virtual workplane, and the transport mechanism being configured to move the build module in to and out of the workstation.

2. The apparatus of claim 1 wherein the build module includes:
a peripheral wall extending past the build-module worksurface opposite the build chamber to define a workspace; and
a window transparent to radiant energy that spans across the peripheral wall to close off the workspace.

3. The apparatus of claim 2 wherein the enclosure comprises one or more seals configured to allow the build module to pass therethrough.

4. An additive manufacturing apparatus, comprising:
a plurality of workstations and build modules according to claim 1 ; and
an electronic central controller operably connected to each of the workstations.

5. An additive manufacturing apparatus, comprising:
a plurality of workstations and build modules according to claim 1 ; and
a central shielding gas supply coupled to each of the workstations.

6. An additive manufacturing apparatus, comprising:
a plurality of workstations and build modules according to claim 1 ; and
a central cooling fluid supply coupled to each of the workstations.

7. An additive manufacturing apparatus, comprising:
a plurality of workstations and build modules according to claim 1 ; and
a central ventilation system coupled to each of the workstations.

8. An additive manufacturing apparatus, comprising:
a workstation comprising:
a directed energy source;
an enclosure sized to enclose a build module;
a powder supply contained within the enclosure;

a build module, comprising:
a first build chamber;
a powder recovery chamber;
a build-module worksurface including a build chamber opening communicating with the first build chamber; and
a peripheral wall extending past the build-module worksurface opposite the first build chamber to define a workspace; and

a transport mechanism operable to move the build module into and out of the workstation, the transport mechanism comprising a turntable or a conveyor disposed partially within the enclosure and defining a transport-mechanism worksurface configured to receive the build module therein, the transport-mechanism worksurface being coplanar with the build-module worksurface so as to define a virtual workplane;
wherein the powder supply is configured to drop powder onto the transport-mechanism worksurface; and
wherein the workstation further comprises a moveable powder applicator disposed in the workspace and contacting the transport-mechanism worksurface.

9. The apparatus of claim 8 wherein each module includes a window transparent to radiant energy that spans across the peripheral wall to close off the workspace.

10. The apparatus of claim 8 wherein the enclosure comprises one or more seals configured to allow the build module to pass therethrough.

Assignees

• Gen Electric
• General Electric Comany

Inventors

• Shaw Mark
• Barnhart David Richard
• Redden Ronald
• Anderson Theodore
• Morris Gregory Muster

Classifications

• B29C64/321

  Feeding · CPC title

• B29C64/364

  Conditioning of environment · CPC title

• B29C64/25

  Housings, e.g. machine housings · CPC title

• B22F12/80

  Plants, production lines or modules · CPC title

• B22F12/38

  Housings, e.g. machine housings · CPC title